02 General Specifications-For All Project

Proposed Warehouses (G+M) and Service Block Plot No WT-05, DWC, Dubai. Project No. 537-OI

Client: M/s GRAND STORE L.L.C. General Specifications Period: November 2013

TABLE OF CONTENTS

Section No.

Description

Page Nos.

Section 1000

Preliminaries..................................................................

2 – 15

Section 2000

Excavation and Earthworks...........................................

16 – 30

Section 2300

Piling Works...................................................................

31 – 38

Section 3000

Concrete Works.............................................................

39 – 84

Section 4000

Masonry Work...............................................................

85 – 94

Section 5000

Metal Works...................................................................

95 - 115

Section 6000

Carpentry and Joinery....................................................

116 - 123

Section 7000

Thermal and Moisture Protection........................................

125 – 132

Section 8800

Glazing.............................................................................

133 – 143

Section 9000

Finishes................................................................................

144 – 159

Section 9900

Paint and Decoration............................................................

160 – 167

Section 15400

Plumbing Installation............................................................

168 – 178

Section 15500

Fire Fighting System..........................................................

179 – 194

Section 15600

Fire Detection and Alarm System.......................................

195 – 208

Section 15800

Air Conditioning and Ventilation Installation System.....

209 – 270

Section 16000

Electrical System.......................................................

271 - 331

D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc

02 General Specifications-for all project Page 1 of 331

T05-20/11/2013



.

SECTION 1000

PRELIMINARIES / GENERAL ITEMS



T05-20/11/2013



Section 1000 PRELIMINARIES / GENERAL ITEMS

1000.1 SCOPE OF WORK The work shall comprise the Construction, Completion, Maintenance and handing over of the project Proposed Construction of Warehouses (G+M), Service Block and External Works at plot no. WT 05 at DWC, Dubai, comprising of: a) Warehouses Building (G+M) b) Service Block c) Other works comprising of Interlocking tiles, Boundary Wall, Gates & Plinths protection, etc. All complete as specified, detailed on drawings and to the approval of the Engineer. 1000.2 DRAWINGS i.

Design

(a) Consultant will provide preliminary design and general specification for the project and the Contractor shall be responsible for the final structural & electro mechanical design, which shall include all necessary construction and workshop drawings. (b) Contractor will be responsible for satisfactory performance of the building. (c) The Contractors must ensure that all works shall in complying with statutory authority requirements and standards

ii. Drawings A list of Contract Drawings available with the Tender is attached to these Specifications



T05-20/11/2013



1000.3 ABBREVIATION OF STANDARDS The following abbreviations have been used for the Standard applicable to the Works under the Contract. BS CP ASTM ACI ISO ANSI AASHTO DIN SEN EN UL IEC CENELEC

- British Standards - Code of Practice - American Society for Testing and Materials - American Concrete Institute - International Organization for Standardization - American National Standards Institute - American Association for State Highways & Transportation Officials - Deutshes Institute for Normung - European Standards – Adopted as British Standard - Euro norms Harmonized Standards - Underwriters Laboratories, Inc. - International Electrotechnical Commission - Committee European de Normalisation Electrotechnique

Referenced Standards are part of the Contract Documents and have the same force and effect as if bound with this Specification. 1000.4 DEFINITIONS Wherever in the Contract Documents, or on Drawings, the words “as directed”, “as described”, “as ordered”, “as requested”, “as required”, “as permitted” or words of like import are used, it shall be understood that the direction, description, order, request, requirements or permission of the Engineer is intended. Similarly, the words “approved”, “acceptable”, “satisfactory” and words of like import shall mean approved by, acceptable to, or satisfactory to the Engineer. 1000.5 INCONSISTENCY IN CONTRACT DOCUMENTS The Contractor shall execute the Works according to the provisions of the Contract Documents. Any work indicated in one of the documents but omitted and/or not stated in one or more of the other documents shall be treated as though it were included in all of them. Any discrepancies between the quantities or their descriptions in the Bills of Quantities, the Specification and/or the Tender Drawings, shall be referred for clarifications prior to the submission of the Tender which shall be clarified as Addendum to the Tender. Any discrepancies noted after the Tender has been accepted shall be referred to the Engineer for a ruling. The ruling of the Engineer shall be final and binding on the Contractor and the Contractor shall execute the works accordingly without any increase in cost or extension of time to the Project. 1000.6 ERRORS IN COMPUTING CONTRACT DOCUMENTS The Contractor shall be responsible for any error which he makes in computing any quantities of material and labour required or costs involved or through any lack of knowledge of the site or misunderstanding of anything shown or implied on the Drawings or in the Specifications and/or Bills of Quantities. The Contractor must refer any discrepancy in the Drawings or the Specifications to the Engineer before proceeding with any of the Works. The decision of the Engineer as to the interpretation of the discrepancy will be final as specified above under the “inconsistency in Contract Documents”. 1000.7 USE AND PROTECTION OF SITE



T05-20/11/2013



The Contractor shall be responsible for the security of the site including his own and Sub-Contractors work, plant, materials, etc., and the safety of public and adjoining property, and shall be liable for any claims arising for any loss or damage suffered. The Contractor shall protect the Site during the course of the Works as directed by and to the entire satisfaction of the Engineer. Site Hoarding The contractor shall provide and maintain hoarding around the site protection of the site for security and safety. The hoarding shall be Corrugated Aluminum sheet panels with frame (this part will be for front elevation only, for other three sides to be 12mm thick commercial plywood erected on painted timber supporting structure suitably braced to ensure stability and safety on all sides of the site to the approval of the Engineer. The hoarding shall be painted in plain colour with consultant (CCE) as shown on drawings & contractor logo and the Client Logo (same will be provided). The fresh look of the hoarding shall be maintained at all times until completion of the works. Adequate number of entrances with gates/barriers shall be provided at suitable locations and shall be manned at all times as approved by the engineer. The Contractor shall not load permit any part of the structure to be loaded with a weight that will endanger its safety. Areas surrounding the latrines shall be deodorized. 1000.8 SCAFFOLDING The Contractor shall provide, erect, maintain, dismantle and clear away at completion proper and adequate scaffolding including that required for Sub-Contractors and Specialists. Putlon holes should be made good to match the adjacent surface as the scaffolding is dismantled. The Contractor shall be entirely responsible for all safety precautions in connections with the scaffolding and for its entire sufficiency for the work. 1000.9 PROTECTION OF THE WORKS AND THE PUBLIC In pursuance of his obligations under the Conditions of Contract the Contractor shall wherever required or directed by the Engineer cover up and protect the Works from the weather and from damage by his own or other workmen performing subsequent operations. He shall provide all necessary dust sheets, barriers and guard rails etc. and clear away same at completion. 1000.10 SEPARATE CONTRACT The Employer reserves the right to let other separate Contracts in connection with this work under similar conditions. The Contractor shall afford other Contractors reasonable opportunity for the introduction and storage of their materials and the execution of their works, and shall properly connect and coordinate his work with theirs. 1000.11 SHEDS The Contractor shall erect and maintain ample temporary and watertight sheds for proper storage and protection of his own and Subcontractor's materials. Cement and other perishable material shall have floors raised 150 mm off the ground. The Contractor shall clear away at completion and make good all work disturbed. 1000.12 ADVERTISING D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The Contractor shall not affix or place any placards or advertisements of any description or permit the same to be affixed or placed in or upon any hoardings, gantry, building or structure other than that approved by the Engineer. 1000.13 APPROVED, DIRECTED, SELECTED The terms "approved", "directed" or "selected" mean the approval, direction or selection of or by the Engineer. 1000.14 LEGAL AUTHORITY WORKMEN The Contractor shall at all times give access to workmen employed by the Local of other Authorities and provide with proper, sufficient and if required special scaffolding, hoists and ladders and provide them with water and lighting and leave or make holes, grooves, chases etc., without extra charge 1000.14.1 NO OBJECTION CERTIFICATES (NOC’S) The said to be obtained from all authorities by the main contractor. 1000.15 KEEPING THE SITE FREE FROM RUBBISH The Contractor shall keep the building and the site free from rubbish during the progress of the work and at completion, including that of Subcontractors and Local Authority, or special tradesmen. All materials condemned by the Engineer are to be removed immediately and replaced at the Contractors expense. 1000.16 MATERIALS TO BE IMPORTED The Contractor will be required to produce documentary evidence that all materials to be imported have been ordered within 8 weeks after the Contract has been signed. This means materials which are not obtainable on the local market and which have to be ordered especially from abroad. As soon as orders have been placed, copies of such orders shall be submitted to the Engineer. 1000.17 MATERIALS, GOODS AND WORKMANSHIP GENERALLY The whole of the workmanship, goods and materials incorporated in the works shall be new and of the best quality available and shall be to the approval of the Engineer. Should the Engineer discover on the Works any materials other than those approved he may order their removal from the Site. 1000.18 BRITISH STANDARD In this and in any other Contract Documents and/or drawings the letters "B.S." followed by a number will refer to the edition of the British Standard current at the time of tendering. Reference to British Standards shall not preclude the use of materials from sources where other standards apply, but no materials to be incorporated in the works shall be in any respects inferior to those which specifically comply with the relevant British Standard. 1000.19 COORDINATION OF BUILDERS WORK The Contractor shall coordinate the requirements for holes, fixings and other similar builders work. The Contractor shall ensure that such builders work as shown on the drawings is in accordance with his own and his Subcontractor requirements. Details of holes, fixing, etc., which are not shown on the drawings but are required by the Contractor or Subcontractors, shall be forwarded to the Engineer for his written D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



approval at least three weeks before work proceeds. No holes or fixing shall be formed without prior approval by the Engineer. No claim will be entertained for work executed abortively due to lack of coordination. 1000.20 TEMPORARY WORKS The Contractor shall furnish to the Engineer full particulars, drawings etc. of all temporary works necessary for the execution of the Work and shall allow sufficient time for the Engineer to consider the same. The Engineer reserves the right to comment on the Contractor's proposals if he considers that modification should be made, but the Contractor shall solely be responsible for the stability and safety of all temporary works and unfinished permanent works and for the quality of the permanent works resulting from the arrangement eventually adopted for their execution. 1000.21 TEMPORARY ROADS The Contractor shall form all temporary roads crossover footpaths tracks hard standings etc. within the Site. 1000.22 WORK 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. 1000.23 PROTECTING FINISHED WORKS The Contractor shall carefully protect his own finished work, the work of Subcontractors or the work of Local Authority workmen and he shall be liable for the re-instatement of any work damaged during the progress of the work, caused by any reason whatsoever. 1000.24 CUSTOMS AND LOCAL DUTIES All state dues, tolls rates, duties, fees and charges in connection with the Works shall be deemed to be included by the Contractor in his contract unit rates. 1000.25 EXPATRIATE LABOUR The Contractor shall make his own arrangements for the engagement of expatriate labour and staff if required and for the housing, health, welfare and repatriation of same and shall conform in all respects with the conditions and requirements of any law and of any regulations or orders of the government of the country wherein the site is situated or any Authority which may be applicable including such law, regulation or order passed or made or coming into force after the date of tender and/or during the execution of the Works. 1000.26 ALTERNATIVE MATERIALS In the event of the acceptance of any alternative materials or items a suitable price reduction shall be made in respect of any decrease in value but no price addition shall be made in respect of increase in value. Should the contractor wish to offer alternative items or materials to those specified he shall supply details of such alternatives together with details of any reduction in the contract price should the alternative be allowed to be substituted for the specified items or materials. All offered alternatives shall



T05-20/11/2013



comply fully in respects with the specifications of the particular items or materials. Acceptance or refusal of any alternatives will be entirely at the discretion of the Engineer. If during the course of the contract certain materials or items required for use in the works should be unobtainable, despite the best effort of the contractor, the contractor may offer for the approval of the Engineer alternative materials or items, provided that they posses the minimum requirements of the originally specified materials. In the event of acceptance of any alternative materials or items a suitable price reduction shall be made in respect of any decrease in value but no price addition shall be made in respect of increase in value. In the event of refusal of any alternative materials or items the contractor for any loss occasioned by his failure to provide the materials or items as specified. No claims shall be entertained or considered from the contractor for any loss of time due to the process of investigation study and approval by the Engineer. In the event of refusal of any alternative materials or items, the Contractor shall not be relieved of any of his obligations under the contract and shall be solely liable if any delay or loss occasioned by his failure to provide the material or items as specified. 1000.27 ATTENDANCE The Contractor shall allow for the attendance of one trade upon another and shall execute and make good all necessary chases, holes, mortises, channels, etc. in any materials and shall provide all necessary attendance on Sub-Contractors. 1000.28 COMPETENCE OF TRADESMEN Only competent and experienced tradesmen who have proven their ability in performing their specialist trades shall be employed on the work. 1000.29 DIMENSIONS Figured dimensions only shall be followed. No dimensions shall be scaled from drawings. 1000.30 SAMPLES AND TESTING OF MATERIALS Prior to ordering or delivering any material or manufactured items to the Site the name or names of the Manufacturer(s) and, where required by the Engineer, adequate samples, with full product details, technical data, sample schedules and manufacturer's certificates of all the materials and goods to be used in the Works shall be submitted to the Engineer for approval and in the case of rejection further samples to be submitted until such are approved. If judged necessary by the Engineer, the samples shall be tested for compliance at the Contractor's expense in a laboratory designated by the Engineer, and finally approved samples shall be retained in a separate room on the site and not used in the work without the written permission of the Engineer. 1000.31 SHOP DRAWINGS The Contractor shall furnish the Engineer with any shop drawings which he shall reasonably require, detailing materials, layouts, sizes, dimensions, etc., clearly and neatly. Such drawings must be provided at least ten days prior to the commencement of the relevant work on site. No such work shall be put in hand until the Engineer's approval of shop drawings has been obtained in writing. 1000.32 DELIVERY, HANDLING AND STORAGE OF MATERIALS



T05-20/11/2013



All materials or manufactured items that are liable to damage shall be delivered in the original package, containers, etc. bearing the name of the manufacturer and the brand. Materials or manufactured items shall be carefully loaded, transported, unloaded and stored in an approved manner, protected from damage and exposure to weather or dampness during transit and after delivery to the Site. Damaged material or manufactured items shall not be used in the work. Any material or manufactured items damaged during and after fixing in position shall be removed, repaired or replaced by and at the Contractor's expense as required by the Engineer. 1000.33 WATER FOR THE WORKS The Contractor shall provide water for the Works including that required by Subcontractors, pay all charges and provide all necessary temporary pipework, pumps, storage tanks, etc., and remove on completion, and make good all work disturbed. Any cost of importing water by tanker and storing on site, should this prove necessary, shall be allowed for by the Contractor. No extension of time will be granted due to failure of and dependence upon a main water supply. 1000.34 ELECTRICITY FOR THE WORKS The Contractor shall provide electric light and power for the Works including that required by Subcontractors, pay all charges and provide all temporary installations and remove on completion and make good all work disturbed. Any cost of Temporary Electricity generating equipment, should this prove necessary, shall be allowed for by the Contractor. No extension of time will be granted due to failure of and dependence upon a main electricity supply. 1000.35 EXISTING SERVICES The Contractor shall allow for ascertaining for himself the position of any live services within the confines of the site. Any accidental damage must be reported to the Engineer immediately and the Contractor shall be liable for any charges incurred for repairs. 1000.36 ACCIDENTS The Contractor shall promptly report by telephone and in writing to the Engineer any accident whatsoever arising out of or in connection with the performance of the work whether on or adjacent to the Site which caused death, personal injury or property damage, giving full details and statements of witnesses. If any claim is made by anyone against the Contractor or any Subcontractor on account of any accident, the Contractor shall promptly report the facts in writing to the Engineer giving full details of the claim. 1000.37 CLEANING AT COMPLETION The Contractor shall clean the whole of the buildings at completion to the Engineers satisfaction and leave the work and the Site tidy and the buildings ready for immediate occupation. The Contractor shall clean all windows inside and out, clean and leave in a proper condition all sanitary fittings, etc., to the satisfaction of the Engineer. Immediately prior to handing over the building for occupation, the whole of the drain pipes and gullies are to be cleared of any obstruction, debris and superfluous matter by rodding or other approved means.



T05-20/11/2013



1000.38 PHOTOGRAPH AND ADVERTISING The Contractor shall supply once a month, as directed by the Engineer, three unmounted sets of coloured photographs. Each set shall comprise of five (5) photographs of size 20 x 25 cm, showing the progress of the works. 1000.39 ENGINEER'S SITE OFFICE The Contractor shall provide and maintain on the site for the duration of the Contract a temporary office for the accommodation of the Engineer and staff. a) This office and facilities shall comprise of: - 2 Rooms of 12 metres square each. - Separate sanitary facilities. - Electric outlets and lamps. - Hot and cold water. - Elevated water tank 10(ten) m3 capacity. - Split Air conditioning units. - 2 desks with 3 swivel chairs. - 10 chairs. - Fire extinguishers as necessary. - Conference table with chairs. - One small refrigerator with approx. 12 c.ft. capacity. - One samples rack as required by the Engineer. - 1 filing cabinet. - 1 Laptop (latest specifications). - Internet Facilities - Photocopier - One telephone line (all local calls charges within the UAE including rental to be borne by the Contractor) for the sole use of the Engineer. - Provision of stationery for site office use as required by the Engineer.

charges

b) The Contractor shall provide covered car park to accommodate two cars, exclusively for Engineer's staff. An extra covered car park shall be provided for the Employer. c) The Contractor shall provide 2 Nos. approved Sign Boards written in Arabic and English. The size of the Sign Board and Lettering including the wordings shall be as directed by the Engineer. 1000.40 TOILET FACILITIES The Contractor shall provide and maintain clean portable toilet facilities. The Contractor shall include in his contract sum for the above provision as applicable. The Contractor shall not use the permanent facilities within the building. 1000.41 SIGN BOARDS 2 Nos. Illuminated Primary sign boards shall be provided in Arabic and English giving the names of the “EMPLOYER”, PROJECT”, “ENGINEER” and “MAIN CONTRACTOR” only, and strictly in accordance with the format attached herein. However a perspective view of the project mounted in a suitable glass frame and illuminated adequately shall also be fixed on the board. The size of this perspective view will be as agreed with the Engineer.



T05-20/11/2013



The signboard shall consist of a supporting structure securely anchored to the ground and with sign plates fitted on it. All working details including sitting and positioning shall be submitted for approval and shall be approved before fabrication or erection commences. The sign boards shall be properly illuminated to the required illumination levels and good Engineering Standards and to the approval of the Engineer. The Contractor shall comply with current regulations of the Municipality and obtain approval of the Municipality. The Contractor shall keep clean and maintain the signboards and remove them and make good all works disturbed upon completion of the Contract. The Contractor shall provide space for signboards and pay all costs in connection with them including Municipality fees. 1000.42 PERIODIC REPORTS This report shall be submitted to the Engineer by the 5th day of each month. The exact format for the report will be mutually agreed between the Engineer and the contractor, as a minimum, it shall include the following:a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) w) x) y) z)

Labour force working during that period. Quantity and quality of materials and equipment used during that period. Report of actual date of arrival of approved materials at site. Detailed quantity of work executed and description. Climatic conditions with special reference to any direct effect they may have on the Works. Unforeseen circumstances (if any) which may hamper the progress of the Work. Graphs showing the relation between the executed portions of the Works and the corresponding portions in the work programme. Copies of the important correspondence exchanged between the Engineer and the Contractor during that period. Copies of the important site instructions issued to Contractor by the Engineer during that period. Copies of the minutes of meetings held during that period. Executive summary narrative highlighting major home office (if applicable), local office and construction worksite activities accomplished during the month. Status of works, overall and a comparison between planned and actual areas of concern. Proposed remedial actions recommended correcting stated situations and avoiding potential problems. Effectiveness of remedial actions taken previously. Narrative and summary of drawings / documents progress – actual versus planned. Narratives and summary of subcontract award progress – actual versus planned. Narrative and summary of procurement progress – actual versus planned. Construction progress – activities performed and progress achieved, actual versus planned by sub-contractors and overall construction. Plans and schedules during important activities in the immediate future, updates and forecasts. Site materials delivery details and forecasts including specific information on late materials deliveries likely to affect progress. Progress, productivity and man-hour data to include planned; actual and forecast progress together with trend identification and analysis by each sub-contract. Project schedule status, highlighting the status of critical activities along with schedule trend analysis indicating the actions proposed to be taken to ensure timely completion of the Project. Project milestone status. Drawings and materials hold-up analysis and report. Productivity analysis for each sub-contractor. Project trends summary.

The Contractor shall prove to the Engineer's Representative upon his request the correctness of the above mentioned reports without having the right to use such documents to support a claim for any extra payment or compensation whatsoever in regard or in relation to such reports. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



1000.43 SITE PROGRESS MEETINGS During the course of the Works, Site progress meetings shall be held at regular intervals at least once every two weeks in the presence of the Engineer for the purpose of coordinating the Contractor's works. Minutes of such Site meetings will be recorded, copies will be distributed to all persons concerned and full effect shall be given to all instructions contained therein. The Contractor shall have no claim against the Employer for costs incurred by him in changing the method of working or in the provision and use of other additional plant. 1000.44 PROGRESS REPORTS The Contractor shall prepare typed site progress reports for each section of the Works for discussion at the site meetings. The progress reports shall be related to the Contractor's programme for the Works and shall state the percentage of work completed each month. The Contractor shall prepare materials schedules, listing key materials, together with dates for ordering. 1000.45 SAFETY OF ADJOINING EXISTING BUILDINGS The Contractor shall take all necessary precautions during the excavation which are adjoining existing buildings shall protect such buildings from the damage or collapse by means of temporary or permanent shoring, strutting, sheet piling or underpinning or excavations in short lengths and/or other methods as he deems fit, also he shall properly support all foundations trenches, walls, floors etc., affecting the safety of the adjoining existing buildings. 1000.46 PROGRAMMES FOR THE WORKS a)

Two weeks after the date of acceptance of his Tender the Contractor shall submit to the Engineer for his approval a programme showing the order of procedure, delivery of materials and methods in which he proposes to carry out the works, including the work of sub-contractors. The programme shall show the execution of each trade separated to show time for completion. The submission to the Engineer of such programme shall not relieve the Contractor of any of his duties or responsibilities under these Conditions, nor his obligations to apply in writing for instructions as required by the Conditions of Contract.

b) The Contractor shall submit three copies of programmes to the Engineer and keep one copy in the site office. He shall record progress on a copy of the chart kept on site, and update and redraft if any circumstances arise which affect the progress of the Works and submit copies of all revisions to the Engineer. 1000.47 SETTING OUT THE WORKS The Contractor shall be responsible for the true and proper setting-out of the Works in relation to original points lines and levels or reference given by the Engineer in writing and for the correctness of the position levels dimensions and alignment of all parts of the Works and for the provision of all necessary instruments appliances and labour in connection therewith. 1000.48 CLEARING UP OF SITE ON COMPLETION On completion of the Works the Contractor shall clear away and remove from the Site all Constructional Plant surplus materials rubbish and Temporary Works of every kind and leave the whole of the Site and Works clean and in a workmanlike condition to the satisfaction of the Engineer.



T05-20/11/2013



The Works shall be cleaned thoroughly inside and out, removing all splashes, deposits, rubbish and surplus materials. The Contractor shall remove all temporary markings, covering and protective wrappings unless otherwise instructed. 1000.49 SAFETY, HEALTH AND WELFARE The Contractor shall comply with enactments and regulations relating to safety, health and welfare of work people, and the public at large. The Contractor shall provide and maintain First Aid facilities on the Site to the approval of the Engineer. 1000.50 NOISE CONTROL ON WORK SITES All plant and equipment supplied by the Contractor for use on the Works shall be effectively `soundreduced' by means of silencers, mufflers, acoustic linings or shields or acoustic shed or screens to a level of 75 decibels (dBA) measured outside the nearest occupied property or to the satisfaction of the Engineer. 1000.51 NOMINATED SUBCONTRACTORS Where prime cost or provisional sums are included in the Schedule of Rates or Bills of Quantities for persons to be nominated by the Engineer to supply and fix materials or to do work. a)

Such sums shall be expended in whole or in part in favour of the persons nominated by the Engineer or wholly deducted from the Contract Sum if not required to be expended. Such persons shall be called `Nominated Subcontractors'. But no person shall be nominated against whom the contractor shall make reasonable objections or who will not enter into a Subcontract with the Contractor provided: 1)

b)

That the Nominated Subcontractor shall indemnify the Contractor against: i)

The same obligations in respect of the Subcontract as those for which the Contractor is liable in respect of this Contract.

ii)

Claims in respect of any negligence by such Subcontractor, his servants, or agents, or any misuse by him or them of any scaffolding or other plant, and shall insure himself against any such liability and produce the policy or policies and premium receipts as and when required by the Engineer.

2)

That payment in respect of any work, materials or goods comprised in the Subcontract shall not be due until receipt by the Contractor of the equivalent payment against an Engineer's certificate which includes the value of such, materials or goods.

3)

That the Engineer shall have a right of access to the workshops and other places of the Nominated Subcontractor.

The sums directed by the Engineer to be paid to Nominated Subcontractors for work, materials or goods comprised in the Subcontract shall be paid by the Contractor within fourteen days of receiving the equivalent payment from the Employer including the value of such work, materials or goods less only any retention money which the Contractor may be entitled to deduct.

1000.52 FIRE PROTECTION Adequate precautions shall be taken against fire throughout all the Contractor's and Subcontractor's operations. Flammable material shall be kept at an absolute minimum, and, if any shall be properly D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



handled and stored. Gasoline and other flammable liquids as well as pressurized gas tanks shall be stored in and dispensed from safety containers; however, storage of such containers shall not be within the building. Except as otherwise provided herein, the Contractor shall not permit fires to be built or open type heating devices to be used in any part of the work. 1000.53 KEEPING THE SITE FREE FROM RUBBISH The premises and the job site shall be maintained in a reasonable neat and orderly condition by the Contractor(s) and kept free from accumulations of waste materials and rubbish during the entire construction period. The Contractor shall remove all crates, cartons and other flammable waste materials or trash from work areas at the end of each working day. 1000.54 SAFETY-GEAR Safety helmets & boots shall be worn at all times by all personnel. Of the Contractor trades requiring use of hand gloves shall be required to do so. 1000.55 LABOURER'S LINES The Contractor is to make all arrangements and bare all costs in connection with the housing of local or imported labour. No accommodation for this purpose will be provided on site premises. However, accommodation for watchman shall be provided at a location approved by the Engineer. Such housing must be kept in clean sanitary conditions and removed on completion of the Contract to the satisfaction of the Engineer. 1000.56 MAINTENANCE MANUAL Arrange for and provide the Engineer at Practical completion with 6 No. copies of a Maintenance Manual in a 4 ring binder, size A4, with rigid plastic covers, containing guarantees and manufacturers printed brochures, and detailed instruction sheets prepared for this contract covering items of plant, equipment and control used for all works described in the Electrical and Mechanical Specifications. The manual is to contain names, address and telephone numbers of; • • • • • • • •

Installation Contractors Place where spare parts may be obtained Service Departments Include a List of Contents sheet and rigid divider sheet to separate each section. The face and spine of the manual to have approved engraved or embossed plastic labels identifying its purpose (i.e. Maintenance Manual) together with the name of the development. The manual is to be of approved design and format, agree details with the Engineer prior to its assembly. The manual is to contain the manufacturers' instructions for the removal of ceiling tiles in suspended ceilings, and their refixing, together with recommendations for cleaning. The manual is to contain manufacturers' instructions for the maintenance of all plastic, stainless steel, aluminium and enamel finishes (plain or anodized) and prescribed contents of warranty against use and mechanical wear and tear.

1000.57 AS-BUILT DRAWINGS All prints of the drawings where required, shall be corrected by the Contractor to show work as executed and submitted to Engineer for approval as the work proceeds. These shall include "As-Built" and schematic arrangement drawings of Mechanical and Electrical Engineering installations. Upon completion of the works, the Contractor shall prepare a complete set of drawings for the project as



T05-20/11/2013



executed and submit to the Engineer for approval. When approved by the Engineer, the Contractor shall submit one set of original polyesters and three prints of all drawings duly marked "As-Built". The Contractor shall not be entitled to any extra payment or extension of time for the correction, preparation and supplying of the above mentioned drawings and original polyesters. The "As-Built" drawings should show the following: 1.

The complete installation, including the sizes and runs of all cables and conduit and trunking and their contents, and the size and runs of all pipework, the precise location of all pipework which may be buried within the structure.

2.

The position of all underground services including electrical, cold water, telephone, gas, drainage and sewerage services on the site together with their depths and the locations of switch and fuse gear and isolating cocks, the positions of all other apparatus.

3.

Thermal or other protecting envelopes around buried services.

4.

The geographical location and identification number of each fuse board, distribution board, isolating device and control valve.

5.

The manufacturers' names, model and type numbers, duty and rating of all plant including thermostatic control equipments.

Fix a print of each as-built circuit and layout diagram securely to the inside of the hinged front of the main electrical control panels, as appropriate or as agreed with the Engineer and protect by non-flammable material. Where inadequate space exists reduce the prints to an agreed size. 1000.58 GUARANTY / WARRANTY The Contractor shall provide guaranty/warranty of the product used in the project in accordance with the specification.

1000.59SOIL INVESTIGATION The soil investigation report enclosed herein is for reference and guidance only. The Contractor shall ascertain the soil conditions on his own by carrying out necessary soil investigations as required. It shall be the responsibility of the contractor to ensure that the minimum design soil strength is met with. Any modification required to the foundations or the soil strata under the foundations to satisfy the design requirements shall be carried out at no extra cost and/or time to the Contract. The Contractor shall however submit all the necessary details of his findings and his proposed modifications for the approval of the Engineer before commencing work. However, any such approval accorded shall not relieve the Contractor of any of his contractual obligations and responsibilities.

End of Section



T05-20/11/2013



SECTION 2000

EXCAVATION AND EARTHWORKS



T05-20/11/2013



Section 2000 EXCAVATION AND EARTHWORKS 2000.1 SCOPE All necessary work required for excavation and site preparation, removal of existing structures, backfilling, disposal of surplus excavated material, site survey, take levels and other sundry works in accordance with the Drawings and/or Bills of Quantities and as directed by the Engineer and in full compliance with the local authorities requirements. 2000.2 SITE INFORMATION The Contractor shall be deemed to have visited the Site of Works and satisfied himself as to the nature of the ground and made himself conversant with the local conditions to be encountered during the execution of the Contract. 2000.3 EXISTING SERVICES The Contractor shall ascertain the whereabouts of all existing services on the Site, both above and below ground. Such services shall be protected, maintained, removed, sealed or re-routed in a manner prescribed by the Public Authorities concerned at the Contractor's own expense as specified under "Locating, Protecting Maintaining and Diverting Services and Public Utilities" in Section 01". Excavations to locate services shall be carried out by hand. 2000.4 SETTING OUT The Contractor shall stake-out the work as shown on the Drawings and secure the Engineer's approval of his stake-out before proceeding with construction. If, in the opinion of the Engineer modification of the line or grade is advisable before or after stake-out the Engineer will issue the detailed instructions in writing to the Contractor for such modification and the Contractor shall revise stake-out for further approval as instructed by the Engineer. The Contractor shall perform all excavations to true lines, widths and depths shown on the Drawings or to such further lines, depths or dimensions as may be directed by the Engineer to reach suitable bearing strata. 2000.5 MATERIAL Backfill and imported fill material shall be any structurally sound material obtained either from excavations or from borrow pits, approved by the Engineer. The material shall in general comprise non-plastic granular matter, and well graded. It shall be free from organic or other perishable items and shall not contain an excess of fines. Suitable Material for fill shall comply with the following limits: Liquid Limit

(AASHTO89) (ASTMD423)

30% max

Plasticity Index (AASHTO T90) 6% max (ASTM D424) Total Water Soluble Salts

5% max

The nature of the materials shall govern both their acceptability for backfill and methods best suited for their placement and compaction in backfill.



T05-20/11/2013



The following definitions of Earthwork materials shall apply; -Sweet Soil: shall be fertile, friable soil obtained from well drained arable land and shall be free draining, non toxic and capable of sustaining healthy plant growth. -Suitable Material shall be approved soil obtained from pits approved by the Engineer as specified.

excavations within the works or from borrow

-shall not contain fines in excess of 20% passing No.200 sieve (ASTM Cl 17) or in excess of 2% organic materials (BS 1377: Part 3). -maximum particle size shall not exceed 75 mm. -shall not be susceptible to spontaneous combustion. -shall not contain any other material which the Engineer may deem to be unsuitable for earthworks. -Screened Gravel (Structural fill): shall be material as directed by the Engineer and comply with the specification. Test Standards Los Angeles Abrasion

ASTMC 131

40% max.

Soundness (Na2So4 Solution) ASTM C 88

12% max.

Liquid Limit

ASTM D 4318 25% max.

Plasticity Index

ASTM D 431

86% max.

Compaction test

ASTM D 1557-

(Modified Proctor)

(Method D)

C.B.R. at 100% of modified

(ASTM D 1883)

Proctor density (96 hr soaked)

80% min.

Field density

ASTM D 1556/D2922

100%min.

Sulphate Content

BS 1377 (part 3)

0.5%max.

Chloride Content

BS 812 (Part 1.1. 7)

1 % max.

-moisture content of the compacted material shall not vary more than 3% of the optimum moisture content (OMC). 2000.5.1 Structural Fill A.

Sound, clean, durable, granular materials free from deleterious matter and in accordance with the following gradations: ASTM Sieve

Total % Passing by Weight



T05-20/11/2013


51mm 38mm 25mm 19mm 9mm No. 4 No.10 No. 40 No. 200


100 70-100 55-85 40-70 30-60 30-60 20-50 10-30 5-15

B.

Gradiations in the table above represent the limits which shall determine suitability of aggregate for use from the sources of supply.

C.

Structural fill may be classified as well graded granular soils- group 1 (non-plastic soils with a uniformity coefficient exceeding 10).

D.

Use structural fill under mat concrete slabs, sidewalks, paving, under utility pipes, and at other soil bearing situations for fill within 300mm measured horizontally of foundation walls, retaining walls, edges of footings and other below-grade vertical surfaces as approved by the Engineer, except where drainage fill is indicated or specified.

E.

If sufficient structural fill material is not available from excavation under this Contract, then additional fill, suitable for use, shall be brought to the Site from other sources. Both excavated material from the Site for use as structural fill, and material brought to the site for use as structural fill, shall meet the above requirements.

2000.5.2 Ordinary Fill A.

Ordinary fill shall be natural soil, well-graded and free from all organic, weak, compressible and expansive materials (such as high plastic clays) and also free of materials subject to decay or decomposition, and shall contain no stone larger than 150mm in maximum dimension.

B.

Ordinary fill may be classified as uniformly graded material –Group 2 (non-plastic soil with a uniformity coefficient of 10 or less).

C.

Use ordinary fill for general grading and backfilling except in areas where structural or drainage fill is required.

D.

If sufficient ordinary fill material is not available from excavations under this Contract, then additional fill, suitable for use, shall be brought to the Site from other sources. Both excavated material from the Site for use as ordinary fill, and material brought to the Site for use as ordinary fill, shall meet the above requirements.

2000.5.3 Drainage Fill A. Drainage fill shall be fine aggregate, clean, well-grade, free-draining sand, complying with ASTM C33. 1.Drainage fill material shall be placed where called for in the Specification or Drawings, (e.g. under pipe and utility trenches). 2000.6 REQUIREMENTS AND TESTING The following requirements, tests and frequencies shall be followed: D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Density and OMC for each fill material as defined by ASTMD1557 Method D and determined in an approved laboratory shall be referenced to the Engineer. The percentage of compaction shall be determined by the percent of maximum dry density at OMC in accordance with ASTM D 1 557 Method D. The area of excavation and the length of trench open at any one time shall be controlled according to the site conditions and subject to limits as directed by Engineer. Gradation Analysis - one test per 4,000 m3 of excavated material on-site stockpiled for use as compacted on-site fill material and as instructed by the Engineer. -Liquid Limit and Plastic Limit and Plasticity Index - One test per 4000 m3 of excavated soil on-site stockpiled for use as compacted fill material and as instructed by the engineer. -Moisture Density - One per 4000 m3 of soil placed and/or whenever visual inspection indicates a significant change in material gradation. -In-Place Density - Areas greater than 1 00 m2; one per 800 m3 placed, or one per alternate lift, whichever results in a greater frequency, Minimum percentage compaction. Areas 100 m2 or less; one per every half (1/2) meter of compacted fill. -Screened Gravel: (Structural Backfill) Contractor's to provide sufficient tests conducted by approved testing laboratory to ensure fill material in accordance with the specification and compaction equipment are well in use. -Gradation Analysis - One from each source and where there is significant change in material gradation. 2000.6.1 Testing of Materials The Soil Testing Laboratory shall perform all tests herein specified and any additional tests as may be required and submit test reports to the Engineer, including the following: A.

One optimum moisture – maximum density curve for each type of soil encountered in Subgrades and fills under a raft foundation and slabs on grade and paved areas. Determine maximum densities in accordance with ASTM D1557.

B. Each type of borrow material shall receive: 1) Mechanical Analysis – ASTM D422/AASHTO T88. 2) Moisture-Density Curve Determination – ASTM D424/AASHTO T91 3) Moisture-Density Curve Determination – ASTM 1557 4) Four CBR test as a measure for bearing capacity under raft foundation 2000.6.2 Testing of Subgrade and Fill Layers Subgrades and fill layers shall be approved by the Soil Testing Laboratory and the Engineer before construction of any further work thereon. Tests of Subgrades and fill layers shall be taken as follows:



T05-20/11/2013



A.The top 300mm of subgrade resulting from excavation shall have a maximum density at optimum moisture as here-in-before specified. In fill areas, each layer of fill shall meet the required density as here-in-before specified. Make at least one (1) field density test of the subgrade for every two hundred square metres (200m2) of paved area or slabs on grade, but in no case less than three (3) test. Perform field density tests in accordance with ASTM D1556 or ASTM D2167. B. At foundation wall backfill take at least eight (8) field density tests (ASTM 1556 or ASTM D2167) at locations and elevation as directed by the Engineer.) 2000.6.3 Cooperate with the Soil Testing Laboratory in every respect in the performance of the required tests. 2000.6.4 If, based on reports of the Soil Testing Laboratory and inspection, the subgrade or backfill are found to be below the specified density, the Engineer may require additional compaction and testing and all this shall be carried out at the expense of the Contractor. 2000.7 COMPACTION REQUIREMENTS Suitable fill material shall be compacted to 95% maximum dry density. Suitable fill material placed within 150mm of formation level shall in addition have a minimum soaked CBR value of 15 percent at 95% maximum density as determined by the modified proctor AASHTO test carried out in accordance with BS 1377 test no.13. 2000.8 PROCEDURE IN EVENT IN EVENT COMPACTION BEING UNACCEPTABLE If the material deposited as fill subsequently reaches a condition such that it cannot be compacted in accordance with the requirements of the contract, the contractor shall at the Engineer’s discretion, either; 1-make good by removing the material and replacing it with suitable material. 2-Make good the material by mechanical or chemical means to improve its

stability

3- Cease work on the material until its physical condition is again such that it can be compacted as described in the contract. Any of the method used subject to Engineers approval In no case the contractor is allowed to compact soil without the knowledge of the Engineer. If compaction is carried out without such permission, the engineer will require additional density tests to verify the adequacy of the compacted soil. If the state of compaction is thereby shown inadequate the contractor shall at his own expense carry out such further work as the Engineer may decide is required to comply with the terms of the contract. 2000.9 EXISTING SERVICES The Contractor shall ascertain the whereabouts of all existing services on the Site, both above and below ground. Such services shall be protected, maintained, removed, sealed or rerouted in a manner prescribed by the Public Authorities concerned at the Contractor's own expense as specified under "Locating, Protecting Maintaining and Diverting Services and Public Utilities" in Section 01". Excavations to locate services shall be carried out by hand. 2000.10 TOLERANCES



T05-20/11/2013



Finished surfaces shall be constructed to plus or minus 25 mm of the elevations as indicated on construction drawings. Cut and fill areas shall be graded to within plus or minus 60 mm of the grades indicated. The Engineer shall be provided with adequate survey information to verify compliance with above tolerances. Moisture content of fill material shall be maintained within _ 2 % of optimum moisture content (OMC) as specified in the case of structural backfill. 2000.11 SUBMITTALS The Contractor shall submit the following for the approval of Engineer. -Detailed sequence of work, description of construction methods, including dewatering and erosion control measures. Formulated schedule and procedures to eliminate possibility of undermining or disturbing foundations of partially and completed structures, pipelines and embankments or existing structures. -Information on proposed compaction equipment at least two weeks prior to use. Compaction operations shall not be commenced until the equipment has been reviewed and approved by the Engineer. -Details of dust control measures at least two weeks prior to start of any earth moving activities. -Locations of proposed borrow sources for screened gravel and selected borrow, at least two weeks prior to use of material. -Laboratory test results every week or as required by the Engineer. -Written verification of fill lift thickness and compaction weekly or as required by the Engineer. -Tamping tools adapted for the backfilling of retention system voids after its removal. 2000.12 WORKMANSHIP 2000.12.1 Excavation Excavation shall be carried out in all materials and by whatever means necessary, accurately to the lines and levels on the drawings or as ordered by the Engineer. The Contractor shall trim all permanent excavations to slopes gradients shown on the drawings and surfaces shall be smooth unless stated otherwise. Any additional excavation occasioned by slips, falls, washings etc. shall be made good at material as ordered by the Engineer. a. Tolerance The tolerance limits in general shall be: • • • b.

Finished surfaces shall be constructed with in +/- 25mm of indicated levels. Cut and Fill shall be +/- 60mm of the grades indicated. Embankments shall be +/- 60 mm of the slope lines.

Finish of Excavation and Inspection The Engineer shall be provided with the adequate information of the survey to verify compliance with the tolerances.



T05-20/11/2013



No excavation shall be refilled nor any permanent work commenced until the formation has been inspected by the Engineer and his permission to proceed. If required by the Engineer the bottom 150 mm of the excavation shall not be removed until just before the commencement of the construction of permanent work. c.

Dewatering Where the excavation level is under the water table level, it is necessary to install special form of dewatering equipment around the perimeter of the excavated area. The Dewatering amount will be deducted from the contract value if the same has not been executed. The excavations shall at all times be kept free from storm water, percolating water or subsoil water by any means necessary. The contractor shall provide, maintain and clear away on completion any equipment necessary together with temporary drains and the like. Under no circumstances shall concrete be poured, fill placed, pipes laid or appurtenances installed in excavations containing water. Where the excavation level is below the natural water table and it is necessary to pump continuously form the excavation or to install a specialist form of dewatering equipment around the perimeter of the site or excavation, the Contractor will be responsible for ensuring the safety and stability of all adjoining structures and services or utilities above or below ground level. It will also be the responsibility of the Contractor, the equipment installed, shall ensure the excavation and subsequent construction shall be carried out in dry conditions. Continuous or permanent dewatering of the excavation or site may not be undertaken without the written approval of the Engineer to the work and the methods to be employed, which shall also comply with Codes of practice and local authority requirements. The water pumped from the excavations or well points shall be pumped to disposal points or sumps as approved by the Engineer and/or Local Authority and if so required be passed through settling tanks before disposal. Under all circumstances, water must be disposed off to the Municipality's sewer systems or as instructed by them. The de-watering system catering for de-watering upto about 50 cm below the final excavation level of the bottom of the blinding concrete of the pile-cap/raft shall be handed over by the Piling Contractor at the commencement of the project. If the dewatering system does not maintain the groundwater level to obtain the specified sub grade conditions, the Engineer shall be notified and the system shall be modified appropriately at no additional cost to the Client. If dewatering system causes sub grade soils to be unable to meet density requirements due to dewatering interruptions or an inadequate system, notify the Engineer and modify the system to perform as specified at no extra cost to the Client. The Contractor shall submit the following for the approval of the Engineer: Shop drawings to a scale agreed with the Engineer. Drawing shall indicate the locations and sizes of berms, dikes, ditches, all deep wells, observation wells, sand and gravel filters, settlement points, well points, sumps, recharge systems and discharge lines, including their relation to sedimentation ponds. Capacitates of pumps, prime movers, and standby equipment



T05-20/11/2013



Unless otherwise specified, continue dewatering uninterrupted until the structures, pipes, and appurtenances to be built there have been completed such that they will not be floated or otherwise damaged by an increase in ground water elevation. Dewatering Discharges Install sand and gravel filters in conjunction with well points and deep wells to prevent the migration of fines from the existing soil during the dewatering operation. Transport pumped or drained water, without interference to the other work, damage to pavement, other surfaces, or property discharge pumped water to a sedimentation pond or drainage system or as approved by the local Municipal Authorities. Do not discharge water into any storm or sanitary sewer system. Discharged water must be visible or allowed to be observed to verify compliance with U.A.E Regulations. Provide separately controllable pumping lines. The Engineer reserves the right to sample discharged water at any time. Materials for backfilling shall comply with and be laid in accordance with BS'6031 1981 Code of practice for earthworks. Approved suitable excavated material as specified under "Materials’ shall be used on the backfilling and filling next to footings, foundations, underground structures, under sub- floors, etc. and shall be laid in layers not exceeding 200 mm thick and compacted with compaction equipment or mechanical tampers when not possible to use such compaction equipment, as approved by the Engineer. A relative compaction of at least 95% of the Laboratory maximum dry density shall be achieved at optimum moisture content determined in accordance with Test 13 of BS 1377. No backfill shall be executed until the footings, foundations, etc. have been inspected, measured and approved by the Engineer. Compacted layers shall be well rammed and consolidated before the next layer is placed, until the trench is completely filled to the required levels. Power ramming shall be permitted on layers which are 300 mm above the crown of the pipes provided that all the lower layers have been hand rammed to a satisfactory level of compaction and tested in accordance with the requirements of this specification. 2000.12.2 PROTECTION SHEETING AND SHORING Sheeting and shoring shall be provided at excavations to ensure complete safety against collapse of soil at sides of excavations, to provide protection to workmen and to prevent damage to adjacent property, structures, paving and utilities. 2000.12.2.1 General The earth shoring system shall be either singular or multiple staged, comprised of soldier piles and laggings, sheet pile wall and bracing, raker or timber sheet piling, wall bracing or secant piping bracing and tieback systems. Contractor has the option of selecting a mentioned or combination of several methods to design, and to construct the shoring system as approved by the Engineer. The Contractor shall determine the size of excavation in order to accommodate the proposed methods of support. However the design shall evaluate the effect of excavation size and the proposed support system on the adjacent structures. Adjacent structures are those that are within a distance equal to twice the total depth of the excavation away from the closest edge of excavation. The Contractor shall be responsible to obtain all necessary Municipality approvals before commencing any shoring system.



T05-20/11/2013



indicating all details of the methods he proposes to adopt along with the necessary design calculations and drawings. The Contractor shall comply with the following:Earth retention systems shall be designed to withstand an additional 0.5m of excavation below the proposed bottom of excavation without design. Shoring shall be designed for stability of excavations through overburden soils and for safety during construction. Support of excavation system, including dewatering procedure shall be designed to contend with groundwater flows. Obtaining and complying with all permits, laws, regulations and codes of the Municipality and all other authorities having jurisdiction. 2000.12.2.2 TIMBER -Timber sheeting and planks shall conform to the following: -Allowable working stress of not less than 84 Kg/cm2. -Nominal thickness not be less than 75 mm (3 inches). A complete structural report to be submitted for Engineer’s approval prior installing the wood. The timber shall be first time in use.

2000.12.3 WATER Water shall be clean potable water as specified under SECTION 3000 Concrete Work. 2000.12.4 CONCRETE Concrete used as fill for making up to correct levels, of over- excavated shall be where required as instructed by the Engineer, with Grade as specified in CONCRETE WORKS. 2000.12.5 EXCAVATION PERMITS The Contractor shall be responsible for obtaining all permits relating to excavation works and shall bear all costs involved. The Contractor shall abide by all conditions, etc. laid down in such permits. 2000.12.6 UNAUTHORIZED EXCAVATIONS Excavations performed below the elevations shown or specified without the Engineer’s prior written approval shall, at the Engineer’s discretion and without additional cost be backfilled with mass concrete of approved strength or with approved structural fill, unless instructed otherwise by the Engineer. 2000.12.7 EXCAVATION IN ROCK Rock shall be defined as boulders, exceeding 0.5 m3 in volume. 2000.12.8 EXCAVATION FOR PAVED AREAS AND KERBS A. Subgrades Subgrades shall be approved by the Engineer before proceeding with construction of pavements and kerbs.



T05-20/11/2013



1) The top 300mm of subgrade resulting from excavation shall be free unsuitable material and be equal to the following percentages of maximum density at optimum moisture when tested in accordance with ASTM D1557: - Under paved areas and kerbs: - 95% 2) If the sub grade does not meet the above requirements after proof-rolling, compact the sub grade by rolling with suitable compaction equipment to obtain the density specified. 2000.12.9 VARIATIONS IN DEPTHS OF EXCAVATIONS Should the soil at the design foundation bottom level contain organic matter, the Contractor shall excavate deeper as directed by the Project Manager until non-organic soil is encountered. The additional work involved shall be measured on completion and the additional cost involved shall be adjusted in the final account. 2000.10 EXCAVATION FOR FOUNDATIONS AND SUBSTRUCTURES The levels to which the Contractor shall excavate are shown on the Drawings. Should it be found necessary to reach a more suitable strata, the Contractor shall perform all additional excavation as directed by the Engineer. During excavation for foundations, the bottom layer of excavation of minimum 200 mm in thickness, shall be left undisturbed and subsequently removed manually only when the concrete blinding is about to be placed in order to avoid softening or deterioration of the surfaces of the excavation. 2000.13 STORING OF SUITABLE EXCAVATED MATERIAL During excavation, materials suitable for backfill and fill shall be stockpiled on the Site at sufficient distance from the sides of the excavation to avoid over-loading and prevent any cave-in or mixing with the concrete during the construction of foundations. 2000.14 DISPOSAL OF UNSUITABLE AND SURPLUS EXCAVATED MATERIAL Upon the order of the Engineer, all unsuitable and surplus excavated materials shall be immediately removed, loaded and transported off Site area by the Contractor to dumps located by and approved by the local authorities concerned. 2000.15 COMPACTION Compact each layer of fill with equipment to achieve the following percentages of maximum density at optimum moisture when tested in accordance with ASTM D1557: Location Under Raft Foundations Under Paved Areas and kerbs Under Slabs on Grade General Grading

% Max. Density 98 95 95 90

A. Do not compact soil when the moisture content varies more than 3% from the optimum moisture content. Maintain moisture content by wetting or drying manipulation. Suspend compacting



T05-20/11/2013



operations when satisfactory results cannot be obtained because of rain or other unsatisfactory conditions. B. In lieu of drying by manipulation, hydrated lime, monohydrated lime or similar beneficial ingredients may be used to reduce the moisture content, reduce the plasticity index or improve workability. Apply such ingredients in a manner and quantity as recommended by the manufacturer or as required by the Soil Testing Laboratory and approved by the Engineer. 2000.16 BACKFILLING AGAINST FOUNDATION WALLS After completion of foundation walls and removal of forms, clean the excavation of all rubbish and debris before application of waterproofing and placement of backfill. Backfill as here-in-before specified for fill operations. Maintain symmetrical backfill loading and compact each layer by hand tampers or other suitable equipment. The excavated material arising from all excavation or any other imported material as directed shall be used as filling. The filling layers shall not exceed more than 150mm loose depth and compact other than Rock Fill. The excavated material; arising from all excavations declared by the Engineer's Representative to be suitable for fill is to be used as filling all other filling material shall be imported. The imported materials shall be: a. Sand and or subkha and obtained form an approved source in accordance with the latest instructions issued by the Department of Municipalities regarding the winning of material for filling. b. Shall contain no perishable or organic rubbish and no protocols in excess of 150mm in diameter. c. MDD “maximum dry density” not less than 1600kg/m3. Filling or backfilling shall be placed in layer not exceeding 15cm thickness after compaction, each layer shall be spread and moistened or dried by aeration to ensure the OWC “optimum water content” and shall be compacted uniformly up to the specified density “98%”, the number of the density test per layer shall be as instructed by the Engineer’s Representative. When machine compacted, compaction shall be by means of a 6 ton smooth wheeled roller. The Engineer's Representative shall have the right to disapprove any compacting device of inadequate capacity or in his opinion, of type unsuited to the character of the material being compacted. Heavy equipment for spreading and compacting fill and backfill shall not be operated closer to walls than a distance to the difference in height between the opt of the footings and the layer being compacted Testing to determine the density of enplane soil shall be by means of ASSHTO Standard Method of Test T147 or in accordance with BS1377: 1975. The number of density tests per layer shall be as instructed by the Engineer's Representative. When backfilling behind the retaining walls or the basement walls, no compaction shall be carried out until the wall concrete has achieved its full strength. Compact fill shall consist of approved materials obtained either from excavations or from other approved sources. Compacted fill shall comprise of suitable granular materials well graded and shall not include perishable matter or an excess of fines and should give a dense fill layer. The material shall be free of organic matter and have the following properties. Minimum Soaked CBR of 15% when the material is compacted to 95% of the maximum dry density D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



2000.17 ANTI-TERMITE TREATMENT Termite control treatment shall be carried out by an approved specialist Sub-contractor. The Contractors shall submit full details of the specialist Sub-Contractor whom he proposes to use for the approval of the Engineer. The Contractor shall submit a method statement to the Engineer detailing the most appropriate method along with the rate of application for the existing site conditions and taking in to consideration the configuration and lay of the building, for the approval of the Engineer before commencing any work. The Contractor shall also furnish full details of the chemicals he proposes to use along with all necessary documental evidence as required for compliance with the regulations, local authorities’ requirements and proven track record. The most appropriate method to be used shall be decided at the time of construction after considering all aspects. However any approval accorded by the Engineer shall not relieve the Contractor/Subcontractor of any of their responsibilities and contractual obligations. The Contractor shall follow the principle of creating a toxic barrier within the soil beneath and around the buildings, through which termites cannot pass. All internal and external back filling shall be treated prior to casting ground slabs. Particular emphasis is to place on site cleanliness during the works and the Contractor is to ensure that no timber cardboard or other cellulose containing materials discharged during the work is left in or on the ground on completion of the project. The Contractor shall ensure that the treated areas shall not be disturbed by re-leveling, digging or earth filling once the treatment is completed as this will disturb the chemical barrier. In case the treated areas are disturbed (in any way), the area shall be retreated to restore the chemical barrier at his own expense. The treatment shall guarantee that the building is safe from termite infestation for a period of 1 0 years after completion of the works. The Specialist Sub-Contractor shall give an undertaking that in case of infestation of the said structure he shall carry out such treatment as may be necessary to render the structure free from termite infestation without any extra cost to the Employer. The Contractor shall submit a counter-guarantee stating that the works have been carried out in accordance with the drawings and specifications and shall be guaranteed free from termite infestation for a period of ten (1 0) years from the issue of completion certificate. Method of Application ¾

Stage I Footings: Treatment will be carried out by spraying the termicide emulsion under the foundation using a power sprayer at the rate of (4 lit/m2 ) as per material supplier recommendation.

¾

Stage II (Treatment to Tie Beams) Treatment will be carried out by spraying the termiticide emulsion on the compacted surfaces before construction of the Tie beams.

¾

Stage III (Ground Slab) Method:



T05-20/11/2013


Client: M/s GRAND STORE L.L.C. General Specifications Period: November 2013 2

To produce a termicidal barrier, emulsion will be applied at the rate of (4 lit/m ) as per material supplier recommendation. To the formation soil before pouring the ground slab and if the fill is washed gravel or other coarse material, application will be made at the rate of (4 lit/m2) as per material supplier recommendation so that the emulsion will reach the soil beneath the fill. Application will be done by a low-pressure spray using a coarse spray nozzle. ¾

Stage IV A trench of 30cm wide and 60cm depth has to be provided by the contractor and emulsion applied (10 lit) / linear meter of trench. Application will be carried out by trenching and spraying the termiticide into the trench.

Important notice to the Contractor ¾ ¾

¾ ¾

All debris should be cleared form the site before compaction. Do not disturb the treatment area by reveling, digging or earth filling as this will break the chemical barrier. In case of any removal of soil is done from treatment area, it should be brought to the attention of the PCO firm so that the disturbed area will be treated again to restore the continuity of the chemical barrier. Construction workers and other individuals should leave the area until the termiticide is absorbed into the soil. Cannot walk in area sprayed for one hour. Before start of treatment the contractor in presence of the consultant or representative should give required spray area in advance so as to maintain effective dilution rates.

Recommendations 1- The mixing of chemical into the water shall not be less than 1/100 Chemical to water ratio. 2- Treated area should be kept undisturbed for 1 hour in order to allow the chemical to bind with the soil. 3- Treated area should be covered with polyethylene sheets to protect treated area form ultra violet rays of the sun. 4- Suitable time of the days to perform the operation is morning or evening to give protection to the treated area from excessive heat and light of the sun. 5- Treated area should be protected from any one approaching the site in order to keep the area undisturbed. 6- Concreting of the treated area should be done within 24 hours. 7- The treatment should not be recommended if there are possibilities of bad weather, i.e. sand storm or rain. Note: In case the water table level was higher than the treated level, the same shouldn’t be applied, and it will be deducted from the contract. 2000.18 Settlement The Contractor shall be responsible for making good all settlement in the works that may occur up to the end of the maintenance period of the Contract, unless stated otherwise in the Specification. 2000.19 Testing The Engineer may at any time carry out dry density tests in accordance with BS 1377, Test No. 13,77, Test No. 13 and such other tests as required under the external works section. The Engineer shall check D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



the results of the tests for the adequacy of degree of compaction by comparison with the degree of compaction achieved. Should the compaction be inadequate then the Contractor shall carry out such further work as is necessary to improve the compaction to comply with the terms of the Contract. All such additional work and testing involved shall be at the expense of the Contractor. End of Section



T05-20/11/2013



SECTION 2300

PILING



T05-20/11/2013



Section 2300 PILING This Specification covers the construction of Concrete Piling for the foundations of the Works under the contract adequate to support the loads specified, design, redesign, construction of piles, testing and replacement of defective piles and all incidental works necessary to complete the works satisfactorily in accordance with the drawings, approved drawings and specification and as directed by the Engineer. Where materials and workmanship of reinforced concrete shall be in accordance with Section 3 Concrete Work. Other items in piling that are not described or need to be further explained shall be in accordance with the relevant specifications in other Sections of this Document. 2300.1 GENERAL Piling shall conform in all respects with the principles contained in BS 8004: 1986. The Contractor shall report immediately to the Engineer any ground conditions that differs from those expected by the Contractor from his interpretation of the site Investigation records which in his opinion would materially affect the bearing capacity of the pile. The heads of piles shall be within 75 mm of the correct plan positions. Vertical piles shall not deviate by more than one degree from the vertical, and raking piles shall not deviate by more than two degrees from the designed angle of rake. Where piles have not been positioned or driven within the limits described in the Contract, no method of forcible correction shall be permitted. The Engineer may require piles so positioned to be withdrawn and re-driven, or take such other action as he considers necessary all at the expense of the Contractor. The Contractor shall carry out the work in such a manner and at such times as to minimize noise and disturbance. Any proposals by the Contractor for ground treatment of any nature or for temporary lowering of the water table by well points or any other method shall be subject to the approval of the Engineer. The Contractor shall however remain fully responsible for any effects of such ground treatment or control of the level of water tables',-uploadings and structures in the vicinity of the Works. Any proposals by the Contractor for underpinning, existing structures in the vicinity of the works shall be subject to the approval of the Engineer. The following British, ACI and ASTM Standards shall be complied with where applicable: BS No.

Title

BS 12:1991 BS 812 BS 882:1992 BS 1199 & 1200:1976 BS 1881 BS 3148: 1980 BS 4254: 1991 BS 4466: 1989

Ordinary Portland cement. Testing of aggregate. Aggregates from natural sources for concrete. Building sands from natural sources. Testing Concrete (including non-destructive tests methods). Tests for water for making concrete. Two part polysulphide based sealant. Scheduling,dimensioning,bending & cutting steel reinforcement. Cold reduced steel wire for reinforcement. Steel fabric for the reinforcement. Methods of testing cement.

BS 4482: 1985 BS 4483: 1985 BS 4550



T05-20/11/2013



BS 5075 Part 2: 1991 Part 3: 1990 Part 4: 1990 BS 5642: Part 1: 1978 : Part 2: 1983 BS 6954 BS 7263: Part 1: 1990 : Part 2: 1990 BS 8007: 1987 BS 8110

Concrete Admixtures. Concrete mixes. Procedures for producing and transporting concrete. Sampling, testing and assessing compliance of concrete. Sills. Copings. Tolerances for building. Pre-cast concrete flags, kerbs, edging and quadrants. Code of practice for Laying Pre-cast concrete units. Concrete structures for retaining aqueous liquids. Structural use of Concrete.

BS EN 196-61992 BS EN 196-71992 BS EN 196-21:1992

Methods of testing cement - Determination of fineness. Method of taking and preparing samples of cement. Determination of chloride, C02 & alkali content of cement.

ACI ACI 305 ACI 308 ACI 318:89

Hot Weather Concreting. Standard Practice for Curing of Concrete. Building Code Requirement for Reinforced Co

ASTM ASTM A615/A615M-93 ASTM C33 -93 ASTM C94-94 ASTM C 1 50-94

Deformed and Plain Billet Steel Bars Concrete Aggregates. Ready mixed concrete Ordinary Portland cement, Type 1.

ASTM C 1 86-94

Heat of Hydration of Cement.

Details of soil investigations will be provided to the Contractor. However no responsibility shall be accepted by the Employer/ Engineer for the accuracy of the report including opinions and conclusions therein. The Contractor is to carry out any further soil investigations he requires at his own expense. 2300.2 PILING SYSTEM Piles shall be cast-in-situ reinforced concrete, bored system using temporary casing without Bentonite slurry, unless necessitated due to collapse of sides in rock or otherwise specified, all as shown on the Drawings and as directed by the Engineer. The bearing capacity and crushing strength of each pile shall be as indicated on the Drawings. On receipt of the Soil Investigation report the Contractor shall submit a method statement along with detailed Drawings and Specifications for the piles he intends to use or for any alternative piling system he proposes to adopt based on Contract Drawings and Specifications together with calculations and details of the type, number and length of piles, loads carried, casting and/or driving methods, lengthening arrangements and pile caps where required for the approval of the Engineer. Such drawings and specifications, as approved by the Engineer, shall form an integral part of the Contract Documents. The Contractor shall be responsible for providing piles/pile groups to withstand the loading specified with a sufficient margin of safety as required by the loading test.



T05-20/11/2013



From the results of the test piles and other available information, the Contractor shall determine the lengths of piles necessary to carry the specified safe working loads and shall submit his proposals to the Engineer for approval. He shall not cast any piles without prior approval of the Engineer. Approval so accorded shall not in any way relieve the Contractor of his responsibility to provide piles capable of carrying the required loading. 2300.3 CONCRETE FOR PILING All concrete work for piling shall comply with the relevant clauses in Concrete Work. 2300.4 CLASS OF CONCRETE The concrete for the construction of piles shall be Grade 40 and with Sulphate resisting Portland cement complying with ASTM C 150 Type V. 2300.5 COMPOSITION AND STRENGTH OF CONCRETE The composition of concrete shall be such that it meets the requirements specified in Table l. The concrete mixes shall be as detailed under prescribed mixes and trial mixes in Section 3000 Concrete Work except that the details of table 1 herein shall be followed: TABLE 1 28 Day Cube Strength Grade Characteristic Prescribed Min.Maximum Consistency/Strength Trial Mix Cement Water (Slump)Content Cement Ratio 40

40N/mm2

45N/mm2

420 Kg/m3

0.45

150-200mm

All concrete aggregates, cement and water shall be sampled and tested as frequently as deemed necessary by the Engineer as detailed under the relevant clauses in Section 3000-Concrete Work. All test samples shall be supplied by the Contractor at his own expense. Samples shall be obtained in accordance with the latest editions of ASTM, ACI Code or any equally approved standard. The minimum cover to the reinforcing bars shall be 75 mm unless otherwise shown on drawings and the Contractor shall ensure that no steel is displaced from its position during 2300.6 PLACING CONCRETE No concrete shall be placed until all boring within a radius of 3 times the diameter of the larger pile (centre to centre of piles) has been completed, nor until all the shells for any one cluster have been completely bored. If this cannot be done, all boring within above limits shall be discontinued until the concrete in the last pile cast, has been set for at least 24 hours. All piles except those that are to be finished at a lower level shall be placed with their tops at least 1 metre above pile cut-off level in their respective pile caps. All boreholes, except for piles that are to be finished at a lower level or unless otherwise specified, shall be filled with concrete to the top of the hole so that the Engineer can be assured that all the bentonite has been displaced by the concrete. Bore holes for piles where concrete is to be finished at a lower level and is not to be filled to the top of the bore, if approved by the Engineer, shall be filled to the minimum of 1500 mm above the designated cut-off



T05-20/11/2013



level. Empty pile borings shall not be left open but shall be backfilled with surplus excavated material to ensure site safety. 2300.7 REINFORCEMENT The reinforcement shall be deformed high grade steel with a minimum yield strength of 4200 Kg/cm2, to sizes and lengths as indicated on the Drawing and in conformity to the specifications described under Concrete Works - Section 3000. 2300.8 PILE RECORDS A record of all piles installed shall be kept by the Contractor and a copy of the record of work done each day shall be given to the Engineer within 24 hours. On completion of the piling, the Contractor shall deliver to the Engineer a drawing recording the final depths of all piles relative to cut off depth or penetration depth as appropriate. 2300.9 SONIC INTEGRITY TESTING In addition to the other specified tests all piles shall be sonic integrity tested in accordance with the following requirements: (a)The work must be carried out by an independent testing company approved by the Engineer, experienced in the use of the equipment and in the interpretation of the results with respect to cast-insitu piles. (b)The pile head must be clean, accessible, sound and free from standing water. The area to be hammered shall be ground smooth to the satisfaction of the testing company and/or the Engineer. (c)The concrete should not be less than 7 days old at the time of testing. (d)Details of the appropriate lengths of the piles and the ground conditions should be made available to the testing company. (e)The method of testing, equipment to be used, output and report formats shall be submitted to the Engineer for his approval before work commences, (f)A full report of the tests carried out complete with full references to individual piles and their locations shall be provided to the Engineer within 7 days of the tests being carried out. (g)Any pile found possibly defective will be reported by the testing company to the Engineer immediately, without waiting for the full report. (h)Sonic integrity tests on working piles to be subject to load tests shall be carried out before and after the piles have been load tested and/or as directed by the Engineer. (i)Testing of piles shall be carried out once piles have been cut back to their final working level and/or as directed by the Engineer. 2300.10 LOADING TESTS Before commencing work, the Contractor in collaboration with the Engineer shall establish tentative penetrations and depths for the piles. This does not relieve the contractor of his responsibility to deliver piles having the bearing capacities required and passing the required load tests. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The Contractor shall not perform any load test without securing the written approval of the Engineer on the method to be adopted and the equipment and tools to be used for the test. Loading tests shall be carried out at the date ordered on individual piles selected by the Engineer. Piles selected by the Engineer shall be tested in accordance with BS 8004:1986 or ASTM Dl 143 for the test loads indicated on drawings as follows: (a)The test load shall be applied by a method approved by the Engineer and shall be measured within an accuracy of 2 percent. Settlements shall be measured with in an accuracy of 0.25 mm. (b)The test load and unloading shall be applied in suitable increments and as smoothly and expeditiously as possible. (c)The load after each increment shall be kept constant until the rate of settlement does not exceed 0.25 mm per hour. (d)The amount of settlement shall be recorded before the next increase of load. (e)The full test load shall be maintained for 48 hours and the total settlement recorded. (f)The load after each reduction shall be kept constant until the rate of recovery does not exceed 0.25 mm per hour. (g)The amount of recovery shall be recorded before the next decrease of load. (h)The Contractor shall within. 24 hours of the completion of the test submit to the Engineer for each pile tested graphs showing: Load and settlement plotted above and below a common line of time: (ii)Settlement and recovery plotted vertically against a base line of load. (i)The settlement of the pile under the test load and the recovery of the pile after it’s ubsequent removal shall be within the limits agreed with the Engineer. Each pile to be tested shall be loaded axially with not less than 150% of the working load or as specified on the Drawings. The test shall not be commenced until the concrete has been set at least for seven days after concreting, and shall be maintained on the pile as aforementioned or for such further period as the Engineer may direct. Non-production test piles shall be tested to failure or 300 % of the working load whichever occurs first. 2300.11 DYNAMIC PILE TESTING Dynamic pile test shall be carried out by a specialist testing agency with a proven record and who is fully conversant with the test, interpretation and reporting procedures using a pile driver analyzer, strain transducers and accelerometers. Dynamic pile test shall be carried out strictly in accordance with ASTM D 4945-89 for loads as indicated on drawing and to piles selected by the Engineer at site. The Contractor shall be responsible to ascertain and coordinate the requirements of the specialist testing agency as regards the preparation of the pile surfaces, additional exposed lengths of the pile (1.5 to 2 times the pile dia.), providing hole in the center of the pile top (about 130 mm dia. x 155 D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



mm deep) for placing test rod, levelling of the pile top, etc., and ensure that the same are provided either by the Piling contractor during piling or by the contractor himself depending on the type of work and their capabilities. Based on the field test results the specialist testing agency shall perform the required laboratory analysis and review the following: -Driving stresses (Compression or tension) -Integrity of the Pile. -Bearing capacity. The specialist testing agency shall submit in triplicate a detailed report of the tests along with the results and his finding, recommendations and comments to the Engineer. All testing shall be as detailed under the laboratory testing clause. 2300.12 FAILURE OF PILE A pile shall be considered to have failed when any of the following conditions occur: (a)On completion of a load test, the residual settlement after rebound exceeds 6 mm. (b)The safe working load (designed pile load) as specified in the drawing shall not have been achieved. (c)The maximum settlement exceeds 10 percent of the least lateral dimension of the pile under the ultimate load. 2300.13 RECTIFICATION OF FAILURE In the event of a pile failing a load test, notwithstanding any contrary proposals by the Contractor, the Engineer may insist on the following methods of rectification (as a minimum): When a non production test pile fails and is confirmed that the failure is due to design aspects and not due to defects in the piling operation, the Engineer shall order such changes in the design of the pile as he considers necessary. For each main piling operation test pile failure 3 piles further shall be tested. If these piles fails, the Engineer shall order such changes in the design of the piles as considered necessary. In the case of the pile of the main piling operation failing a test load but subsequently piles passing the load test new piles shall be driven to replace the defective piles in positions agreed by the engineer at the expense of the Contractor. In the event of additional works being carried out as a result of new piles being required under this Clause, the cost of this additional work will be at the expense of the Contractor. 2300.14 CORE TESTING OF PILES 10 percent of all piles which are filled in blind boring (piles where concrete flow out is not achieved) shall be core tested in the following manner: (a)

The top 1 000 mm of the pile shall be cut away to expose a height of 500 mm of pile above the cut off level.

(b)

The top of the exposed pile shall be levelled to allow for a 1 00 mm diameter diamond cone 300 mm deep to be taken in the centre of the pile.



T05-20/11/2013



(c)

The core shall be removed and tested for compressive strength and any contamination by deleterious substances such as bentonite.

(d)

Once the core test has been approved the pile in question shall be cut down to its final level in the pile cap.

(e)

Should a core test fail on a particular pile the contractor may take a further 200 mm core after cutting the pile down to 200mm above cut off level. If this test should also fail the pile shall be condemned.

(f)

If any of the core tests on the 1 0% of the pile fail then all piles will be tested in the above described manner at no extra cost to the Employer.

2300.15 CLEARANCE OF WORKS Upon the completion of the works the Contractor shall clear away and remove from the Site all constructional plant, equipment, surplus materials,-rubbish, etc. and leave the whole of the Site and Works clean and in perfect condition to the satisfaction of the Engineer.

End of Section



T05-20/11/2013



SECTION 3000

CONCRETE WORKS



T05-20/11/2013



Section 3000 CONCRETE WORK 3000.1 GENERAL This section deals with different types of concrete, materials, design, testing and specification, workmanship. Except where standards are varied by the requirement of the this specification the provisions of the British Standard codes of practice BS 8110-1985 the structure use of concrete in building be help to be incorporated in the specification. The contractor shall follow the guide lines contained in the latest edition of the codes, specifications and standards, except where more stringent requirements are shown or specified. Plant, field inspection, concrete, reinforcement and other ingredients testing shall be on behalf of the contractor and shall be performed by the independent laboratory and as per the instructions of the Engineer. This section describes and specifies work required for plain and reinforced concrete, including formwork intended to be used for the Project under the Contract in accordance with the Drawings, and or Bills of Quantities and as directed by the Engineer.

Concrete In all mixes, except MASS, the proportion of cement, fine and coarse aggregate and aggregate and the water-cement ratio are to be determined minimum cube strength specified in the following table and have the workability required for the work in hand, But the cement- aggregate ratios shall not be less than specified in the Table - The Engineer shall be informed of the proportions proposed. The concrete to be used in each part of the works shall be of the class described in the drawing and shall conform to the requirements of the grade as per the standard unless otherwise specified. Mix for structural concrete shall be designed by the contractor. The grade of concrete shall be as shown on the drawings and as denoted by the minimum 28 day works cube strength and the maximum size of aggregate. Cement for blinding and Sub Structure concrete shall be sulphate resisting.

The contractor to be fully responsible to submit the Mix design for the engineer approval before commencement of work. Concrete strength to be as follows (See Structural Drawings): Ready-Mixed Concrete -- Ready-mixed concrete to be used for all concrete work. Amount of Water and Slump Test The amount of water used in concrete mixtures shall not exceed the minimum amount necessary to produce suitable concrete according to the approved mix design. Type of Work Nominal Slump Maximum Slump cm’s cm None reinforced concrete

2.5 – 7.5

7.5

Reinforced concrete Structures, foundations Footings

2.5 – 7.5

10.0



T05-20/11/2013


Reinforced concrete Walls, slabs, columns


2.9 – 9

11.0

The temperature of the concrete when placed shall not exceed 32ºC or shall be concrete mixed or placed when the shade air temperature is 35C or above, or is expected to reach such a level during concreting, without special permission from the Engineer. 3000.2 APPLICABLE CODES AND TESTS Prior to commencement of Concrete Work, the Contractor shall submit samples to the Engineer before sending them to the laboratories for testing to establish the probability of the materials passing tests for specified requirements. After the Engineer is convinced that the samples with their sources are truly representative samples and sufficient materials are available on the Site for the completion of all concrete works under the Contract, the samples shall be approved and sent to the laboratories for testing. All concrete aggregates, cement and water shall be sampled and tested as frequently as deemed necessary by the Engineer. All test samples shall be supplied by the Contractor at his own expense. Samples shall be obtained in accordance with the latest editions of the American Society for Testing and Material (ASTM), American Concrete Institute (ACI) Code or any equally approved standard. The requirements of the British Standards, BS 81 1 0 "The structural use of Concrete", BS 8007:1987 "Code of Practice for the Design of Concrete Structure for retaining Aqueous Liquids", shall be followed where applicable. 3000.3. QUALIFICATIONS The Contractor shall follow the guide lines contained in the latest editions of the codes, specifications and standards listed above, except where more stringent requirements are shown or specified. All tests including re-testing of rejected materials and installed work shall be done at the Contractor’s expense. 3000.4 METHOD STATEMENT During the mobilization period the Contractor shall submit a method statement detailing his proposal for the organization of all concreting activities at the site as well as off site for the approval of the Engineer. MATERIALS FOR CONCRETE 3000.5 CEMENT Cement shall be Portland type, originating from approved manufacturers, obtained in sealed and labelled bags, each 50 kgs. net capacity. The name and brand of the manufacturer shall plainly be identified on the bags and the cement shall be delivered to the Site in good condition. Ordinary Portland cement complying with BS 12 or ASTM C 150 for Type I shall be used for all concrete work. Cement shall be of recent manufacture and shall be used within a period of 3 months from production.



T05-20/11/2013



Cement delivered in bulk shall be accepted only if a central mixing plant is used. The quality of cement shall conform to the Standard Specifications for PORTLAND CEMENT of ASTM Designation C 150 - 74 Type I for use in general concrete construction and Type V - for use when high sulphate resistance is desired. 3000.6 CEMENT TEST AND ANALYSIS Prior to any shipment to site the Contractor shall supply the Engineer with the manufacturer's statement of specification and test certificate together with the date of manufacture certified by an independent agency in the country of origin. The Engineer shall have access to the cement store and have the right to take samples for these tests in accordance with ASTM C186-94, BS EN 196-6:1992 and BS EN 1967:1992 at no extra cost to the Employer. 3000.6.1 Storage of Cement All cement shall be stored in suitable weatherproof and approved storage sheds which will protect the cement from dampness. The Contractor shall remove all rejected cement from the site without delay. Not more than 1 0 bags shall be piled one on top of the other while shoring in bags. Suitable shading shall be provided to limit the temperature to 40 deg. C. 3000.6.2 Rejection The Contractor shall notify the Engineer of dates of delivery so that there will be sufficient time for sampling the cement either at the mill or upon delivery. 3000.7 AGGREGATES 3000.7.1 GENERAL All aggregates fine and course shall comply in every respect with BS 882: 1992 and ASTM C33. They shall be well graded, clean, hard, free from undesirable material, and obtained from an approved source in Ras Al Khaimah. 3000.7.2 GRADING OF AGGREGATE Course aggregate shall be prepared as single sized and blended to produce a normal size grading. The combined grading shall be within the appropriate grading limits laid down in BS 882 and as described below. Course aggregate shall be prepared as single sized and blended to produce a normal size grading. The combined grading shall be within the appropriate grading limits laid down in BS 882 and as described below. The gradation of fine aggregate shall be in accordance BS 882 and shall be crushed from Ras Al Khaimah. All-in aggregate shall be permitted for low-grade concrete only. For normal use, aggregates shall consist of fine aggregates (those passing a 5 mm (3/16") sieve, and coarse aggregates (those retained on a 5 mm (3/16") sieve batched separately which, when combined together, give a grading curve which lies within the following limits: Sieve Size%

Size% Passing by wt.



T05-20/11/2013


Grading Sieve No . 3/4 3/8 3/16 7 14 25 52 100


Percent Passing 100 45 - 75 30 - 50 23 - 40 15 - 34 9 - 12 2 - 10 0 - 15

The amount of material passing BS 75 micron sieve in the combined aggregates when tested in accordance with BS 812 (wet sieving method) shall not exceed the following limits:- Fine aggregate - 3% by weight - Coarse aggregate - 1 % by weight 3000.7.3 COARSE AGGREGATE All coarse aggregate for concrete shall conform to Standard Specifications for Concrete Aggregate ASTM Designation: C-33. Coarse aggregate shall consist of gravel, crushed gravel, or crushed stone, having hard, strong durable pieces, free from adherents. It shall not contain harmful materials such as iron pyrites, coal, mica, alkali, laminated materials, or any material which may attack the reinforcement, in such a form or in sufficient quantity to affect adversely the strength and durability of the Concrete. If necessary, coarse aggregate shall be washed to remove deleterious substances, and shall conform to the requirements of these specifications. 3000.7.3.1 Deleterious Substances The amount of deleterious substances shall not exceed the following limits: Max.Permissible - Soft fragments ……………………… 2.0 - Coal and Lignite ……………… …….. 0.5 - Clay lumps .............………………….. 0.25 - Materials passing the No.200 sieve . ..... 1.0 - Thin or elongated pieces (length greater than 5 times average thickness).......………………. 4.0 - Other local deleterious substances ..............…………………. 0 - Shell content ………………………… 1.0 3000.7.3.2 Percentage of Wear Coarse aggregate shall conform to the following requirements: Percentage of wear. Los Angeles test, not more than .........30 30007.3.3 Soundness When the coarse aggregate is subjected to five alternations of the sodium sulphate soundness test, the weighed loss shall not exceed 10 (ten) percent. In the event of failing to obtain a satisfactory result it shall be subjected to an alternate freezing thawing test.



T05-20/11/2013



Coarse aggregate, when tested according to the requirements of ASTM, shall meet the following gradation and shall be uniformly graded within the limits stated in Table I here below: _________________________________________________________________ Percentage by Weight Passing _______________________________________________________________ Grading Grading Grading (3/4" to No.4) (1" to No. 4) (2" to No. 4) 2 1/2 inch 100 2 inch 95 - 100 1 1/2 inch 100 1 inch 100 95 – 100 35 - 70 3/4 inch 95 - 100 1/2 inch 25 - 60 10 - 30 3/8 inch 20 - 55 No. 4 0 - 10 0 - 10 0- 5 No. 8 0- 5 0- 5 No. 200 0- 1 0- 1 0- 1 ASTM

Remedial Treatment of Surfaces Any remedial treatment of surfaces shall be approved from the Engineer following inspection immediately after removing the form work and shall be carried out without delay. '' Any concrete, the surface of which has been treated before being inspected by the engineer, shall be liable to rejection. No claim of any sort will be admissible for carrying out any such repair work. Finishes All concrete surfaces which are not exposed (sawn form work ) are to be left as struck from the mould, except that any surfaces which are found to be honeycombed shall be made good as soon as they have been inspected by the Engineer. The making good shall be done with a mixture of fine aggregate and cement in similar proportions to the concrete and as dry as possible. All exposed concrete surfaces with wrought form work are to have a rubbed finish, which shall mean the application of rubs. The first rub shall be made after the removal of the forms; the surface shall be wetted and rubbed with a No. of 20 carborandum stone to remove all mould marks. The second rub shall be made when finishing the concrete work when the surface shall again be wetted, and rubbed with a No of 24 carborandum stone, excess paste being removed with a we brush. The final surface shall be free from all irregularities and discoloration and shall be an even level surface. If any honeycombing is found on exposed faces, the Engineer's decision as to whether the concrete shall be cut and replaced or made good shall be final. 30007.4 Fine Aggregate All fine aggregate for concrete shall conform to Standard Specification for Concrete Aggregates of ASTM Designation: C-33 and also to the detailed requirements given Table 300A (appended here below). It shall not contain harmful materials such as iron pyrites, coal, mica, shale, alkali, coated grains, or similar laminated materials such as soft and flaky particles, or any material, which may attack the reinforcement, in such a form and in sufficient quantity to affect adversely the strength and durability of the concrete. Fine Aggregate passing sieve No. 4 shall not contain D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



any voided shells. Fine aggregates shall be washed with clean water and sieved to remove deleterious substances and shall conform to the requirements of these specifications and as per Dubai Municipality requirements. Fine aggregate from different sources of supply shall not be mixed or stored in one pile nor used alternately in the same class of construction or mix. Table 300A ___________________________ Grading Percent Sieve Passing No. 3/8 100 4 95 - 100 8 80 - 100 16 50 - 85 30 25 - 60 50 10 - 30 100 2 - 10 Organic Impurities

The Colour shall have an intensity not darker than twothirds the intensity of the standard colour solution. (Not darker than Plate 2 as determined by the Standard Method of Test for Organic Impurities in Sands for Concrete of ASTM Designation: C-40.

Silt

Not more than 2 percent.

Mortar strength

Compression ratio not less than 95 percent.

Soundness

Weighted average loss when subjected to 5 cycles of the soundness test using magnesium sulphate, not more than 10 percent.

Shrinkage

The mean aggregate shrinkage test shall be of lowest shrinkage category given in category given in table 1 of BRE Digest 35, 1968.

3000.7.5 Testing of Aggregates All fine and coarse aggregates shall be imported from sources approved by the Engineer and shall be within the limits laid down in the table below in respect of contamination and reactivity: Property Clay, Silt and Dust

Method test and Standard Wet Sieving through 0.075 mm sieve, BS 812: Part 103.

Maximum Limit (by %weight) Coarse Aggregates Natural or Crushed Gravel 1%

Crushed Rock 1% Fine Aggregates Natural Sand or Crushed Crushed Rock 1% Crushed Rock 1% D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Fine Aggregates Natural Sand or Clay Lumps Organic Impurities

ASTM C 142 ASTM C 40

Chlorides AS Cl

Acid soluble BS 812: Part 1 1 7

Sulphates as S03

Acid Soluble BS 812: Part 1 1 8

Potential alkali reactivity

Coarse Aggregate Fine Aggregate

1% 1%

Colour standard not darker than Plate No. 3 Coarse Aggregate 0.0002 Fine Aggregate 0.0005 Coarse Aggregate Fine Aggregate

0.003 0.003

If the total amount of potentially reactive material exceeds 0.5 % by weight of the total aggregate the alkali in the cement shall be restricted to 3 Kg/m3 of concrete Innocuous

ASTM C 289

Chemical method of Cement

ASTM C 289

Innocuous

Aggregate

ASTM C 227

6 month expansion,

0.1 % max

The tests and the maximum acceptable limits and samples taken for testing in accordance with the relative specified standards shall be as indicated in the table below: Description Contamination and Reactivity

Standard As detailed in the table above

Maximum Limit (% by weight)

Grading

BS 812: Part 103 (Dry)

Surface texture

Descriptive, BS 812

Limit not applicable

Water absorption

Weighing dry & saturated ASTM C 128 / C127

Coarse Aggregate 2 % Fine Aggregate 2.3 %

Soundness 5 Cycles

ASTM C 88

Drying shrinkage

BS 812: Part 120

MgSO40.12 Na3SO40.12 Shrinkage

Shell content Coarser than 1 0 mm Size 2.36 & 5 mm Finer than 2.36 mm

BS 812 Part 106

As detailed Aggregates

maximum maximum

under

0.0005

0.05 0.1

Particle shape D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Flakiness index Elongation index

BS 812 Part 105.1 Part 102.2

maximum maximum

0.25 0.25

Specific Gravity

ASTM C 128/C 127

Course & Fine aggregate 2.6

Mechanical Properties

1 0% fines, BS 812: Part 1 1 1 Impact Value Part 112 Los Angeles abrasion test (ASTM C-1 31 or C-535)

Minimum

100 kN 30 % 0.3

The contractor shall allow for frequent testing of aggregates as described in the table below. The Engineer might alter the frequency of testing depending on the condition of material delivered to site or at the concrete supplier yard. 3000.8 SAMPLING OF AGGREGATES Sampling and testing of aggregates when required by the Engineer shall be carried out in accordance with BS 812. If adequate laboratory facilities do not exist on site, samples must be taken and sent to a testing laboratory approved by the Engineer. Samples of about 0.015m3 (1/2 cu.ft.) and 0.03 m3 (1 cu.ft.) of fine and coarse aggregate shall be sent in suitable airtight containers. 3000.9 STORAGE OF AGGREGATES The ready mix concrete supplier shall at all times maintain sufficient quantities of each type of aggregate considered by the Engineer to be sufficient to ensure continuity of work. Each type and grade of aggregate shall be stored separately in bins, in such a manner that segregation of the various size particles shall not occur. The floors of the bins shall be of concrete or other approved material having sufficient slope to ensure adequate drainage of aggregates before being used for concreting. 3000.10 AGGREGATE FOR MORTAR Aggregate for mortar shall conform to the Standard Specifications for Aggregate for Masonry Mortar of ASTM Designation : C-144 and shall consist of hard, strong, durable uncoated mineral or rock particles, free form injurious amounts of organic or other deleterious substances. 3000.11 ORGANIC IMPURITIES Fine aggregate for mortar when subjected to the colorimetric test for organic impurities and producing a colour darker than the standard colour shall be rejected. 3000.12 WATER Water for mixing of concrete shall be fresh, clean and free from injurious amounts of oil, acid, or any other deleterious mineral and/or organic matter. It shall not contain chlorides such as sodium chloride in excess of 1000 ppm nor sulphates such as sodium sulphate in excess of 500 ppm. It shall not contain any impurities in amount sufficient to cause a change in the time of setting of Portland Cement of more than 10 percent, nor a reduction in compressive strength of mortar of more than 5 percent compared to results obtained with distilled water. The pH of the water for mixing and curing of concrete shall not be less than pH 4.5 or more than pH 8.5 3000.13 ADMIXTURES Admixtures in concrete shall be used only when approved by the Engineer and shall conform to the D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



requirements of the ASTM Standard Specifications Designations C-494 Type "D" Water Reducing and Retarding Admixtures. 3000.14 COMPOSITION OF CONCRETE The cement content, coarse aggregate size, water content, consistency and the approximate weights of fine and coarse aggregate (saturated surface - dry basis) for the class of concrete shall be within the requirements of Tables I and II below. Table II is given for indicative purposes and is not binding. The total sodium chloride content of any materials used for making concrete shall be less than : - For mass concrete ................. 1.5 percent - For reinforced concrete ........... 0.7 percent expressed as a percentage, by weight of the cement. In calculations made under the provisions of this Clause, any chloride, other than sodium chloride in the materials shall be converted to the equivalent of sodium chloride and be added to the amount of sodium chloride. The sulphate content shall not exceed 0.03 percent by weight of the cement. All concrete up to and including ground floor slab shall use sulphate resisting cement. Concrete above this level shall use ordinary Portland cement. 3000.15 VAPOUR BARRIER Polyethylene sheeting minimum 0.15mm thick of approved manufacturer tested in accordance with ASTM E96 and E154. 3000.16 CURING MATERIALS 3000.16.1

Liquid Membrane Compound AASHTO M148 or ASTM C309, Type 1-D with fugitive dye 2; formulated to disintegrate after 28 days, and guaranteed not to affect the bond of applied finishes. Methods for determining the efficiency of curing compounds shall be in accordance with ASTM C156 or United Kingdom Ministry of Public Building and Works (M.P.B.W) for curing membrane or United Kingdom Department of Transport (D.O.T)

3000.16.2

Polyethylene Film ASTM C171, 0.10mm thick, opaque black

3000.16.3

Water B.S. 5328 and B.S. 3148

3000.16.4

3000.17

Notwithstanding what has been stated above, the Contractor must allow in his Tender for testing the type curing compound he proposes to use.

MOIST CURE, HARDENER AND SEALER



T05-20/11/2013



A. Hardeners 1) ‘Lapidolith’ – Sonneborn Contech, USA 2) ‘Nitoflor Lithurin’ – Fosroc 3) ‘Sciolith’ – Chem-Masters Corp., USA 4) ‘Pena-lith’ – W.R. Meadows Inc., USA 5) Other equivalent products from F.E.B. B. Sealers 1) ‘Son-No-Mar’ – Sonneborn Contech, USA 2) ‘Nitoflor FC110’ – Fosroc 3) ‘ Traz’ – Chem Masters Corp., USA 4) ‘Tiah’ – W.R. Meadows Inc. USA 5) other equivalent products from F.E.B. 3000.18 WATERSTOPS Extruded shapes formed of virgin polyvinylchloride, tensile strength 134 Kg/cm2, minimum elongation 200%. The type and size of the water stop shall be suitable to its particular application as recommended by the manufacturer and be subject to the approval of the Engineer. Use prefabricated joints. 3000.19 COMPACTION AND VIBRATION Full compaction of the concrete shall be achieved throughout the entire depth of the layer and generally vibrators shall be used to achieve this. The concrete shall be thoroughly worked against the formwork and around the reinforcement and successive layers shall be thoroughly worked together. Air bubbles formed during mixing shall be expelled as far as practical and particular care shall be taken where sloping formwork is used. Unless otherwise directed by the Engineer, approved power driven vibrators shall be inserted at such distances apart or applied in such a manner as will ensure that the concrete is satisfactorily and uniformly compacted. Immersion vibrators shall penetrate the full depth of the layer and when the underlying layer is of fresh concrete shall enter and re-vibrate the layer to ensure the successive layers are knitted together. Over vibration (causing segregation, surface laitance or leakage through the formwork) shall be avoided. Immersion vibrators shall be withdrawn slowly and vertically to prevent the formation of voids. Vibrators shall not be used to work the concrete along the forms, or in such a way as to damage formwork, other parts of the works, or displace the reinforcement. External vibrators shall not be used except with the approval of the Engineer. 3000.20 FORMWORK 3000.20.1

For unexposed surfaces and rough work, use Exterior Type Douglas Fir, Grade B-B (concrete form) plywood, conforming to NBS ps-1, minimum 19mm thick. Before reusing forms, withdraw nails and thoroughly clean surfaces to be in contact with concrete.

3000.20.2 For exposed surfaces not otherwise specified use special exterior Type Douglas Fir, Grade A-B plywood, conforming to NBS ps-1 minimum 19mm thick or high density (60-60) overlay ply form, Class 1 EXT-DFPA, sanded grade having a hard semiopaque resin-fibre overlay on both sides, minimum 19mm thick and constructed so that finished concrete will be straight, smooth, dense, free from honeycombs, bulges, or depressions. Keep joints between plywood sections to a minimum and make tight and strongly backed so that adjoining edges remain flush and true. Unsightly joint D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



marks will not be permitted. Cover joints on exposed surfaces with smooth-faced fibre reinforced tape. 3000.20.3 Location of joints must be submitted to the Engineer for approval. 3000.20.4 Prefabricated formwork systems may be used for all classes of concrete provided the manufacturer’s printed instructions and recommendations are followed and the system has been approved by the Engineer. Joints between sections of prefabricated forms shall be taped unless otherwise recommended by the manufacturer and provided always, in the case of such recommendation, the forms are water and mortar-tight to the Engineer’s satisfaction. 3000.21 FORM COATING B.P. CCM3 (British Petroleum) or B.P. CM3® (British Petroleum) or Calform (Caltex) or Form wax of a type which does not impart any stain to concrete nor interfere with the adhesion of any finish, sealant, waterproofing material applied to any concrete surface and must be approved by the Engineer. 3000.22 FORM TIES For securing forms where surfaces will be exposed in the finished work, use tie screws with removable plastic cones, removable bolts, special removable ties, tie wires or series 3000 stainless steel snap ties. For all other forms, either bolts or wires may be used. Use ties of such type that when forms are removed, no metal is closer than 40mm from the finished concrete surface. 3000.23 GROUT Non-Metallic One of the following or equal approved: 1) “Sono Grout” (Sonneborn – Contech) 2) “Five Star Grout” (U.S. grout Corp) 3) “Materflow 713” (Master Builders Co.) 4) “Euco NS” (The Euclid Chemical Co.) 3000.24 PROPORTIONS After the materials provided by the Contractor have been accepted for the works, the proportions and equivalent batch weights shall be determined which will produce concrete having not less than the strength required. 3000.24.1 Trial Mixes The actual proportions shall be determined on the basis of trial mixes made by the Contractor and conducted with the content being determined by means of yield test in accordance with American Society for Testing Material (ASTM) Designation (C-138). The proportions will be such as to require (within a tolerance of plus or minus one (1) percent), the cement content shown in Table I as the minimum cement content, provided, however, that if the materials supplied by the Contractor are of such a nature or are so graded that proportions based on the minimum cement content cannot be used without exceeding the maximum allowable water content specified in Table I, the proportions will be adjusted so as to require the least amount of cement which will produce concrete of required plasticity and workability without exceeding such maximum allowable water content. No additional compensation will be made for the increase in quantity of cement required. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013


3000.24.2


Contents

The mixes required will be designated in kilograms of fine coarse aggregate exclusive of free water, per sack (50 kilograms) of cement and in litres of total mixing water per sack of cement on the basis of the required amount of cement per cubic meter of concrete. 3000.24.3 Batch Weights Since the proportions are designated in terms of aggregates in surface-dry condition, the equivalent batch weights to be used in the work shall be corrected periodically to take into account the actual moisture content of the aggregates at the time of use. 3000.25 CONCRETE COMPRESSION AND SLUMP TESTS 3000.25.1 Cube Test The compression tests shall be performed as based on standard specification for compressive strength of cube concrete specimens of B.S. 5328. Test cubes made in the field shall have a dimension of 15 x 15 x 15 in accordance with B.S. 5328. The Contractor shall provide, at his own expense, three (3) sets of six (6) cubes for each one hundred (100) cubic meters of concrete or fraction thereof, placed during a single day run, of any one pour forming a unit or work or as deemed necessary by the Engineer or Engineer's Representative. All tests shall be carried out on dry specimens after seven and twenty eight days of curing and such sampling and testing shall be carried out in a laboratory approved by the Engineer at the Contractor's own expense. The Engineer may request extra cubes to be made for testing at three days whenever he deems necessary. 3000.25.2 Slump Test Slump Test shall be carried out periodically to ensure the appropriate water cement ratio in accordance with the Standard Method of Test for Slump of Portland Cement Concrete of the ASTM Designation: C-143. 3000.26 TEST OF HARDENED CONCRETE IN THE STRUCTURE Where the results of specimens indicate that the concrete does not meet specification requirements, core boring tests, conforming to the current issue of ASTM Designation: C-42 shall be performed, as directed by the Engineer, all at the Contractor's expense. 3000.27 MIXING OF CONCRETE Unless otherwise authorized by the Engineer, concrete shall be machine mixed. The mixing of concrete or mortar shall not be permitted when the temperature is above 40 deg. C or when the temperature is below 5 deg. C. The maximum temperature of fresh concrete shall be 30 °C. 3000.27.2 Truck Mixing Truck mixers, unless otherwise authorized by the Engineer, shall be of the revolving drum type, watertight, and so constructed that the concrete can be mixed to insure a uniform distribution of materials throughout the mass. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



3000.28.3 Partial Mixing at the Central Plant When a truck mixer provided with adequate mixing blades, is used for transportation, the mixing time at the mixing plant may be reduced to 30 seconds and the mixing completed in the truck mixer. The mixing time in the truck mixer shall be as specified under Section 3.8.3 for truck mixing. 3000.27.4 Plant Mix Mixing at a central plant shall conform to the requirements for mixing at the Site and shall conform to the applicable requirements of the Standard Specification for Ready mixed Concrete of ASTM Designation: C-94 3000.27.5 Time Hauling and Placing Concrete If the distance from the mixing plant to the construction Site is so great that between the time of mixing and pouring, the concrete temperature would rise above 32 deg.C or the traveling time is more than 30 minutes, truck mixers must be employed. When truck mixers are used, concrete shall be discharged and placed in its final position in the forms within thirty (30) minutes after water is first added to the mix 3000.27.6 Delivery The rate of delivery of concrete during the concreting operations shall be such as to provide for the proper handling, placing and finishing of the concrete. The rate shall be such that the interval between batches shall not exceed 20 minutes. The methods of delivering and handling the concrete shall be such as will facilitate placing with the minimum of re-handling and without damage to the structure of the concrete. 3000.27.7 Re-tempering The Concrete shall be mixed only in such quantities as are required for immediate use and any concrete which has developed initial setting shall not be used. Concrete, which has partially hardened, shall not be re-tempered or remixed. 3000.28 HANDLING AND PLACING CONCRETE Prior to pouring concrete in any structure, the Contractor shall secure a written order to commence from the Engineer. In preparation for the placing of concrete all sawdust, chips, and other construction debris and extraneous matter shall be removed from the interior of forms. Concrete shall be placed so as to avoid segregation of the materials and the displacement of the reinforcement. The use of long troughs, chutes and pipes for conveying concrete from the mixer to the forms shall not be permitted unless the authorization in writing of the Engineer is obtained. In case an inferior quality of concrete is produced by the use of such conveyors, the Engineer may order discontinuance of their use and the substitution of a satisfactory method of placing. When placing operations would involve dropping the concrete more than 1.50 meter, it shall be deposited through sheet metal or other approved pipes. As far as practicable, the pipes shall be kept full of concrete during placing and their lower ends shall be kept buried in the newly placed concrete. After initial setting of concrete, the forms shall not be jarred and no strain shall be placed on the ends of reinforcement bars which project. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



3000.28.1 Vibrating Concrete Concrete, during and immediately after depositing, shall be thoroughly compacted. The compaction shall be done by mechanical vibration subject to the following provisions: a) The vibration shall be internal unless special authorization of other methods is given by the Engineer or as provided herein b) Vibration shall be of a type and design approved by the Engineer. They shall be capable of transmitting vibration to the concrete at frequencies of not less than 4500 impulses per minute. c) The intensity of vibration shall be such as to visibly affect a mass of concrete of 25 mm slump over a radium of at least 500 mm d) The Contractor shall provide a sufficient number of vibrators to properly compact each batch immediately after it is placed in the forms. Concrete shall be placed in horizontal layers not more than 300 mm thick except as hereinafter provided. When less than a complete layer is placed in one operation it shall be terminated in a vertical bulkhead. Each layer shall be placed and compacted before the preceding batch has taken initial set to prevent injury to the green concrete and avoid surfaces of separation between the batches. Each layer shall be compacted so as to avoid the formation of a construction joint with preceding layer which has taken initial set. 3000.29 Footpaths Materials •

Cement The cement used in the manufacture of precast concrete paving blocks shall comply with the requirements of either BS 12, 4027 or BS 146 The cement content of compacted shall not be less then 400 kg/m3.

•

Aggregates The aggregates shall consist of naturally occurring crushed or uncrossed materials which apart from grading requirements comply with BS 882 Water The water shall be clean, ph value the basic range (7-9)

•

Pigments Any pigment used shall comply with BS 10014.

3000.29.1 INTERLOCKING AND PAVING Pattern colours and layout subject to approval To be for the road areas and the car park areas as indicated in sitting out plan. Interlocking block shall be 80 mm pre cast concrete block, shape colour and pattern up to the engineer approval. lead on well compacted bed of 50mm layer of clean crushed Black sand over minimum 250mm layer of road base well compacted to 95% @ OMC as per BS1377 test 13, and laid over properly well compacted and watered of base course. Spaces between interlock to be filled with white sand 3000.29.2 PRE CAST CONCRETE KERBSTONE D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Precast or cast-in-situ kerbstones shall be of vibrated concrete class "A" as specified under "CONCRETE" cast in steel moulds to the dimensions and shapes as directed by the Engineer and shall be uniform in colour free from cracks, flaws or other defects and with well defined arises The kerbstones shall be either prefabricated in standard units of 800 mm long or cast-in-situ to the lengths as directed by the Engineer's Representative. Samples of kerbstones proposed to be used shall be submitted to the Engineer for his approval prior to order or manufacture. Precast concrete kerbs shall be laid by a method approved by the Engineer. The kerbs shall be dense with regular sides, arises and chamfers finished to a fine surface free from blow holes and dragging to the dimensions described in the contract. Cube strength of 30.0 N/mm2. The mix shall contain not less than 370kg’s of cement per cubic meter of concrete Kerbs shall remain firmly secure on the surface on which they laid. Kerbs shall be cut whilst the concrete is green to form expansion/contraction joints at two meter centers. The joints shall be filled and sealed with materials approved by the Engineer. 3000.29.1.1 Pre-cast Concrete Kerbs, Channels, Edgings and Quadrants Pre-cast concrete kerbs, channels, edgings and quadrants shall comply with BS 340 and shall be laid and bedded on a mortar bed on concrete foundations as shown on the Drawings. The carriage way or foundation shall be thoroughly cleaned and prior to placing the backing, the tile levels and joints of all units and quadrants shall be hydraulically pressed. Joint of kerbstones shall be not less than 6 mm not more than 10 mm in width, and thickness shall be uniform from top to bottom. Joints shall be completely filled with mortar and shall be pointed before the mortar has set. Expansion joints will be provided at 6m spacing along the kerb run. The expansion joints shall be formed of suitable flexible materials to the approval of the Engineer.

3000.30 CONSTRUCTION JOINTS Construction joints shall be made only where located on the Drawings. If not detailed on the drawings, or in the case of emergency, construction joints shall be placed as directed by the Engineer. Shear keys or inclined reinforcement shall be used where necessary to transmit shear or bond the two sections together. STRUCTURAL EXPANSION AND ISOLATION JOINTS Floors and walls will have proprietary elastomeric joints. The sealant shall be two part Polysulphide + sealant, to BS 4254:1991 and capable of 25% movement (minimum). The colour and sealant shall be to the approval of the Engineer. CRACK CONTROL JOINT IN MEDIUM AND HEAVY DUTY FLOORS The sealant shall be two part chemical-fuel and oil resistant and abrasion resistant elastomeric sealant capable of + 5% movement (minimum) and to the Engineer's approval. 3000.31 BONDING Before depositing new concrete on or against concrete which has hardened, the forms shall be D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



retightened. The surface of the hardened concrete shall be roughened as required by the Engineer, in a manner that will not leave loosened particles of aggregate or damaged concrete at the surface. It shall be thoroughly cleaned of foreign matter and laitance, and saturated with water. To ensure an excess of mortar at the juncture of the hardened and newly deposited concrete, the cleaned and saturated surfaces including vertical and inclined surfaces, shall first be thoroughly covered with a coating of mortar or neat cement grout against which the new concrete shall be placed before the grout has attained its initial set. The placing of concrete shall be carried continuously from joint to joint. The face edges of all joints which are exposed to view shall be carefully finished true to line and elevation. 3000.32 FORMWORK The Contractor shall be responsible for the design and stability of the formwork. The Contractor shall submit a full programme of work indicating the various phases for the erection and removal of forms and the manner in which he intends to execute all concrete works. 3000.32.1 Materials All forms shall be of commercial plywood and shall be built mortar tight and of sufficient rigidity to prevent distortion due to the pressure of the concrete and other loads incident to the construction operations. Forms shall be constructed and maintained so as to prevent warping and the opening of joints due to shrinkage of the timber. The forms shall be substantial and unyielding and shall be so designed that the finished concrete will conform to the proper dimensions and contours. The Contractor shall take into consideration the effect of vibration on the formwork, and shall be responsible for any damage or default resulting thereof. 3000.32.2 Workmanship Reference shall be made to BS 5975 and Appendix “C” of the Concrete Society Technical report No. 13, ‘Formwork and the CIRIA Data Sheet’ “Concrete pressure on Formwork”. Except for few areas having suspended false ceiling within the project, most of the structure is either exposed or receiving applied finish. Therefore, tolerances specified under this part are more stringent than those specified in ACI 301. Provide structural cambers as specified on drawings. Unless otherwise specified for spans greater then 6M provide L/600mm camber. The shuttering for suspended slabs of more than 6m span shall be generally laid to an upward camber of L/1000mm span plus the specified structural camber. All formwork shall be constructed plumb, true, water and mortar-tight, sufficiently rigid and strong to prevent sagging between supports and to maintain true position and shape during and after placing of concrete without bowing and distortion. Exceptional care shall be taken to minimize fins, ridges, offsets, leaking of fins and other defects. Only workmen experienced in formwork shall be used for this work. Supports shall be designed to withstand the worst combination of self-weight and other loads including formwork, reinforcement, wet concrete, construction and wind loads together with all incidental dynamic effects caused by placing vibrating and compacting concrete. Deflection D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The maximum permissible deflection under all loads shall not exceed 2mm or 1/600 of the free span, whichever is less. Forms for beams and girders shall be designed to permit removal of at least one side without shock to the partially set concrete and without disturbing the bottom portion of the forms or its supports. Prefabricated formwork shall be used in strict accordance with manufacturer’s printed instructions and approved shop drawings. Provide 15 x 15mm wrought hardwood fillet or other suitable material in the angles of the formwork as shown on drawings or as required by the Engineer to provide chamfers in columns, beams and walls. Anchor, bolts, plates, sleeves, pipes, inserts, fixtures, electrical boxes, reinforcing steel, duct openings, conduits, etc. shall be installed as per Drawings. Ample time shall be allowed for the proper installation of such items. All steel items (other than reinforcement embedded in concrete) shall be hot-dipped galvanized. Form Ceiling All forms shall be thoroughly cleaned before placement of concrete and suitable temporary openings provided to permit removal of undesirable materials from the interior without disturbing the whole formwork. All surfaces in contact with concrete shall be wetted or treated with an approved form releasing agent before placing of reinforcement. All formwork shall be thoroughly cleaned of any old concrete or any other deposit before re-use. All formwork shall be inspected and approved by the Engineer. This approval however does not relieve the Contractor of any of his liabilities and responsibilities under the Contract. Forms should be inspected by the Engineer prior to installation of reinforcement. The shape, strength, rigidity, water tightness and surface smoothness of re-used forms shall be maintained at all times. Any warped or bulged timber must be resized before being re-used. Forms which are unsatisfactory in any respect shall not be re-used. Metal ties or anchorages within the forms shall be so constructed as to permit their removal to a depth at least 40 mm from the face without injury to the concrete. In case ordinary wire ties are permitted, all wires, upon removal of the forms shall be cut back at least 10 mm from the face of the concrete with chisels or nippers. For green concrete, nippers are necessary. All fittings for metal ties shall be of such design that the cavities produced upon their removal are the smallest possible. The cavities shall be filled with cement mortar and the surface left sound, smooth, even and uniform in colour. All forms shall be treated with oil and saturated with water immediately before placing the concrete. For members with exposed faces, the forms shall be treated with an approved oil to prevent the adherence of concrete. Any material which will adhere to or discolour the concrete shall not be used. The Contractor shall provide means for accurately measuring the settlement of the forms during placement of the concrete and shall make all necessary correctness as directed by the Engineer. 3000.32.3 Removal of Formwork D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



In the determining of the time for removal of forms, consideration shall be given to the location and character of the structure, the weather and other conditions influencing the setting of the concrete, and the materials used in the mix. In general, the forms of any portions of the structure shall not be removed until the concrete is strong enough to prevent injury to the concrete when the forms are removed. Unless otherwise directed by the Engineer, forms shall remain in place for the following specified period of time. a) Centering under beams

:

14 days

b) Floor slabs

:

10 - 12 days

c) Walls, sides of beams and other vertically formed surfaces.

:

3 days

Method of forms removal likely to cause overstressing of the concrete shall not be used. In general, the forms shall be removed from the bottom upwards. Forms and their supports shall not be removed without the written approval of the Engineer. Supports shall be removed in such a manner as to permit the concrete to uniformly and gradually take the stresses due to is own weight. Centres shall be gradually and uniformly lowered in such manner as avoid injurious stresses in any part of the structure. The Contractor shall include in his prices for any formwork which may have to be left in position due to the impossibility of removal of same. 3000.33 CHAMFER All exposed external angles of concrete shall have 25 x 25mm chamfers and the formwork construction shall allow for that. 3000.34

REINFORCEMENT

All reinforcement shall be placed strictly in accordance with the Drawings and as instructed in writing by the Engineer. Nothing shall be allowed to interfere with the required disposition of the reinforcement, and the Contractor shall ensure that all parts of the reinforcement are placed correctly in position and are temporarily fixed where necessary to prevent displacement before or during the process of tamping and ramming the concrete in place. The ties, links or stirrups connecting the bars shall be taut so that the bars are properly braced, the inside of the curved part shall be in actual contact with the bars, around which they are intended to fit. 3000.34.1. Type and Quality of Steel Reinforcement - Reinforcement for Concrete Steel reinforcement shall generally be one of the following types: All the reinforcement works to be with Turkish / Saudi / Qatar Steel. I) hot rolled mild, high yield steel deformed bars complying with BS 4449 or similar approved standard. ii) Cold twisted bars complying with BS 4482 or similar approved standard. iii) Steel fabric reinforcement complying with BS 4482 or similar approved standard.



T05-20/11/2013



No concrete shall be deposited until the Engineer has inspected the placing of reinforcement and has given permission to place concrete. Steel Reinforcement -

-

Hot rolled mild steel bars and hot rolled high yield bars shall comply with the requirements of BS 4449. Cold worked steel bars shall comply with requirements of BS 4461. Bars complying with the requirements of BS4449 or BS4461 shall be type 2 as defined in those standards. In the case of bars complying with the requirements BS4449 or BS4461, the contractor shall provide a certificate confirming that sample, taken from the bars delivered to the works, pass the re-bend, tensile steers and chemical test (Carbon contain). The frequency of sampling and the method of quality control shall be in accordance with respective BS standards. Steel fabric reinforcement shall comply with the requirements of BS 4483 and shall be delivered to the site in flat mats. All steel reinforcement shall be stored in clean conditions. All rust and contamination shall be removed by blast cleaning.

- Cover Blocks (Buried Concrete Surfaces) i) Concrete cover blocks required for ensuring that the reinforcement is correctly positioned, shall be as small as possible consistent with their purpose, of a shape acceptable to the Engineer, and designed so that they will not overturn when the concrete is placed. They shall be made of concrete with 10mm maximum aggregate size to produce the same strength as the adjacent concrete. Tying wire complying with the requirements of section e last paragraph shall be cast in the block for the purpose of tying it to the reinforcement. ii) Cover Blocks (Exposed Concrete Surfaces) Concrete cover blocks required for ensuring that the reinforcement is correctly positioned, shall be as small as possible consistent with their purpose, of a shape acceptable to the Engineer, and designed so that they will not overturn when the concrete is placed. They shall be made of asbestos cement, factory produced and of the same strength as the adjacent concrete. Tying wire complying with the requirements of section e last paragraph shall be cast in the block for the purpose of tying it to the reinforcement. 3000.34.1.1. Hot-Rolled Steel Plain Rods and Bars Hot rolled steel plain rods and bars shall conform to the strength requirements and minimum elongation of the Standard Specification for Deformed Billet - Steel Bars of Grade 40 with minimum yield strength 2800 kg/cm2 (40000 psi) for Concrete Reinforcement of ASTM Designation (A-615) or equivalent. 3000.34.1.2

Deformed Steel Rods and Bars

Deformed steel rods and bars shall conform to the requirements of the Standard Specification for Deformed Billet - Steel Bars of Grade 60 with minimum yield strength 4200 kg/cm2 (60000 psi) for Concrete Reinforcement of ASTM Designation (A-615) or equivalent. 3000.34.1.3

Wire

Wire for binding reinforcement bars shall be of soft black annealed mile steel wire. The diameter of the Wire shall not be less than 16 S.W.G. (1.6mm) and the binding shall be twisted tight with proper pliers. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The free ends of the binding wire shall be bent inwards. 3000.34.2

Order Lists

Before ordering material, all order lists and bending diagrams detailed in accordance with the latest revision of ACI Building Code shall be furnished by the Contractor for the approval of the Engineer, and no material shall be ordered until such lists and steel bending diagrams have been approved. The approval of order lists and bending diagrams by the Engineer shall in no way relieve the Contractor of his responsibility for the correctness of such lists and diagrams. Any expense incurred to the revision of material furnished in accordance with such lists and diagrams to make it comply with the design drawings including cut and waste shall be borne by the Contractor. 3000.34.3 Protection of Material Steel reinforcement shall be protected at all times from injury. When placed in the work it shall be free from dirt, detrimental scale, paint, oil, loose, rust, grease or other foreign substances. 3000.34.4

Fabrication

Bar reinforcement shall be bent to the shapes shown on the Drawings and Steel Bending Diagrams, Bending dimensions and Scheduling of bars for the reinforcement of concrete. All bars shall be bent cold, unless otherwise permitted by the Engineer. No bars partially embedded in concrete shall be bent except as shown on the plans or specifically permitted by the Engineer. 3000.34.5 Placing and Fastening All steel reinforcement shall be accurately placed in the position shown on the Drawings and firmly held during the placing and setting of concrete. Bars shall be tied at all intersections except where spacing 300 mm in each direction, in which case alternate intersections shall be tied. Distance from the forms shall be maintained by means of stays, blocks, ties, hangers, or other approved supports. Blocks for holding reinforcement from contact with the forms shall be precast mortar blocks of approved shaped and dimensions or approved metal chairs. Metal chairs which are in contact with the exterior surface of the concrete shall be galvanized. Layers of bars shall be separated by precast mortar blocks or by other equally suitable devices. The use of pebbles, pieces of broken stone or brick, metal pipe and wooden blocks shall not be permitted. Reinforcement in any member shall be placed and then inspected and approved by the Engineer before placing of concrete begins. Concrete placed in violation of this provision may be rejected and its removal is required. 3000.34.6 Splicing All reinforcement shall be furnished in the full lengths indicated on the Drawings. Splicing of bars, except where shown on the drawing, will not be permitted without the written approval of the Engineer. Splices shall be staggered as far as possible. Additional splices, other than those shown on the Drawings and allowed by the Engineer, shall be at the Contractor's own expense. The cost of steel supports for holding reinforcement bars shall be borne by the Contractor. 3000.35 CURING AND PROTECTION The method, procedure, materials, and equipment for curing shall be approved by the Engineer. Curing D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



may be accomplished by any of the following methods or combination thereof, as approved. 3000.35. 1

Water Curing

All concrete shall be cured for a period of time required to obtain the full specified strength, but not less than seven (7) consecutive days. Unformed surfaces shall be covered with sand, burlap, or other approved fabric mats kept continually wet. If the forms are removed before the end of the curing period, curing shall be continued as on the uniformed surfaces. When burlap, sand or other approved fabric materials are used they shall not cause any undesirable finish such as rough surface and discolouring where exposed to sight. Unhardened concrete shall be protected from heavy rains or flowing mechanical injury and the Contractor shall submit for the Engineer's approval his construction procedure which is designed to avoid such an eventuality. No fire or excessive heat shall be permitted near or in direct contact with concrete any time. Water for curing shall conform to Section 325.0 3000.35.2

Curing with Curing Media

Curing media shall meet all requirements of the Specifications for Liquid Membrane-Forming Compounds for Curing Concrete of ASTM Designation : C-309 and test for water retention by concrete curing materials of ASTM Designation :C-156. The compound shall be applied to the concrete surface by means of a sprayer, roller or lamb's wool applicator and shall be sprayed on. Ample time shall be allowed for the concrete surface to harden and to prevent any damage. The compound shall have a drying time not to exceed thirty minutes, and shall be applied undiluted directly from the manufacturer's labelled container in accordance with the manufacturer's direction and to the satisfaction of the Engineer. The compound shall be completely compatible with adhesives, joint sealants and cement grout. 3000.35.3 Payment No separate payment shall be made for curing with water or with curing media. The cost of such curing shall be deemed to be included in the Unit Prices of "CONCRETOR". 3000.36 EXPOSED CONCRETE (FAIR FACE) SURFACES 3000.36.1

Formwork

Formwork for exposed concrete surfaces shall conform to the applicable requirements of Section 3.14 in addition to these specifications. All concrete surfaces that are to be left exposed to view as a finished surface, shall be produced by the surface of the form either metal or wood. The quality of the surface of concrete exposed to view shall be consistent throughout the Project and the following methods shall be adopted to obtain the required finish. a) Metal forms of an approved type. b) Hard-pressed fiber-board with one smooth face at least 6 mm thick The Contractor may submit alternative proposals for the Engineer's approval if he so desires. 3000.36.2 Coating Forms with Mineral Oil In addition to the above forms or linings, the forms shall be coated before placing reinforcements with an approved colourless mineral oil free of kerosene. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



All surplus oil on form surfaces and any oil on reinforcing steel shall be removed. 3000.27

JOINTS AND EMBEDDED ITEMS

3000.37.1

Construction and Control Joints

Constructions joints, if they are not clearly indicated on the Drawings, shall not be allowed. Construction joints, in cases where weather conditions so require shall be studied in detail ahead of time and the joint shall be grooved in a predetermined pattern approved by the Engineer at no additional cost to the owner. A. Comply with BS 8110, Section 6, Paragraph 6.12, or ACI 301, Chapter 6, Paragraph 6.1 B.S. 5337. B. Construction joints other than when formed at movement joints shall be kept to a minimum possible consistent with the convenience of construction and design consideration. Concreting shall be carried out continuously up to locations of construction joints. C. Where it is necessary to introduce construction joints, careful consideration shall be given to their exact location. The location of construction joints shall be subject to agreement between the Engineer and the Contractor before any work commences. Construction joints shall be at right angles to the general direction of the member and shall take due account of shear and other stresses. D. Concrete shall not be allowed to run a feather edge and vertical joints shall be formed against a stop board. The top surface of a layer of concrete shall be level and reasonably flat unless design considerations make this undesirable. Joint lines shall also be so arranged that they coincide with features of the finished work. E. Kickers (i.e. starter stub) shall be at least 150mm high and carefully constructed and shall be cast along with the main concrete. F. Immediately prior to recommencement of concreting on a joint, the surface of the concrete against which new concrete will be cast shall be free from laitance and shall be roughened to the extent that the largest aggregate is exposed but not disturbed. Care shall be taken that the joint surface is cleaned immediately before the fresh concrete is placed against it. G.

Saturate the cleaned surface with water and slush with a coating of 1;1½ cement-sand grout. Place new concrete before grout has attained its initial set. Clean horizontal construction joints and pour the cement-sand mortar over joints in walls to a depth of 25mm before depositing concrete. In walls, do not space construction joints more than 15 meters apart, unless otherwise shown. In slabs do not space construction joints more than 20m apart with a maximum pouring area of 35 square meters. For foundations maximum pour shall be 300 square meters.

H. Particular care shall be taken in the placing of the new concrete close to the joint. This concrete shall be particularly well compacted and vibrated. J.

Control joints for control of thermal cracking should be formed using crack inducers or waterstoppers having built in inducers. Control joints shall be introduced in slabs on grades, tanking walls and retaining walls at spacing indicated on structural drawings.



T05-20/11/2013



3000.37.2 Waterstops Comply with B.S. 5337, Appendix D, Paragraph D4 or ACI 301, Chapter 6, Paragraph 6.3. clamp water-stops at construction joints in retaining walls and water tank walls in a manner to form continuous diaphragm in each joint. Water stops shall be of polyvinyl chloride (PVC) and shall be of size (25cm) from a manufacturer approved by the Engineer. Water stops shall be produced from virgin PVC base resin and shall not contain any reclaimed material whatsoever. The centerline of the water stop should coincide with the joint line. Splices in the continuity, and at ends shall be heat sealed as recommended by the manufacturer. The handling, storage, and installation of the water stops shall be strictly in accordance with the manufacturer’s instructions and to the satisfaction of the Engineer. Extreme care shall be taken by the Contractor while placing / compacting concrete in the vicinity of water stops to ensure the following: No air pocket/honey combing is included /forms. The correct alignment of the water stop is maintained without any wrinkles /twisting. No damage is caused to the water stops. Specified concrete cover to reinforcement is maintained around the water stops. 3000.37.3 Embedded Items A. Comply with ACI 301, Chapter 6, Paragraph 6.4 and 6.5. B. Accurately set anchorage devices by line and transit, and coordinate the location of all anchorage devices to be set for the accommodation of the work of other trades. C. Locate anchor bolts and/or threaded type inserts and bars as shown on the Drawings and on shop drawings. Obtain n necessary templates from the mechanical trades as required for the proper setting of anchor bolts and other items for mechanical equipment, as required. D. Assist other trades in the installation of piping, pipe sleeves, conduit and similar items where such items are to be installed in concrete. Provide frames to securely hold anchor bolts and anchorage devices in place during construction, and take care that no displacement occurs during the pouring of concrete. Under this Section furnish and set items not furnished by other trades using approved standard type items suitable for their intended purpose. 3000.38

SAMPLES AND WORKMANSHIP

The Contractor shall submit for approval a sample panel not less than 600 x 1200 mm to demonstrate the quality of the exposed concrete produced by forms at his own expense. The quality of the finished work shall be measured against the equality of the approved sample panel and work of inferior quality shall be repaired or replaced as directed by the Engineer without any additional cost. The quality of the finished surfaces shall be uniform in colour and consistency throughout the Project. Should there be any inconsistency, whether in colour or in texture, in any of the finished surfaces, the Engineer may order the repair or the demolition of that portion of concrete work and the reconstruction of same at the expense of the Contractor and the Contractor shall have not right to claim for any expenses or time delay incurred.



T05-20/11/2013



Alternatively the Engineer may order the Contractor to plaster all exposed surfaces and bush-hammer the entire area of concrete in the Project so as to render all exposed surfaces of concrete consistent throughout the project at the Contractor's own expense. 3000.39 MONOLITHIC SMOOTH FINISH SURFACES All concrete surfaces which are not in acceptable condition and which are required to be surface-finished as designated herein, shall be rubbed to a smooth and uniform texture with a carborandum brick and clear water as soon as the forms are removed and the concrete is ready to hone. The loose material formed on the surface shall be removed as soon as it dries by rubbing the surface with burlap or other approved material. A cement wash shall not be used. Concrete surface shall be free from honeycombing, air holes, fins and projections arising from defective mixings, placing or formwork. When the formwork has been struck off, the surface of concrete shall be left untouched until inspected by the Engineer. Any defective concrete work, shall at the discretion of the Engineer, be demolished completely and rebuilt or cut out and made good with concrete of the same proportions as the original. Such rectifications shall be to the satisfaction of the Engineer at the Contractor's own expense. 3000.40EXPANSION JOINTS All internal and external expansion joints, whether vertical or horizontal, shall be constructed according to details shown on the Drawings and called for in this specification. 3000.40.1

Materials

3000.40.2

Premoulded Expansion Joint Filler

Non-extruding and resilient non-bituminous type shall conform to ASTM Specifications for Preformed Expansion Joint Fillers for Concrete Designation (D-1752) or non extruding and resilient bituminous fibre types shall conform to ASTM Specifications for Preformed Expansion Joint Fillers for Concrete Designation (D-1751) and/or equivalent. The type of joint filler shall be as shown on the Drawings and/or as indicated in the Bills of Quantities. 3000.40.3 Expansion Joint Sealer Joint sealing compound shall be of polysulphide synthetic rubber or other approved joint sealer compound suitable for expansion joints and shall be of the best quality and obtained from an approved manufacturer. Expansion joints which are exposed to view shall be two part Thiokol or approved equivalent. 3000.40.4 Workmanship Expansion joints shall be formed in reinforced concrete members by the insertion of premoulded expansion joint filler as specified above and shall be of the thickness as shown on the Drawings. The joint filler shall be set in correct position when the concrete on one side of the joint is placed. When the form is removed, the concrete on the other side shall be placed. The joint filler shall be cut back for a depth at least fifteen (15) mm. from the edge of concrete when the expansion joint is to be filled or pointed with joint sealer compound as specified above. The joint sealer shall be finished smooth after application. 3000.41 CONCRETE PROTECTION All foundations and concrete structures that are in direct contact with soil shall be laid on a sheet of 1000 D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



gauge (0.254mm thick) polythene over blinding concrete. The surfaces of the foundation and concrete structures shall be wrapped with rubber/bitumen compound coated polythene self-adhering, self-sealing, waterproofing membrane having total thickness not less than 1.5 mm, approved by the Engineer and shall be applied in accordance with the manufacturer's instructions. The wrapping membrane shall be terminated at 150 mm above the ground level. Should the height of the foundation or concrete structure above the ground level be less than 150 mm the exposed length of the membrane shall be reduced accordingly. The exposed edge of the membrane shall be secured in a purpose made groove in the surface of the concrete above the ground level to prevent the membrane from lifting off the surface of the concrete and shall be protected by plain concrete fillet. The polythene sheeting laid previously on the blinding shall then be turned up the sides of the foundation and be bonded with bitumen to the outside face of the waterproofing membrane to provide an overlap of 150 mm. 3000.42 STRIKING OF FORMWORK 3000.42.1 3000.42.2

3000.43.2

Comply with B.S. 8110:85, Section 6, paragraph 6.9.3 or ACI 301, Chapter 4, paragraph 4.5. Do not remove forms or support until the concrete has thoroughly hardened and has attained sufficient strength to support its own weight and construction live loads to be placed thereon, without damage to the structure. In general, do not disturb forms or supports until the concrete has attained at least 40% of design strength for bottom forms. Be responsible for proper form removal and replace any work damaged due to inadequate maintenance or improper or premature form removal. The following shall be minimum period before striking the formwork, unless otherwise directed by the Engineer, at normal temperatures: A. Vertical formwork to columns, walls and large beams B. Beam sides C. Beams soffits formwork D. Props to beams E. Soffit formwork to slab F. Props to slab

- 24 hours 24 days - 15 days - 21 days 6 days 15 days -

-

3000.43.3

The removal time may be decreased with the Engineer’s approval where surface temperature of concrete is 16°C and above; refer to Table 6.6, Section 6 of BS 8110, Part 1:1985.

3000.43.4

Care shall be exercised in form removal to prevent chipping of corners and other damage. Experienced foremen shall supervise form removal.

3000.43.5

Removal of bottom form linings between props prior to the removal of supports may be permitted, provided the formwork has been designed to allow such removal without disturbing the supports.

3000.43.6

No new permanent structure shall be erected on any part of the already erected structure while the latter is still supported by formwork unless walls are built above another wall carried on a properly supported base. This requirement does not prohibit the use of props to take the load of more than one level of framing.



T05-20/11/2013



3000.44 TOLERANCES 3000.44.1 Comply with B.S. 5606 or ACI Standard 117-81, Part 5, unless noted otherwise. A. Plumb (allowable variation) a) In the lines and surfaces of columns, piers, walls and in arises: In any 3m 3mm Maximum for the total height of the structure 15mm b) For exposed corner columns, control-joint grooves and other conspicuous lines: In any 6mm 3mm Maximum for the total height of the structure 7.5mm B. Exposed slab soffits, beam soffits and in arises, measured before removal of supporting shores: In any 3m +/- 3mm In any bay or in any 9.6m +/- 5mm Maximum for the total of the structure +/- 10mm 3000.45 FINISHING 3000.45.1 Monolithic Floor Finish Level surface and remove excess laitance by tamping, screeding and preliminary wood floating. When the slab has hardened sufficiently so that the water and fine material will not be worked to the top, compact the surface with motor-driven floats of the disc type and trowel smooth with two steel towelling operations. Do the second towelling after the concrete has become so hard that no mortar will adhere to the edge of the trowel, and exert heavy pressure to thoroughly compact the surface. Leave floors with a smooth, hard finish free of blemishes and to a maximum tolerance of 3mm in 3 metres. Monolithically finish surface scheduled to receive the following: A. Hardener and Sealer B. Carpeting C. Where no other finish is specified. 3000.45.2

Motor Float Finish Level surface and remove excess laitance by tamping, screeding and preliminary wood floating. When the slab has hardened sufficiently so that the water ad fine material will not be worked to the top, compact the surface with motor-driven floats of the disc type. Leave floors/roofs with a smooth finish and true to a maximum tolerance of 300 in 3 metres. Motor float finish scheduled to receive the following: A. Membrane Waterproofing

3000.45.3

Rough Slab Finish Tamp the concrete using special tools to force the aggregate away from the surface, the screed with straight edges to produce a reasonably true and uniform surface.



T05-20/11/2013



Rough slab finish surfaces scheduled to receive the following: A. Ceramic tiles B. Marble 3000.45.4

Interior Exposed Concrete Surface of Slab, beams, Columns and Walls Unless otherwise shown, leave a smooth finish, even-textured and free of blemishes. Repair or replace defective areas, as directed. As soon as the face forms are removed, remove all fins and other projections carefully, level offsets and grid where necessary. Repairing, replacing and pointing and filling voids shall be to the Engineer’s satisfaction. Patch as specified under paragraph “patching”.

All concrete surfaces which are not exposed (sawn form work ) are to be left as struck from the mould, except that any surfaces which are found to be honeycombed shall be made good as soon as they have been inspected by the Engineer. The making good shall be done with a mixture of fine aggregate and cement in similar proportions to the concrete and as dry as possible. All exposed concrete surfaces with wrought form work are to have a rubbed finish, which shall mean the application of rubs. The first rub shall be made after the removal of the forms; the surface shall be wetted and rubbed with a No. of 20 carborandum stone to remove all mould marks. The second rub shall be made when finishing the concrete work when the surface shall again be wetted, and rubbed with a No of 24 carborandum stone, excess paste being removed with a we brush. The final surface shall be free from all irregularities and discoloration and shall be an even level surface. If any honeycombing is found on exposed faces, the Engineer's decision as to whether the concrete shall be cut and replaced or made good shall be final.

3000.46 HARDENER AND SEALER Apply two coats in accordance with the approved manufacturer’s printed instructions on the following concrete floor surfaces: A. Exposed in the finished work. B. To receive carpeting 3000.47 GROUTING Mix grout in accordance with the approved manufacturer’s instructions to a consistency which will permit placement. Place grout so as to ensure complete bearing and elimination of air pockets. 3000.48 CLEANING FINISHED EXPOSED CONCRETE SURFACES In the event that efflorescence, stains, oils, grease or any unsightly accumulation of foreign materials are visible on the exposed exterior and/or interior surface of finished concrete, the Engineer may require remedial action to be taken to remove these blemishes. Such action may cover all exposed concrete or when irregular lapping can be avoided, only such parts as are affected by the stains or other unsightly appearances. No such remedial action is allowed unless otherwise approved by the Engineer. 3000.49 EXPOSED CONCRETE WORK D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



All exposed concrete work if any shall be fair face cast using White Portland cement as directed by the Engineer and to the minimum specifications mentioned earlier. This should cover all concrete used in the exterior members such as columns, walls, beams, etc., whether cast in situ or pre-cast. 3000.50 WARRANTY The Contractor shall submit to the Engineer a guarantee stating that all Works of waterproofing system of the basement have been carried out in accordance with the drawings and specifications and shall be guaranteed free from defects in material and workmanship and shall be leak-proof for a period of ten (10) years from the date of issuance of the completion certificate. The Contractor shall agree to repair (including any replacement of materials) any leaks resulting from defective materials or workmanship during the guarantee period at no additional costs to the Employer. The Contractor shall also pass on to the owner any and all guarantees provided by the subcontractor and manufacturers of individual members of the system. All horizontal surfaces (basement slab, pile caps, strap/tie beams, etc.): Two layers of 4mm thick SBS modified bituminous membrane shall be laid fully torched on to the primed blinding concrete with a minimum 100mm laps all around. The membrane shall be dressed around the cut, prepared and primed piles. The membrane shall be torched on to the sides (120mm high) and to the top of the piles only up to the reinforcement rings as detailed on drawings or as directed by the Engineer. An extra length of minimum 300mm of the horizontal membrane shall be left over to carry up vertical surfaces to maintain the continuity of the membrane and shall be protected as detailed below. The membrane shall be protected against damage from reinforcement and site traffic by a layer of cement sand screed of 30mm thickness over one layer of slip sheet 200 gm/m2 density. Aggregate size for screed shall be 6mm and shall be used at the discretion of the Engineer. The area of the membrane laid at any one time should not exceed that which can be protected by screed in the same period. Care should be exercised in the sequence of laying screed to ensure that the membrane laid is not damaged due to site traffic or other trade works or any other reason. 3000.51 GLASS REINFORCED CEMENT ELEMENTS (GRC) Glass reinforced cement (GRC) elements shall be to profiles, size , colour and texture as indicated on the Drawings. The manufacturer and assembly of all GRC elements shall be executed by a specialist firm having at least 5 years experience in installation of materials described herein in the U.A.E. The specialist shall provide evidence of successful completion of similar works for the approval of the Engineer before commencing any work. GRC shall exhibit the following properties when tested on 10mm thick boards, acts, vibrated, compacted and cured for 28 days similar to those of the actual members: i) ii)

Modules of rapture (MOR) 9N/mm2 Limit of proportionality (LOP) 5N/mm2 on JJ Lloyd T 5000 test machine or equal

The Contractor shall prepare and submit to the Engineer for his approval, design calculations and mix proportions, to establish the final choice of patter, web layout and cross sectional dimensions to meet the wind loads, structural live and dead loads. These design parameters shall being accordance with the relevant BS/ASTM standards specified for the concrete structure and to meet the prevailing site conditions and fulfil the existing local authority regulations. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The Contractor shall also prepare and submit for the Engineer’s approval, design calculations and details of fixing required. After approval, the Contractor shall submit working drawings incorporating all the details for the final approval of the Engineer. From these approved drawings he will prepare and submit samples as directed by the Engineer to his satisfaction. Any approvals accorded by the Engineer shall not relieve the contractor of his responsibilities and Contractual obligations. GRC members shall be fixed using stainless steel anchor bolts of appropriate type and size. Special reassesses shall be made in the members for the anchor bolt heads which shall then be filled and made good to match the surface. All joints shall be filled with flexible polysulphide sealant and made good. 3000.52 Screed Work 3000.52.1 General Screed is layer of cement, sand, and aggregate to cover slab to give an improved finish with good surface regularity, it is more appropriate where Category 1 fatness is required. Nevertheless subsequent finishing operations such as straight edging prior to and during power trowelling, are the factors which determine good surface regularity. 3000.52.2 Screed Mix Screed mix shall consist of 1:3 mix: - One part of cement - Two part of sand - Two part of sand - One part of aggregate 3/8” The above materials shall comply with the concrete specifications. 3000.52.3 Type of Finishing It is noted that rotary power-trowelling is the method most commonly used to create a dense, sound surface. The power-float is a disc about 900mm diameter which can be used when the concrete has stiffened sufficiently to bear a man’s weight without indenting more than 1m or 2mm. Trowelling is carried out subsequently, with rotary blades fitted to the machine; the blades apply greater pressure to the surface and thus increase its density. Two passes are usually employed. The most common type of power-float or trowel is the single rotor machine, controlled by an operator standing on the concrete slab. The float disc and trowel blades are interchangeable. During the finishing time, while the concrete remains workable, the single machine can finish about 250 M2 of floor P/Day. 3000.52.4 Cure and Protection The screed shall take all necessary precautions to prevent damage or disfigurement to the finishing surface, shall repair all minor defects and all holes. Finishing must never be done while bleed water is still laying on the surface and problems can arise from caring out the power-troweling when the screed is still prone D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



to bleeding. The formation of a thin, dense, compact surface layer, from trowelling, can prevent bleed water from coming to the surface, and so the water becomes trapped and can lead to blistering or separation of the surface skin. This defect may not be detected until the floor is brought unto service. 3000.52.5

Specified Conditions

Steel wire welded mesh reinforcement shall be in accordance with BS 4485, Table 1, galvanized to BS 729. Plain expanded steel lathing shall be in accordance with BS 1329. Galvanized steel wire netting shall be in accordance with BS 1485, 19mm mesh size. Building paper shall be in accordance with BS 1521, Class B, grade 31F. Polythene sheet shall be in accordance with BS 3012, 1000 gauge. Cork joint filler will be bitumen impregnated 20mm thick. Compressed polystyrene board shall be in accordance with BS 3837 self extinguishing grade, 50mm thick to a 1.5 density. Steel wire staples shall comply with BS 1492, part 2, galvanized and annealed iron spacing and tying wire with BS 443 1.2mm thick galvanized. Bonding agent shall be of a type recommended by the Project Managers. Operatives must be skilled in laying screeds. Aerated screeds must be laid by specialist firms. All existing work and approached shall be protected with boards, dust sheets, or other suitable means. During hot weather the Contractor shall ensure that full compaction is not prevented by premature stiffening or drying out of the mix. After compaction rapid drying out shall be prevented. During wet weather freshly laid screed shall be protected from rain. All bases shall be thoroughly cleaned to remove all dirt, dust, rust and oil. Hardened in-situ concrete where screed is to be bonded: Before laying screed the concrete base shall be thoroughly hacked to remove laitance and to expose clean coarse aggregate. All loose concrete shall be washed away and the surface left clean. 24 hours before laying screed the base shall be wetted and surplus water removed. Neat cement slurry shall be brushed on to the surface 20 minutes before laying screed or a bonding agent shall be applied in accordance with the Manufacturer’s Recommendations.



T05-20/11/2013



Insulation shall be protected with building paper on all compressible slabs or quilts, paper to be lapped 50mm at all joints. Wire netting shall be laid over compressible slabs or quilts, lapped 25mm at all joints and tied securely with tying wire at 300mm centres. On bonded concrete screed shall be laid in one course well bonded to base here

screed

is less than 40mm, or laid in two courses, with lower course well bonded to base and thicker than upper courses, and neither course less than 20mm thick. Lower course to be compacted immediately before placing upper course. On unbonded concrete screed shall be laid in two courses without bonding to base, the lower course approximately 40mm thick. Lower course shall be thoroughly compacted before placing upper course. Concrete screeds shall be laid in strips not more than 3.5m wide and 10m long, allowing at least 24 hours between placing adjacent strips, or in bays of not more than 30m2 in checquer-board pattern, allowing at least 24 hours between placing adjacent bays. Square and plain joints shall be formed between screed bays or strips, closely abutted and level, and thoroughly compacted at edges. Movement joints shall be formed in screed over movement joints in base, using jointing material placed to full depth and finished flush surface. The material shall be thoroughly compacted for the full depth, without bringing any excessive laitance ti the surface, removing any which does appear. The surface shall not be wetted. Reinforcement is to be lapped a minimum of 75mm in concrete screeds. Tolerances for floor screed shall be: 1. ±15mm overall in large open areas 2. ±3mm under a 3m straight edge in areas adjacent to doors, walls and where special equipment may be installed. No low spots shall be left between drainage outlets. Surface of internal screeds shall be finished smooth with steel trowel or power float to receive thick sheets of tiles. Surface of roof screed shall be finished with wood or other suitable face float to give an even texture. All defective work in screeds shall be made good before applying finishes. Immediately after laying, the surface shall be protected from wind draughts and string sunlight. The surface shall be covered as soon as it has sufficiently hardened either with : • •

canvas, straw mats, or a 50mm layer of damp sand, kept damp, or waterproof sheeting kept in close contact with the surface and shall be left for not less than 7 days in normal weather conditions. Where different finishes are each side of a door opening an aluminium



T05-20/11/2013



“T” section shall be screwed to provide a dividing strip between the different finishes. (location shall be provided by the resident Engineer)

3000.53 Site Clearance The contractor shall clear the site completely of all buildings walls, Paving and any other such places of all rubbish or other obstructions as directed by the Engineer and deposit them in an approved tip. The tendered shall be deemed to have visited the site ascertain the extent and value of this work. 3000.54 Sundry External Works The contractor shall carry-out other sundry external works as required by the Engineer. All materials not specified elsewhere shall be manufactured available, shall be in accordance with the relevant British Standards and generally to the Engineer’s approval.

3000.55 Clearing Site on Completion The contractor shall clear the site after completion of the project including clearing away all temporary buildings materials, equipment, rubbish, etc. and grading the ground to grades as directed by the Engineer.

SPECIFICATION 3000 APPENDIX -A REFERENCES BS 8100 BS 12

1985 1978

-

The structural use of concrete

-

Portland cement (ordinary and rapid hardening)

BS 882

1973

-

Aggregates from natural sources for concrete (inc. granolithic)

BS 1305

1974

-

Batch type concrete mixers

Part 1 1970

-

Methods of sampling fresh concrete

Part 2 1970

-

Methods of testing fresh concrete

Part 3 1970

-

Methods of making and curing test specimens

Part 4 1970

-

Methods of testing concrete strength

Part 5 1970

- Methods of testing hardened concrete for other than strength

Part 6

-

REFERENCES BS 1881

1971

Analysis of hardened concrete



T05-20/11/2013



BS 1926

1962

-

Ready mixed concrete

BS 2004

1972

-

Foundations

BS 2787

1956

-

Glossary of terms for concrete and reinforced concrete

BS 3148

1980

-

Test for water for making concrete

BS 3587

1963

-

Calcium chloride (technical)

BS 3589

1963

-

Glossary of general building terms

BS 3681 Part 2 1973

-

Methods of sampling and testing of light-weight aggregates for concrete

BS 4027 Part 2 1972

-

Sulphate-resisting Portland cement

BS 4251

1974

-

Truck type concrete mixers

BS 4340

1968

-

Glossary of formwork terms

BS 4449

1978

-

BS 4461

1978

-

BS 4466

1981

-

Bending dimensions and scheduling of bars for the reinforcement of concrete

BS 4483

1969

-

Steel fabric for the reinforcement of concrete

1970

-

Methods of testing cement chemical tests

1970

-

Glossary of terms relating to type of cement, their properties and components

Part 1 1974 water

-

Accelerating admixtures, retarding

Hot rolled steel bars for the reinforcement of concrete Cold worked steel bars for the reinforcement of concrete

BS 4550 Part 2 BS 4627 BS 5075 admixtures and

reducing admixtures Metric units BS 5135

1974

-

Metal-arc welding of carbon and carbon manganese steels

BS 5975

1982

-

False work

ASTM C 87

-Effect of organic impurities in fine aggregate on strength of mortar

ASTM C 142

-Clay lumps and friable particles in aggregates



T05-20/11/2013



ASTM C 227

-Potential Alkali reactivity of cement Aggregate combinations (Mortar bar method)

ASTM C 289

-Test for potential reactivity of aggregates (chemical method)

APPENDIX - B FOAMED CONCRETE 3000.B.1

Scope

This Appendix covers the use of aerated concrete in non-structural screeds. 3000.B.2

Materials 3000.B.2.1

Cement

Unless specified otherwise, cement shall be ordinary or rapid hardening Portland cement to BS 12 or Portland Blast furnace cement to BS 146. 3000.B.2.2 Sand Sand shall be sharp washed to BS 882 Table 2 graded to zones 1, 2 or 3. 3000.B.2.3

Water

Clean and fresh, tested to BS.3148. 3000.B.2.4

Foaming Agent

Resinous air entrainment obtained from an approved manufacturer. 3000.B.3 Properties The "air-dry" density or characteristic strength of the concrete shall be as specified on the drawings or in Specification 5 "Roofing". The proportions of the constituent materials used in the mix depend on the strength and density required. The mix proportions for any particular density shall be as specified by the manufacturer of the foaming agent and approved by the Engineer. Densities between 700 - 15400 kg/cu.m shall be obtained by varying the amount of sand in the mixture; the characteristic strength shall not be less than 1.8 N/sq.mm. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Densities between 500 - 600 kg/cu.m. shall be obtained without introducing any sand; the characteristic strength shall not be less than 1.2N/sq.mm. 3000.B.4 Workmanship 3000.B.4.1

Mixing

For aerated concrete in the air-dry range of 700 - 15400 kg/c.m the cement, sharp washed sand, water and foaming agent shall be mechanically mixed together for approximately 6 to 8 minutes in a mobile mixer consisting of vertical whisk rotating in a stationary drum. The recommendation of the manufacturers of the foaming agent shall be strictly adhered to. For aerated concrete in the air-dry density of 500 - 600 kg/cu.m an emulsion foaming agent shall be initially whisked into a stable foam in an approved foam generator before being fed into the main mixing drum and mixed with the cement and water to form a thick slurry. The recommendations of the manufacturer of the foaming agent shall be strictly adhered to. 3000.B.4.2

Placing

The foamed concrete screed shall not be less than 40 mm thick and if there are conduits on the floor, the screed shall cover them by at least 25 mm; alternatively wire mesh reinforcement as wrapping fabric D49 to BS.4483 shall be placed over conduit runs where the cover is less than 25 mm. Screed shall be laid to a smooth and even surface free from defects. 3000.B.4.3

Curing

The screed shall be maintained in a damp condition for at least seven (7) days after layingby covering immediately after laying with waterproof sheeting with lapped joints kept in close contact with the surface.

SUPER FLAT SLAB 1. FLOOR DESIGN AND LAYOUT 1.1 Design: The floor slab schedule shall be superflat slab.The slip membrane is to be 1200 gauge and lapped 300mm (min). 1.2 Layout: The layout of any Superflat slab is based primarily on the racking system. Therefore, the concrete Superflat slabs must be placed in a similar configuration, with the longitudinal joint between pour strips aligned with the area between each back-to-back rack. The two-way Traffic aisle at the end of the racks would be placed in a similar manner but in the opposite direction. The reason for the narrow strip (typically 4 to 5m) in Superflat work is that it permits the contractor finishing crews to readily reach with bump-cutting tools the full width of the concrete, removing defects time and again in several passes of equipment while the concrete is still in a plastic state. Wider pours do not permit these techniques to be used. Narrow strip pours are fundamental to achieving high tolerances. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



It will require a 1 metre wide strip against walls so that accurate formwork can be installed and removed. The construction joint will fall at mid point of the single rack against the wall. This will also be the case in all the freezer stores if the walls are in place when the floor is cast. Consideration must be made to the bay layout at the end of the racking in the transfer areas. In these areas the forklift trucks are running in the opposite direction to the aisles and the bays in these areas should be cast in that direction. However the joint design in this location is critical when considering a floor with no saw cut joints as the longitudinal joints that meet at this joint can induce shrinkage cracks across the transverse bay. Alpha joint system may be adopted in this location. This will allow movement in the horizontal direction in both directions but still maintain good load transfer capability. Detail attached in the appendix. This detail is advisable in front of the loading docks also. 1.3 Surface Tolerances Superflat or DM1 standard (See appendix 2). The tolerances shall be surveyed and checked as soon as possible after concrete finishing in completed by the use of the Face Differential Profileograph. Each survey will be conducted directly in the wheel-path of the lift trucks, which will operate on the floor. Since the free movement areas at the ends of the aisles will have randomly moving traffic, these and all other areas should be specified to TR 34 FM 2 standard (see appendix 3) It is usual on a superflat foor that on completion of each bay a profileograph survey should be carried out. Each of the Profileograph traces will indicate specific locations on the floor that these tolerances were not achieved. The nature of the deficiencies can then be discussed immediately with construction crews so that similar defects can be prevented on future pour strips. All defects detected can be marked with paint directly on the floor. The Contactor must then conduct corrective grinding at these locations until measured tolerances are within limits.



T05-20/11/2013



2 . REINFORCEMENT 2.1 Distributed Steel: Reinforcement shall be provided as per the floor slab details. Same shall be treated with proper filling material approved by the Engineer/client to maintain super flatness of the slab. 2.2 Load Transfer: To ensure adequate load transfer across all construction joints, 20mm dia, and 1200mm long smooth dowels are specified at mid-depth as shown on the drawings. These must be smooth and have sawn clean cut ends not cropped. Each dowel must be greased on at least one end prior to concrete placement. However dowel spacing should be 300mm on centre at the ends of each pour strip where a forklift truck can travel over the joint. As discussed below in 3.0 Jointing. Where ever the joints can be trafficked by forklift trucks the dowels should be at 300mm cts otherwise 500 mm centres. An Alpha joint type system may be adopted where there is a change in direction of slab construction and in front of the loading dock to isolate. This will give good load transference with the benefit of free movement in both horizontal planes. 3. JOINTING (Appendix 1) 3.1 Isolation Joint: All slabs of this nature must be completely isolated from the surrounding walls and columnbases. The correct jointing details between the columns and the walls is an isolation joint. This is a simple full depth disconnection between slabs and walls or column or column base pads. No steel is permitted to cross any isolation joint. Miothene isolation material (or equivalent approved by Engineer/client) of 12mm thick and 20mm deep to be provided to match floor color. 3.2 Control Joints (Transverse Joint TJ): The control joint shown on the drawing indicates a cut 50mm deep and 3 to 5mm wide. Same shall be filled and treated to achieve super flatness of the slab. 3.3 Expansion Joints: To be provided as per the drawing. Same shall be filled and treated to achieve super flatness of the slab. 3.4 Construction Joints (Longitudinal Joint (LJ) and De-bonded Longitudinal Joint (DLJ)): D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Along the longitudinal construction joint between strip pours, there is a choice of jointing details; use either the square dowel detail, diamond dowels or minimum 16mm dia smooth bars 600mm long and at 600mm cts. The centres for any of the dowels should be closed to 300mm cts in transfer aisle where open to fork lift traffic. Where slabs are cast at right angles to the main long strip bays, either square dowels or Diamond dowels are recommended to allow lateral movement and prevent locking the slab resulting in random cracking. The purpose of these dowel bars is to relieve shrinkage stresses by avoiding locking one slab to another yet be capable of load transfer of both rack leg loads and trafficking of materials handling equipment. Square or diamond dowels have the benefit of allowing additional sideways lateral movement but retain load transfer. 3.5 Other joints It would be advisable to fly the floor slab over the loading dock wall and remove the joint detail around it. 4. Mix Design Mix Design shall be as per the specification subject to JAFZA recommendation. The quality and consistency of the concrete is critical to ensure the achievement of high flatness tolerances. Discussions with the concrete supplier will have to be made at least two weeks before commencement of works and trial mixes tested. After pouring of the first few bays alterations to the mix design may be necessary to alter workability and finish ability. Adjustments will usually be made to slump and dosage of any retarding admixture. Consistency should be controlled by taking slumps of every truck (the concrete supplier should provide a technician to undertake this test). Consistency is critical to high tolerance floors. Monitoring the truck delivery and consistency during the construction of each slab is essential. 5. CONSTRUCTION PROCEDURES (Appendix 5) 5.1 Placing: As indicated in the layout and details above, the photographs in Appendix 5, Superflat construction procedures are conducted in long narrow strips of widths equalling the back-toback dimension of the racks. The strips are poured in alternate bays; if aisle strips are numbered from 1 to 10 for example, aisle 2 would be formed first (and poured in segments full length), then aisle 4, 6, 8 etc. Once completed, infill strips would be poured in aisles 1, 3, 5 etc. Completion of 2 strip segments per day (56m each or up to expansion joint) is feasible once finishing crew were happy with their newly acquired techniques. Each strip segment will require metal, fully adjustable metal formwork system well anchored to the compact base course. Normally these are roughed in close to required level with a laser level and then more accurately checked (even during placing operations) by a cross-hair optical D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



level fitted with a parallel plate micrometer reading off an invar staff. (Often the width of the laser beam is the required tolerance and therefore not sufficiently accurate). For bays against walls and column lines, pour strips must be formed more narrow than normal, with a 1 metre off-set from the wall to permit crews access to both sides of the strip. Provided access is left in the walls at one end of the building, (and sufficient turning radius for trucks is confirmed in the unpaved end Working Areas) concrete could be delivered directly to the placing crews from the truck chute, with the trucks backing down the aisles. If this option is chosen, for the infill where side discharge is not possible, the rebar would be pre-placed on grade and would have to be chaired immediately prior concrete placement; i.e. under the chute. Otherwise, pumps could be used, provided a rapid delivery of consistent slump can be assured. In case of extreme ambient temperature may likely to make concrete placing and finishing extremely difficult, It is advisable that the walls and roof are on before constructing the floor and even then well-lit night work should be considered for the project. 5.2 Straightening/Finishing Specific placing tools and procedures are required for Superflat construction. The concrete must be placed in front of a vibrating screed (the Dynapac beam may be used or an Allen-type truss screed) can be used. Immediately following screeding, the formwork will need to be checked with a optical level and adjusted before a 2-man crew strikes off the surface transversely in a “sawing” action using a 50mm x 150mm (approx) aluminium extrusion straight edge. Some crews perform this “sawing” straighten four or even five times. It is usual to have two teams of two men following one another as this is hard work. These straightedges (5m long would be about right for a 4m bay) could be equipped with handles to make it easier on the crews. Following this strike-off operation, “straightening” perpendicular to the “sawing” takes place once the concrete starts to stiffen. This is done by pushing and drawing a special 3-4m wide “highway” cutting straight-edge from one side of the strip to the other, detecting bumps and dips in the slab, cutting and filling as needed. This process will need two well trained men to learn the skill of using the highway straight edge. Therefore, at least 2 each of aluminium straight edges and 2 highway straight edge tools should be available to each crew to assure timely strike-off. Finishers will then power float the slab (with combination float blades) at a suitable time. Troweling will be carried out several times until a burnished finish is achieved, with each time the blades being increased in angle and speed. The remaining finishing procedures include normal trowelling looking after the edges of the slab by hand trowelling and finally curing. Curing is critical and more so in hot climates. There is no such thing as over cure and therefore a spray on curing agent such as ‘Proseal’ from Sika Armorex or equivalent as approved by the Engineer plus keeping the surface wet and covered with plastic should be considered. 5.3 Grinding Since it is normal to expect some deficiencies in tolerances in each pour, a 250mm diameter wet-grinder should be on hand to remove defects. Grinding should be a normal daily expectation and is best performed daily as work progresses. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013





T05-20/11/2013



Appendix 2



T05-20/11/2013



Appendix 3



T05-20/11/2013





T05-20/11/2013





T05-20/11/2013



End of Section



T05-20/11/2013



SECTION 4000

MASONRY WORK



T05-20/11/2013



Section 4000 MASONRY WORK 4000.1 SCOPE These specifications cover the materials, manufacture and workmanship for concrete block work and associated items to be incorporated into the works. 4000.2. SUBMITTALS The Contractor shall submit for approval of the Engineer, samples for the following along with the manufacturer’s product data and certifications that each type complies with the specified requirements and local municipal laws and regulations. -

each of the masonry items other manufactured products all associated accessories fire stop products

On site mock-up sample panel shall be erected for the approval of the Engineer before progressing any work. Mock ups offsite or on job for the fire stops shall be provided by the Contractor as directed by the Engineer. 4000.3 TESTING The Contractor shall provide samples and carry out the specified tests for each of the items at an approved laboratory at his own cost and submit the report along with any explanations and recommendation of the laboratory whenever called to do so by the Engineer. Testing shall be carried out for each batch received or mixed and produced at site as directed by the Engineer. 4000.4 MATERIALS 4000.4.1 Cement Cement shall be Sulphate Resisting Portland Cement to BS 4027: Part 2: 1972 for work up to the top of the structural ground slab and Ordinary Portland Cement to BS 12 for work above this level. 4000.4.2 Water Water shall conform to the requirements specified for water in the "Concrete Work" section. 4000.4.3 Aggregate Aggregate shall conform to the requirements specified for aggregate in the "Concrete Work" section. 4000.4.4 Additives Additives to mixes for blocks and mortar shall be from approved manufacturers and shall be used strictly in accordance with the manufacturer's instructions. Additives shall only be used with the Engineer's written instruction. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



4000.4.5 Wall Ties Wall ties shall be galvanized wire butterfly-type wall ties to BS 1243 double triangle with wire diameter 4.5mm, minimum tensile strength of material 370 N/sq.mm. Minimum length of tie shall be 100mm in excess of the width of the cavity. Ties from masonry blocks to structure shall be galvanized mild steel fishtail anchors 2mm thick in accordance with BS 5628, Table 8b. Fixing shall be shot firing pins at suitable intervals. 4000.4.6 Damp - Proof Courses Damp-proof courses, cavity trays and the like shall be of rubber/bitumen compound coated polythene membrane 1.5 mm thick obtained from an approved manufacturer or any other fiber base material complying with class E of BS 6398. The damp proof course shall be well overlapped at corner and joints and laid in accordance with relevant clauses of BS 5628 Part 3 1985 and manufacturer instructions. The membrane shall be of a type suitable for hot climates. 4000.4.7 Sand Sand used shall be clean, sharp, and free from salt and organic matter. It shall conform to BS 1200 and shall not contain any harmful materials adversely affect the hardening, strength, durability or appearance of finished concrete. 4000.5 MANUFACTURE OF CONCRETE BLOCKS Block work shall comply with B.S. 2028 and shall be obtained from the Municipality's approved suppliers upon approved load test and production of test certificate. All concrete blocks shall conform to Dubai Municipality order 44190. Aggregate shall be so sized, graded, proportioned and thoroughly mixed in a batch mixer with such proportions of cement and water as to produce homogeneous concrete. The recommended mix to obtain the compressive strength and finish required is as follows: 50 kg sulphate resisting cement 0.15 m3 fine aggregate (graded up to 4.8 mm) 0.30 m3 coarse aggregate (graded up to 9.5 mm) Precast concrete blocks shall be manufactured in approved vibrated machines. If for any reason the strength requirement is not achieved, the cement shall be increased at the Contractor's own expense. The water used in the mix shall be clean and of a sufficient quantity to allow complete hydration of the cement without providing an excess when moulding. Concrete blocks shall be used hard, sound, durable, sharp rectangular shape, clean with well defined arises free from cracks, flaws and other defects. Concrete blocks shall be either obtained from an approved local factory or manufactured on the Site. If manufactured on site, the blocks shall be press moulded in approved moulds and vibrating pressure machines with a minimum of 2800 cycles per minute. Closers and half blocks shall be purpose made; cut blocks shall not be used. Block manufactured on the site shall be cured in the shade by being kept thoroughly moist with water applied by sprinklers or other approved means for a period of at least (7) days. The blocks shall be stacked on a clean and level platform free from earth or other impurities during process, and shall be stacked in honey-comb fashion after curing. The blocks shall not be used prior to one (1) month after the D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



date of manufacture, nor shall any blocks be used that have not been inspected and approved by the Engineer. 4000.6 MANUFACTURE OF CONCRETE BLOCKS Concrete blocks (solid or hollow) shall be of the following dimensions: Height - 200 mm plus minus 1% Tolerance Length - 400 mm plus minus 1% Tolerance Width - As required plus minus 1% Tolerance The nominal width of blocks shall be as indicated on the Drawings and as directed in writing by Engineer. Hollow concrete blocks shall comply with the following requirements:Compressive Strength at Twenty Eight (28) days Over Net Area :Hollow blocks shall be required to withstand a test load of minimum 7.5 N/mm2 over the net area of the blocks, and solid blocks shall be required to withstand a test load of minimum 12 M/mm2 over the net area of the blocks. Water Absorption 20% or less or dry weight. The design of the cavities and webs of the hollow concrete blocks shall be submitted to the Engineer prior to the manufacture. The thickness of the face shell and of the membrane of solid portions shall be nowhere less than forty (40) mm. The combined thickness of the solid portions shall be not less than one fourth (1/4) of the width and length of the block respectively. Blocks for External Walls Blocks for External Walls should be obtained from Dubai Municipality certified manufacturer autoclave aerated concrete building material that combines light weight with high strength and shall be to the approval of the Engineer with the following characteristics: Dry Density Av. Compressive Thermal Conductivity Fire Resistance

525 Kg/Cubic M 3.2 N/mm² 0.007 M/w (under climate conditions of 35 degree and 60% RH) and moisture content 3.8% by mass 4-6 hours depending on thickness (as per BS 5628 Part 3)

4000.7 MORTAR Mortar shall be prepared with the addition of the minimum quantity of clean water for workability. Cement and sand mortar (1:4) mix, shall be composed of one part cement to four parts of sand by volume. The ingredients for mortar shall be measured in proper clean gauge boxes and the mixing shall be carried out by means of an approved mechanical batch mixer. Mortars shall be used within thirty (30) minutes of mixing. Hardened mortars shall not be used in the work and shall upon the request of the Engineer, be immediately removed from the site. 4000.8 JOINT FILLING SEALANT



T05-20/11/2013



Movement joint filling sealants require the approval of the Engineer and shall be from a manufacturer approved by the Engineer. Two parts polysulphide based sealants shall be BS 4254. 4000.9 WORKMANSHIP All block work shall be set out and built to the dimensions, thickness and heights shown on the drawings or as instructed in writing by the Engineer. All walls and partitions, where shown on the drawings without indicating the type of the block to be used, shall be built in hollow concrete blocks, unless otherwise directed by the Engineer. The blocks shall be well soaked before being used and the tops of walls left off shall be wetted before work is recommenced. All blocks shall be well buttered with mortar before being laid and all joints shall be thoroughly flushed up as the work proceeds. All joints shall be uniform and shall not exceed 10 mm. The block work shall be carried up in a uniform manner, no one portion being raised more than 1000 mm above another at one time. Any wall or partition necessarily left at different levels must be raked back. All perpendiculars, quoins, internal and external angles, etc., shall be kept strictly true and square and the whole properly bonded together and levelled round at each floor. All block work shall be plumbed vertically. The surface of the walls and partitions prepared for rendering shall have the joints raked out 15 mm from the face of the wall to form key for the render. All block walls shall be bonded to adjacent reinforced concrete structures by means of wall ties, complying in all respects with B.S. 1243 latest edition. The ties shall be minimum 200 mm long of which 100 mm shall be embedded in the reinforced concrete and the remainder set into the block wall at the rate of two (2) ties per metre. Partitions shall be bonded to main walls by tooting at every fourth course to a depth of not less than 100 mm. th

Expanded metal mesh reinforcement shall be placed horizontally at every fifth (5 ) course to the width of block wall. Cavity wall shall be built raising the skins of block work at a similar rate and incorporating wall ties at 2 m horizontal centres and 600 mm vertical centres spaces diagonally. Cavities shall be kept clear of mortar droppings and the inside faces of block work shall be pointed as necessary for the correct application of the insulation. All walls and partitions shall be properly cured by sprinkling water for a period not less than three (3) days after completion of laying the course. Walls and partitions terminating against soffits of beams or slabs shall be lightly wedged with metal wedges after mortar in bed joints has attained its initial set and the joint packed with mortar. Block work shall be cut and fitted next to the reinforced concrete structure, door and window, jambs and sills, and to form chases for the ends of door and window lintels. No hollow blocks shall abut any built-in fixtures e.g. door and window frames, apertures, louvers etc. Where block work is described as fair faced, selected hard, sharp, clean blocks shall be used with welldefined edges and perfectly rectangular shape. All cutting for services in the concrete block shall be with mechanical means. Joints shall be finished off with neat flush pointing, taking care to keep mortar from adhering to any part of the face of the block. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Block work over lintels shall be reinforced with two layers of expanded metal mesh reinforcement well bedded in mortar and 150 mm longer at each end than the lintel. Block work shall be built to the following tolerances : Tolerance on Line : Length up to and including 5m Length over 5m

+/- 5mm +/- 10mm

Tolerance on Height and Level : Height up to and including 5m Height over 5m

+/- 5mm +/- 10mm

Tolerance on Plumb: Plumb of wall in 5m height

+/- 5mm

4000.9.1 Manufacture Block work shall comply with BS 6073:Part1:1981Type A. Concrete blocks shall be obtained from an approved local factory with a proven record of at least 5 years. Concrete blocks (solid or hollow) shall be manufactured in accordance with BS 6073:Part 1:1981 and in the following dimensions/(Work sizes): Height – 190mm + 1% tolerance (200mm coordinating size) Length – 390mm +1% tolerance (400mm coordinating size) Width – as required + 1% tolerance The thickness and work sizes of blocks shall be as indicated on the drawings and as directed in writing by the Engineer, but shall conform to 75, 90, 100, 140, 190mm work sizes. Coordinating sizes are 85, 100, 150, 200mm. Concrete blocks shall comply with the following requirements: The density of the concrete blocks shall not be less than 1500 kg/m3 but shall not exceed 2160 kg/m3. The compressive strength at 28days shall be 70 kg/cm2 for non-load bearing walls and 100 kg/cm2 for load bearing walls, as expressed as force per unit of net cross sectional area. The water absorption shall be 20% or less of dry weight. The design of the cavities and webs of the hollow concrete blocks shall be submitted to the Engineer prior to manufacture. The thickness of the face shell and of the membrane of solid portions shall not be less than thirty-five (35) mm. The total volume of the cavities shall not exceed 50% of the volume of the block. Concrete blocks shall be hard, sound, durable, sharp, rectangular shape, clean with well defined arises free from cracks, flaws and other defects.



T05-20/11/2013



Closers and half blocks shall be purpose made; cut blocks shall not be used. The Engineer may permit the manufacture of the blocks at site at his discretion subject to the production of sufficient satisfactory evidence that the Contractor has the necessary know how, equipment and facilities to do so. If manufactured on site, the blocks shall be press moulded in approved moulds and vibrating pressure machines with a minimum of 2800 cycles per minute in accordance with BS 673:Part 1:1981. Aggregate shall be so sized, graded, proportioned and thoroughly mixed in a batch mixer with such proportions of cement and water as to produce a homogenous concrete mixture. The recommended mix to obtain the compressive strength and finish required is as follows: 50 kg. cement 0.15 m3 fine aggregate (graded up to 4.8mm) 0.30m3 coarse aggregate (graded up to 9.5mm) Pre-cast concrete blocks shall be manufactured in approved vibrating machines. If for any reason the strength requirement is not achieved, the cement shall be increased at the Contractors own expense. The water used in the mix shall be clean and of sufficient quantity to allow complete hydration of the cement without providing an excess when moulding. Blocks manufactured on the site shall be cured in the shade by being kept thoroughly moist with water applied by sprinklers or other approved means for a period of at least 7 days. The blocks shall be stacked on a clean and level platform free from earth or other impurities during the curing process, and shall be stacked in honeycomb fashion after curing. The blocks shall not be used prior tone (1) month after the date of manufacture, nor shall any blocks be used that have not been inspected and approved by the Engineer. 4000.9.2 Control Joints Control joints shall be provided in the form of reinforced concrete in all walls longer than 6 meters at mid span or as agreed with the Engineer and reinforced concrete bond beams in all walls more than 3.20meters clear height, at mid wall height or at lintel level. The size and reinforcement steel shall be as indicated on the drawings. The anchoring of the bond beams, and bond columns shall be as detailed on the drawings. Concrete, steel reinforcement, etc. shall be as specified under Section 03 – Concrete Work 4000.9.3 Workmanship The block work workmanship shall comply with the recommendations of BS 5628. All block work shall be set out and built to the respective dimensions, thickness and heights shown on the drawings or as instructed in writing by the Engineer. All walls and partitions, where shown on the Drawings without indicating the type of the block to be used, shall be built in hollow concrete blocks, unless otherwise directed in writing by the Engineer. The blocks shall be well soaked before being used and the tops of walls left off shall be wetted before work is recommenced. All blocks shall be well buttered with mortar before being laid and all joints shall be thoroughly flushed up as the work proceeds. All joints shall be uniform and shall not exceed 10mm .



T05-20/11/2013



Block work shall be carried up in a uniform manner no more than six courses being built in one day without prior permission of the Engineer. Any wall left at different levels must beraked back. All prepends, quoins, internal and external angles, etc. shall be kept strictly true and square and the whole property be bonded together and levelled round. All blockwork shall be plumbed vertically. The surface of the walls and partitions prepared for rendering shall have the joints raked out 20 mm from the face of the wall to form key for the plaster. All block walls shall be bonded to adjacent reinforced concrete structures by means of galvanized mild steel wire butterfly type wall tiles at every third course, complying in all respects with BS 1243:1978 and DD140. Half of each tie shall be cast into the reinforced concrete and the remainder set into the block wall. Partitions shall be bonded to main walls by toothing at every third course to a depth of not less than 100mm. Cavity walls shall be built raising the skins of blockwork at a similar rate and incorporating wall ties at 900mm horizontal centres and 600mm vertical centres spaced diagonally. Cavities shall be kept clear of mortar droppings and the inside faces of blockwork shall be pointed as necessary for correct application of insulation. All walls and partitions shall be properly cured by sprinkling water for a period of not less than three (3) days after completion of laying the course. The top most courses of walls and partitions terminating against soffits of beams and/or slabs shall be built with solid blocks of appropriate sizes. Walls and partitions terminating against soffits of beams or slabs shall be tightly wedged with temporary metal wedges after mortar in bed joints has attained its initial sets, and the joint packed with bitumen impregnated building board strips of appropriate thickness (10, 12,1mm) and close with minimum of 20mm mortar on either side or with fire-proofing materials, as required and specified. Special block shall be fitted next to the reinforced concrete structure, door and window jambs and sills, and to form chases for the ends of door and window lintels. If hollow blocks abut any built in fixtures, e.g. door and window frames, apertures, louvers, etc. they shall be filled with grade 17 concrete and where shown reinforced on the drawings. Where blockwork is described as fair faced, selected hard, sharp, clean blocks shall be used with well-defined arises and perfect rectangular shape. Joints shall be finished off with neat flush pointing, taking care to keep mortar away from adhering to any part of the block. Blockwork over lintels shall be reinforced with two layers of expanded metal mesh reinforcement or steel bar as required by design, well bedded in mortar and 150m longer at each end than the lintel. Controlled joints shall be provided as detailed under control joints specified on structural drawing. Boundary Wall Boundary wall be constructed to dimensions and details as shown on the drawings including provision of expansion joints for the full height. Foundations shall have a minimum depth of 1000 mm below ground level, unless otherwise specified. Where boundary walls are in extension to existing boundary, they should completely match the existing unless otherwise specified, in case same is shown on Drawings. 4000.10 STRUCTURAL BRACING D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Any blockwall covering more than 14 square meter area shall be braced vertically by dummy columns and horizontally by dummy beams at lintel level. Such columns and beams shall be of section 200mm x 200mm in 200mm thick wall and shall be 100mm x 200mm in 100mm thick wall and so on. The detailed design of steel reinforcement and spacing of such columns and beams shall be decided and approved by the Engineer. The contractor shall be responsible for obtaining such design and approval from the Engineer, well in advance before starting of super structure works in view of providing necessary dowel bars for dummy columns and beams. The price of blockwall shall include all such activities and cost of such dummy structures in the wall. 4000.11

JUNCTION WITH COLUMNS AND WALLS

Junctions to receive render/plaster shall be suitably covered by a 200 mm wide metal lath from an approved manufacturer. Fixing of the lath shall be by shot firing pins at suitable centers. 4000.12 FIRE STOP PRODUCTS Fire resistant products for fire stops shall be of the appropriate type suitable for the specific application as specified hereunder. The product shall be capable of stopping the passage of fire, smoke and water through fire rated wall, floor and ceiling penetrations, claddings and expansion joints for the specific designed fire rating s of the adjacent areas. The product shall exhibit the minimum designed fire resistant properties when tested as per BS 476:Part 20:1987 and shall be approved by the Engineer. The Contractor shall produce necessary certificates to establish the above for the approval of the Engineer. The products shall be obtained from an approved, established and proven firm and shall be applied by experienced personnel strictly in accordance with the written instructions of the manufacture and to the approval of the Engineer. Mild steel selves appropriate for the size of the cable/pipe passing through it, with the least annular space around them shall be provided in the walls, floors and ceiling. Alternatively similar openings to those of the sleeves may be provided in concrete. The size of the openings shall be minimum recommended by the product manufacturer. The following products shall be provided as appropriate for the situation and as detailed on the Drawings and to the approval of the Engineer. A1) Silicone sealant: Silicone sealant shall be an elastic fire rated silicone sealant, fire tested to BS 476:Part 20:1987 and approved by the Engineer. A2) Mastic: Mastic shall be an intumescent, graphite based mastic with expansion pressure of minimum 7 bar and fire tested to be BS 476:Part 20:1987 and approved by the Engineer. A3) Light Weight Mortar: Mortar shall be lightweight and fire-resistant with vermiculite additive. Light weight mortar shall be used always in conjunction with an intumescent putty as specified below. The mortar shall be fire tested to BS 476:Part 20:1987 and as approved by the Engineer. A4) Intumescent Putty: Intumescent putty shall be putty based on graphite and shall have a 7 bar expansion pressure and shall be test tested to be BS 476:Part 20:1987 and approved by the Engineer. A5) Backing Foam: Backing Foam shall be a one component, ready to use, polyurethane based adhesive expanding sprayed foam. It shall be fire tested to BS 476:Part 20:1987 and exhibit one hour integrity rating. A6) Mineral Wool/Rock Wool: Rock wool/Mineral Wool for fire stop applications shall be of minimum 45 kg/m3 density. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The recommended treatments for various applications shall be as follows in keeping with the recommendations of the manufacturer of the product and shall be read in conjunction with the typical details, detailed on the drawings. B. Junction of block walls terminating against soffits of beams and slabs shall be treated as follows: B1) For 1 hour fire rating: the block wall shall be built so that the gap between the top of the wall and the soffit of slab/beam is a minimum of 10mm. The gap shall then be wedged using steel wedges and shall be packed with fir resistant backing foam for the entire thickness of the wall. B2) Expansion Joints: The gap between walls/slabs shall be filled with mineral wool/rock wool to a minimum depth of 50mm and the ends filled with fire-rated silicone sealant for a minimum depth of 20mm on both the faces of the walls/slabs. B3) Metal pipe crossings: The annular space around the pipe shall be packed with rock wool/mineral wool and the ends shall be filled and sealed with fire rated silicone sealant to a minimum depth of 20mm. the size of the circular opening shall be maintained as the barest minimum as recommended by the mastic manufacturer. B4) Non-metal pipe crossings less than 50mm diameter: The annular space around the pipe shall be packed with rock wool/mineral wool and the ends shall be filled and sealed with fire resistant mastic to a minimum depth of 40mm on one side for floor crossings and on both sides for wall crossings. The size of the circular opening shall be maintained as the barest minimum as recommended by the mastic manufacturer. B5) Non-metal pipe crossings of diameter 50mm and more: Non metal-pipes of diameter 50mm or more shall be provided with a pre-assembled graphite based intumescent wrap contained in a stainless steel housing , fixed around the pipe with metal fixings. Mineral wool/rock wool backing shall be provided as indicated on drawings. The size of the circular opening shall be maintained as the barest minimum as recommended by the mastic manufacturer. 4000.12 FIRE STOP PRODUCTS (cont.) B6) Single Cable or Bunched Cables: The annular space around cable or bunched of cable crossing shall be packed with rock wool/mineral wool and the ends shall be filled and sealed with fire resistant mastic to a minimum depth of 40m on one side for floor crossings and on both sides for wall crossings. The size of the circular opening shall be maintained as the barest minimum as recommended by the mastic manufacturer. B7) Cable trays crossings: Fire resistant intumescent putty shall be applied to a width of approximately 30 to 50 mm at the bottom of the bundles on the cable tray in the centre of opening in the wall/slab. This layer shall be retained by fire resistant putty in the centre of the opening as before and retained by layers of fire resistant mortar on either side. A GI plate/sheet shall then be placed above the layers and any gaps left above the plate/sheet shall be closed with concrete. The total thickness of the fire resistant intumescent putty shall not be less than 1/3 the total thickness of the cables. The mortar thickness shall be at least same as the putty thickness. In case where it is not possible to apply the putty below the cable a double layer of putty could be applied on top of the cables and increasing the thickness of the surrounding mortar accordingly.

END OF SECTION



T05-20/11/2013



SECTION 5000

METAL WORK



T05-20/11/2013



SECTION 5000 METAL WORK 5000.1 SCOPE This specification covers ferrous and non-ferrous metal intended to be used in the Works all in accordance with the Drawings and as directed by the Engineer. MATERIALS 5000.2 STEEL Steel plates and structural steel shaped sections shall conform to the requirements of BS 4:Part 1: 1993 for *Hot-rolled sections, BS 4848:Part 2:1991 for Hot Finished Hollow Sections and BS 4848: Part 4:1986 for Equal and Unequal Angles. *Steel plates and structural steel sections shall be pre-engineered sections for this project. REINFORCEMENT BARS All reinforcement bars shall be of a deformed type in accordance with BS 4449: 1997, except that plain bars may be used where specifically indicated on the Drawings. Plain bars shall be in accordance with BS 4449: 1997 latest edition. All steel reinforcement shall conform to the requirements of the Specifications for Deformed High Yield Steel Bars grade 460 Type 2, unless otherwise shown on the Drawings or specified by the Engineer. Type and Quality of Steel Reinforcement Reinforcement for Concrete Steel reinforcement shall generally be one of the following types: All the reinforcement works to be with Turkish / Saudi / Qatar Steel. I) hot rolled mild, high yield steel deformed bars complying with BS 4449 or similar approved standard. ii) Cold twisted bars complying with BS 4482 or similar approved standard. iii) Steel fabric reinforcement complying with BS 4482 or similar approved standard. No concrete shall be deposited until the Engineer has inspected the placing of reinforcement and has given permission to place concrete. Steel Reinforcement -

Hot rolled mild steel bars and hot rolled high yield bars shall comply with the requirements of BS 4449. Cold worked steel bars shall comply with requirements of BS 4461. Bars complying with the requirements of BS4449 or BS4461 shall be type 2 as defined in those standards. In the case of bars complying with the requirements BS4449 or BS4461, the contractor shall provide a certificate confirming that sample, taken from the bars delivered to the works, pass



T05-20/11/2013


-


the re-bend, tensile steers and chemical test (Carbon contain). The frequency of sampling and the method of quality control shall be in accordance with respective BS standards. Steel fabric reinforcement shall comply with the requirements of BS 4483 and shall be delivered to the site in flat mats. All steel reinforcement shall be stored in clean conditions. All rust and contamination shall be removed by blast cleaning.

Certification. Three (3) copies of a mill test report shall be furnished to the Engineer for each lot of steel reinforcement bars proposed for use on the project. Identification. The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator before being offered for inspection. The tag shall show the manufacturer's test number and lot number and other applicable data that will identify the material with the certificate issued for that lot of steel. The fabricator shall furnish three (3) copies of a certification which shows the heat number or numbers from which each size of bar in the shipment was fabricated. The Engineer reserves the right to sample and inspect all reinforcement Steel upon its arrival at the work site. The Contractor shall provide a certificate confirming that samples taken from the bars delivered to the works pass all the required tests. The frequency of sampling and the method of quality control shall be in accordance with BS 4449-1997 Clause C.3.2. All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust, paint grease, oil or other foreign substance, fins, or tears. There shall be no evidence of visual flaws In the bars, test specimens or on the sheared ends of the bars. Uncoated reinforcement shall be grit-blasted before use to remove rust, oil, grease, salt and other deleterious materials and where pitting has occurred the causes and products thereof. Repeated blasting may be required when the reinforcement is in position, or partially cast in. Partially set concrete adhering to exposed bars during concreting operations shall be removed. The minimum thickness of concrete cover to reinforcement shall be as shown on the drawings. Only approved concrete spacers shall be used. The concrete shall be of similar grade to the main concrete and shall have nonmetallic ties. BAR SCHEDULES AND SHOP DRAWINGS Before ordering reinforcing steel, the Contractor shall check the bar schedules and adjust them if necessary to the approval of the Engineer. Bar schedules shall show the weight of each bar, the total weight of each bar size and the total weight of bars, and bending diagrams for bars in accordance with BS 4466. The Contractor shall provide and submit to the Engineer for approval any working drawings additional to the Contract Drawings which may be found necessary for the production of revised bar schedules or for the completion of the works. The approval of working drawings, or revised bar schedules by the Engineer shall in no way relieve the Contractor of responsibility for the correctness of such drawings or schedules. BAR CUTTING AND BENDING Reinforcement shall be cut and bent in accordance with B,S. 4466. Cutting or bending by the application of heat is not permitted. Welding of reinforcement shall only be permitted when approved in writing by the Engineer. If such approval is given then the workmanship shall be in accordance with BS 5135. The Contractor shall submit full technical details of his proposed procedures prior to seeking approval.



T05-20/11/2013



Hot rolled high yield bars shall not be straightened or bent again, having once been bent. If the Engineer gives approval! to bend mild steel reinforcement projecting from, the concrete, the ;Internal radius of bend shall not be less than four times the nominal size of the bar. PLACING AND FIXING REINFORCEMENT Reinforcement shall be placed and maintained in the position shown in the Contract Drawings. Unless otherwise permitted by the Engineer, all bar intersections shall be tied together using 1.2mm diameter steel wire or No. 18 gauge stainless steel wire as indicated on the drawings and the ends of the tying wire shall be turned into the main body of the concrete. Metal supports, approved by the Engineer, shall be provided, and used to retain the reinforcement at proper distances from the forms. Supports under horizontal bars at the bottom of base slabs shall be spaced at not more than eighty (80) diameters of the bar. All reinforcement shall. be so rigidly supported and fastened that displacement will not occur during construction. Reinforcing steel shall be inspected in place and must be approved by the Engineer before any concrete is deposited. No splices shall be made in the reinforcement except where described in the Contract Drawings or where approved by the Engineer. Reinforcement temporarily left projecting from the concrete at construction or other joints shall not be bent out of position during the periods in which concreting is suspended, except with the approval of the Engineer. WELDED WIRE FABRIC Welded wire fabric to be used for the reinforcement of concrete shall conform to the following requirements: a. Dimensions. Welded steel wire fabric shall conform to the size and dimensions shown on the Drawings. b. Properties. Wire fabric furnished under this specification shall conform to the requirements for "Welded Steel Wire Fabric for Concrete Reinforcement" BS 4483 or equivalent. SPACER BLOCKS Spacers as approved by the Engineer shall be of such material and design as will be durable, not lead to corrosion of the reinforcement and not cause spilling of the concrete cover. Spacer blocks made from cement, sand and small aggregate shall match the mix proportions of surrounding concrete so far as is practicable with a view to being comparable in strength, durability and appearance. 5000.3 BOLTS AND NUTS Bolts and nuts shall conform to the requirements of BS 4190:1967 for “Isometric black hexagon bolts, screw and nuts” 5000.4 WASHERS



T05-20/11/2013



Plain washers shall be made of galvanized steel. Taper or other specially shaped washers shall be made of steel or malleable cast iron and shall conform to the requirements of BS 43220:1968 Metal washers for general engineering purposes. 5000.5 GALVANIZED STEEL PIPES Galvanized steel pipes shall conform to the requirements of BS 1387:1985 (1990) ISO “Medium Series”. 5000.6 PAINT Paint for Metal Worker shall comply with the applicable requirements as specified under “PAINTING AND DECORATING”. 5000.7 ALUMINIUM All aluminium elements shall be manufactured of extruded sections of aluminium alloy, to BS1474:1987 Type HE9 or ISo Al, Mg.Si 6063 or AA 6063 T6 mechanically jointed. All parts and members shall be of aluminium commercial quality like (A1-Mg-Si) heat-treated free from defects impairing their strength and durability and containing not more than 0.1% copper. All exposed surfaces shall be polished to a mirror-like surface, free from defects, and shall be light etched and anodized or polyester powder coated or Duranar coated to colours and/or finishes as shown on drawings and/or as directed in writing by the Engineer. Aluminium shall be treated to comply with BS 1615:1993 and BS 3987:1991 to provide an anodization not less than 20microns thickness or polyester powder coated by electrostatic spraying and hard stoved to not less than 60micron thickness to comply with BS 6496:1984 (1991) or duranar coated to not less than 30micron thickness as indicated on drawings to comply with AAMA 605.2-90 and BS 4842:1991. All aluminium sections shall present clear straight and sharply defined lines and shall be free from defects and imperfections that may impair their strength. All screws , bolts and other necessary accessories shall be of aluminium or stainless steel or other noncorrodible materials and shall match in colour and consistency of the finish of the anodization or the polyester powder coating or duranar coating as applicable. Aluminium elastic glazing beads shall be provided to all windows and doors which are assembled by pressure to fit with relevant groove in the profile. The glazing bars hall be threaded or interlaced at points of intersections and machine tenoned to frame. 5000.8 STAINLESS STEEL Stainless steel sections, sheets and strips shall be austenitic non-magnetic steels to BS 3100:1991 and BS 1449:Part 2:13983:18/10/3 chromium-nickel-molybdenum group, Grade 316 or Grade 304 as detailed on drawings as applicable and as approved by the Engineer. MANUFACTURE 5000.9 GENERAL The Contractor shall be responsible for the correctness and accuracy of the dimensions of the finished articles.



T05-20/11/2013



He shall carefully heck the dimensions indicated on the Drawing, verify any changes and ascertain the size at Site which will enable him to prepare Final Working Drawings for fabrication and erection purposes. Such drawings shall be submitted to the Engineer for his verification and approval. Fabrication orders can only be placed after the contractor has obtained in writing the approval of the Engineer on the above drawings. The steel sections where specified to be factory rust-proofed by hot dip galvanizing, metalizing or sheradizing process. The rust-proofing shall be sufficient to withstand the 72 hours salt-spray test as provided for in BS 7479:1991. If the rustproof coating suffers any damage during the progress of work, the damaged part shall be recoated to a minimum of the original thickness to the satisfaction of the Engineer. 5000.10 ALUMINIUM WINDOWS, DOORS, RAILINGS, ETC. Aluminium windows, doors, staircase, balustrades, etc. with all necessary accessories and fittings shall be of the pattern, design, dimensions and thicknesses shown on the drawings and obtained from an approved manufacturer and shall comply with the following standards: American Aluminium Associations (AA) American Architectural Aluminium Manufacturer’s Association American Institute of Steel Construction (AISC) American Iron and Steel Institute (AISI) American National Standards Institute (ANSI) American Society of Testing Materials (ASTM) American Federal Specifications (FS) American Insulating Glass Certification Council American Flat Glass marketing Association (FGMA) AIR AND WATER INFILTRATION All aluminium units shall be designed and installed to resist leakage of air and water through the system in accordance with the following: Air Infiltration: Air leakage shall not exceed 0.0183 cubic meters per minute per square meter of unit area when tested in accordance with ASTM E 283 at a minimum static air pressure differential of 30 kg.per sq. meter. Water Penetration: There shall be no uncontrolled water leakage as defined in AAMA 501, when tested in accordance with ASTM E331 at a minimum differential pressure of 20 percent of inward design wind load but not less than 30kg. per sq. meter or more than 60 kg. per sq.meter STRUCTURAL PERFORMANCE Design, engineer, fabricate and install the aluminium works to withstand effects of the following: Design Wind Velocity (wind resistance) as defined in British Standard CP3, Chapter V (1972) of 160kph. Design wind pressure shall be calculated based on the above wind speed, height of the buildings, etc. acting inward and outward, normal to the plane of the wall. When tested in accordance with ASTM E330, no material failures or permanent deformation of structural members shall occur.



T05-20/11/2013



Thermal Movements: Shall be capable of withstanding thermal movements resulting from an ambient temperature differential of 50 degree C without causing buckling, stresses on glass, failure of sealants, damaging loads on fasteners, or other detrimental effects. Prints of shop drawings for aluminium windows, doors, frames, etc. showing the dimensions, sizes, thicknesses, materials, finishes, joinings, attachments, fasteners and the relation to adjoining work, shall be submitted to the Engineer for approval before ordering any material. All work shall be fabricated and erected in accordance with the approved drawings. All aluminium windows, doors, frames, etc. shall be factory assembled and reinforced according to the Drawings, complete with hinges, glazing gaskets and anchors. The only site work allowed on aluminium units is fixing in position and glazing. The finished surfaces shall present a clear surface free from alloy defects, scratches or other surface blemishes. All aluminium windows, doors, etc. shall be provided with all necessary Ironmongery required for its efficient functioning 5000.11 ALUMINIUM LOUVRES Aluminium louvers shall be from a proprietary manufacturer and shall be to the Engineer’s approval. The surface coating shall be as detailed on the drawings and as specified herein to colours approved by the Engineers. 5000.12 SAND LOUVRES Sand louvres shall be manufactured from extruded aluminium sections from 6063-T52 alloy, thickness as recommended by the manufacturer. Total louver panel thickness shall be as detailed on drawing to match the adjoining details. The vertical louver efficiency shall be as specified in the mechanical engineering drawings and specifications. Panels shall be fixed to the outer side of walls or doors with matching sealed architraves. All louvers, frames, visible fixings, etc. shall have the finish as detailed on drawings. Unless otherwise indicated all louvers, shall be provided with mesh screens in appropriate frames as detailed on drawings. 5000.13 CAT LADDERS Cat ladders shall be fabricated of extruded aluminium flats and round bars and anchored/fixed to walls as shown on Drawings and to dimensions indicated therein. Cat ladders shall be powder coated as specified under clause 0715. the Contractor shall be responsible to ensure that the sections and anchoring/fixing is sufficient for the carrying a minimum load of 100kg with a factor of safety of two (2). Shop drawings indicating details of materials, fabrication including any surface treatment required. Anchoring/fixing, etc. shall be submitted to the Engineer for approval before fabrication and placing orders. Approval accorded by the Engineer shall not absolve the Contractor from any of his contractual obligations and responsibilities. 5000.14 STAINLESS STEEL RUNGS Stainless steel rungs shall be of Grade 304 to sizes indicated on the drawings. Rungs shall be cast into concrete walls by splitting ends to form anchors. The Contractor shall ensure that the rungs are capable of sustaining the load of one man (75Kg.) with a factor of safety of 2 without bending/working loose. 5000.15 POLYESTER POWDER COATING



T05-20/11/2013



Aluminium extruded sections, curtain walling units, etc. where indicated on drawings shall be treated and polyester powder coated by electrostatic spraying and hard stoved to not less than 60 micron thickness to comply with BS 6496:1991 to colours shown on drawings and/or to the approval of the Engineer. As far as possible the assembled units as a whole shall be coated to avoid joint heat build-up, scratches, touching up joints, etc. Powder coating shall be carried out under quality controlled conditions in a well established factory fully equipped for such works and shall be subject to the approval of the Engineer. Warranty: The Coating shall be warranted for a period of 10years. The contractor shall pass on executed copies of warranty for the above period signed and counter-signed by the Contractor and the applicator against any defects in metal coating and workmanship and shall undertake to remove and replace the damaged work without any extra cost to the Employer. 5000.16 ALUMINIUM The Contractor shall furnish and install all aluminium units as indicated on the Drawings. Workmanship and installation shall be in accordance with recommended standards of first class Aluminium Manufacturers. All aluminium work shall be performed in a shop where the grade of metalwork is of recognized quality acceptable to the Engineer. All items shall be installed plumb, straight, square, level and in proper elevation, plane location and alignment with other work. All work shall be designed for adjustment to field variations, fitted with proper joints and intersections, adequately anchored in place, strictly in accordance with best practice. Where aluminium surfaces come in contact with metals other than stainless steel, zinc, white bronze or small areas of other metals compatible with aluminiuim surfaces, they shall be kept from direct contact with such parts by painting the dissimilar metal with a prime coat of zinc chromate primer or other suitable primer, followed by one or two coats of aluminium metal and masonry paint or other suitable protective coating, excluding those containing lead pigments, or a non-absorptive tape or gasket shall be placed between aluminium and dissimilar metals. Steel anchors and connecting members shall be hot-dip galvanized or zinc plated after fabrication. Aluminium surfaces in contact with lime mortar, concrete, plaster or other masonry materials, shall be painted with alkaline-resistant coatings such as heavy-bodied bituminous paint or water-white methacrylate lacquer. Aluminium in contact with wood or absorptive materials which may become repeatedly wet shall be painted with two coats of aluminium metal and masonry paint or a coat of heavy bodied bituminous paint. Alternatively paint the wood or other absorptive materials with two coats of aluminium house paint and seal joints with a good quality of caulking compound. Where aluminium is in contact with treated wood, wood shall be treated with pentachlorophenol, 5% minimum concentration or approved equal, followed with the protective measures described for aluminium in contact with wood or other absorptive materials. The aluminium work shall be designed and anchored so that the work will not be distorted nor the fasteners overstressed from the expansion and contraction of the metal. Before shipment from the factory, aluminium surfaces requiring protection shall be given a coating which will protect the metal during construction. In areas where appearance of the finish on aluminium items is not important, a coating of methacrylate type lacquer shall be applied as specified hereinafter. Upon completion, the Contractor shall clean all aluminium work as required by removing protective tape or other coating, using mild soap or detergents and clear petroleum spirits. Acids, caustics and abrasives shall not be used. Where cleaners are used to remove excess sealing compounds care shall be exercised to prevent damage to seals or staining or damage to adjacent work.



T05-20/11/2013



The Contractor shall be responsible for the protection of all aluminium work until the completion of the works, and only units in perfect working order and imperfect condition shall be accepted 5000.17 ALUMINIUM DOOR IRONMONGERY All aluminium doors and windows shall be provided with a complete set of ironmongery commensurate with the efficient performance of the doors and window they are designed for. As far as possible all ironmongery shall be from the chosen system/manufacturer. Floor springs shall be from Dorma or Briton or equal and approved. All locks shall be provided with set of 3 keys. Where necessary panic devices shall be provided as required by the Civil Defense Authorities as part of the Ironmongery. Aluminium doors shall have the following minimum ironmongery provisions unless otherwise described: Single Glazed or infilled Doors single swing: 1½ 1 1 1 1

Pairs of Hinges Rebated mortice deadlock Pair 38mm dia. Semi-circular pull handles Heavy duty surface mounted door closer Door stop

Double doors, infilled or glazed; single swing 3 1 2 1 1 2

Pairs of hinges Rebated mortice deadlock Pairs 38mm dia. Semi-circular pull handles Pair rebated flush bolts Pair heavy duty surface mounted door closers Door stops

Single Glazed or infilled doors; double swing 1 1 1 1

Set of springs with cover plate Rebated mortice deadlock Pull handle Push plate

Double door; infilled or glazed; double swing 2 1 2 2

Pairs of floor springs with cover plates Rebated mortice deadlock Pairs of pull handles Push plates

5000.18 STEEL DOOR FRAMES Steel door frames shall be obtained from a specialist manufacturer in accordance with the ASTM E152 or BS 1245: 1986 and to the approval of the Engineer. Frames for fire rated doors shall be to fire ratings indicated on the drawings and in accordance with NFPA 80 or BS 476: Part 20: 1987, Part 2: 1978, Part 23: 1987 and Part 31.



T05-20/11/2013



Frames shall be 16 gauge zinc-coated steel units with single, double or no rabbet as detailed on the drawings. The rabbet shall be designed to suit the size of the shutter thickness as detailed on drawings. Frames shall be finished in self etch stored primer compatible to the paint system specified for the doors and frames, ready to receive further coats and shall be reinforced and prepared for hinges, lock strike plates, etc. Frames shall be supplied with steel wall anchors for building into jambs and of “Prefix type”. It shall be the contractors responsibility to ensure that the appropriate primer compatible to the final paint system is applied as the place of manufacture of the door frames. The Contractor shall submit shop drawings along with detailed catalogues for the approval of the Engineer before placing order or commencing any work. 5000.19 STEEL DOORS Steel doors shutters shall be obtained from a specialist manufacturer with a proven record of at least 6 years and to the approval of the Engineer. Door shall comply with ASTM E152 or BS 6510:1984 and shall be fire rated to resistance ratings as detailed on drawings in accordance with NFPA 80 or BS 476:Part 20: 1987, Part 22:1987, Part 23: 1987 and part 31. Shutters shall be reinforced double skin hollow shell construction of 18 gauge (1.22mm) zinc coated steel sheets infilled with a non combustible honeycomb, polystyrene or polyurethane core insulation for non-fire rated doors, and mineral wool or fiberglass core insulation for fire rated doors with internal reinforcing members fitted to incorporate and protect hardware items. Doors should not have visible seam on edges, and must have continuous reinforcing channel to full perimeter of doors inside. Doors should not have visible seam on edges, and must have continuous reinforcing channel to full perimeter of doors inside. Doors shall be specially constructed with internal reinforcing members fitted to incorporate and protect hardware items. The doors shall be supplied self etch primed compatible to the paint system specified for the doors and frames, ready for installation and receiving further costs of paints. It shall be the Contractors responsibility to ensure that the appropriate prime compatible to the final paint system is applied at the place of manufacture of the doors. All steel doors shall be provided with a compete set of ironmongery commensurate with the intended use and efficient performance of the doors they are designed for and shall follow the type, design and material selected for the timber doors. 5000.20 STEEL ELEMENTS All steel parts shall be accurately set out, cut, framed, assembled and executed using proper bolts or welding electrodes. All cut parts shall be saw cut, no oxygen burning shall be permitted except for pipe supports. All welding shall be electrical welding, clean and of proper workmanship. All cut parts and welded sections shall be ground even and filed smooth with rounded edges. All steel members in contact with the soil shall be painted with two (2) coats of protective asphalt paint. All doors, frames, staircases, etc. shall be given at least one (1) coat of approved rust inhibiting primer before delivery to site. Frames for doors and windows shall be provided with not less than (3) adjustable type anchors on each jamb, maximum distance between anchors shall be eight hundred (8000 mm. All joints shall be machined to a close fit and all pins and screws shall be countersunk and dressed flush after assembly.



T05-20/11/2013



Forging shall be sharp and true. Curves, intersections and members of the same size shall be halved together. The plain surfaces shall be smooth, free from warp or buckle. Molded members and mitres shall be clean, cut straight and true. Construction joints shall be welded their full length and cleaned off flush on exposed surfaces. All work shall be erected and plumb and true to lines and rigidly secured to walls, floors or ceilings as shown on Drawings and to the satisfaction of the Engineer. 5000.21 GLAZED STRUCTURAL CURTAIN WALL SYSTEM A. General Requirements Curtain walls shall be designed, manufactured and installed by an approved sub-contractor as qualified under Quality assurance herein. B. Scope of Work These specifications cover the materials, manufacture, workmanship, design and installation of the Aluminium Structurally Glazed Curtainwall System as detailed on the Drawings and to the approval of the Engineer. All work shall be performed in accordance with the applicable Building Codes, and/or the requirements of this specifications, whichever are more stringent. The work shall include but not be limited to the following: Aluminium glazed curtainwall Operating windows Louvre Panels/doors including sand trap louvres Entrance Doors Aluminium sandwich panel cladding Related glass and glazing Finishes of all curtainwall components Insulation – Fire safing Sealant and Caulking Preparation of shop drawings, construction details and structural calculations stamped and sealed by Professional Engineer In-plant quality control testing programme. C. Design Parameters and responsibilities The curtainwall is to be two (2) sided Structural Silicone Glazed System as detailed on drawings. The curtainwall system shall be capable of accommodating: Thermal movement of the curtainwall itself Building movement, thermal and dynamic Structural loading due to wind pressure Building Construction variation Building settlement/shrinkage both short and long term It is recognized that the architectural drawings and design details do not cover all conditions, and/or that some modifications may be required. Also the details are indicative. It is intended that details shall be developed through the Contractor’s shop drawings to the designed level of aesthetics and in compliance with the performance criteria.



T05-20/11/2013



D. Quality Assurance The work in this section shall be designed and performed by an experienced Contractor who has been regularly engaged in the Engineering, manufacture, glazing, and installation of multi-storey high-rise curtainwalls and has a minimum of five (5) years experience in Structurally Glazed Curtainwall Systems. All fabrication shall be done in the Contractor’s own plant under the full time quality controlled conditions. The Contractor shall submit for approval a Quality Control Program covering all aspects of production and glazing. That has been reviewed and approved in writing by the approved silicone manufacturer. A full time in plant test programme as herein specified, is to be implemented and maintained for the full duration of the project, with weekly reports submitted to the Engineer covering all aspects of the Structural Glazing operation. Sub-contracting of any work included hereunder is specifically prohibited, except when approved in writing by the Engineer. E. Performance Requirements American Aluminium Associations (AA) American Architectural Aluminium Manufacturer’s Association (AAAMA) American Institute of Steel Construction (AISC) American Iron and Steel Institute (AISI) American National Standards Institute (ANSI) American Society of Testing Materials (ASTM) American Federal Specifications (FS) American Insulating Glass Certification Council (AIGCC) American Flat Glass marketing Association (FGMA) General Curtainwall system as erected shall meet o exceed the structural and weather resistance requirements detailed below: Air and water infiltration Design and install the manufacturer’s curtainwall system permanently resist leakage of air and water through the system in accordance with the following: Air Infiltration: Air leakage shall not exceed 0.0183 cubic meters per minute per square meter of unit area when tested in accordance with ASTM E 283 at a minimum static air pressure differential of 30 kg.per sq. meter. Water Penetration: There shall be no uncontrolled water leakage as defined in AAMA 501, when tested in accordance with ASTM E331 at a minimum differential pressure of 20 percent of inward design wind load but not less than 30kg. per sq. meter or more than 60 kg. per sq.meter Structural Performance Design, engineer, fabricate and install the aluminium works to withstand effects of the following:



T05-20/11/2013



Design Wind Velocity (wind resistance) as defined in British Standard CP3, Chapter V (1972) of 160kph. Design wind pressure shall be calculated based on the above wind speed, height of the buildings, etc. acting inward and outward, normal to the plane of the wall. When tested in accordance with ASTM E330, no material failures or permanent deformation of structural members shall occur. Structural Test pressure shall be equal to 150 percent of the inward and outward acting design pressure. Deflections: The curtainwall system shall be capable of withstanding building movements and weather exposures including wind loading and of performing within the following limitations, under the required design load both positive and negative. Perpendicular Deflection: Deflection of framing members, measures perpendicular to the plane of wall, shall not exceed 1/180 of the unsupported span (defined as the distance between anchor center lines) but deflection shall not exceed what is permitted by code. Thermal Movements: Shall be capable of withstanding thermal movements resulting from an ambient temperature differential of 50 degree C without causing buckling, stresses on glass, failure of sealants, damaging loads on fasteners or other detrimental effects. Provisions for Movement of the Structure The curtainwall shall be designed to accommodate dead load and live load deflection, thermal expansion, creep, elastic shortening and/or sway and torsion of the building frame, and resist seismic forces as may be anticipated, which shall be reduced to the minimal expression without accumulation in a manner such that no undue stresses are created that may distort, overstress or otherwise jeopardize other components such as glass, metal panels, anchors, fasteners, etc. To this end, the Contractor shall obtain all necessary projected data and make such provision in the Work as may be necessary. The amount of such movement that is accommodated in the Contractor’s design shall be identified on the Contractor’s submittal drawings. Differential movements shall be accommodated by way of specifically designed two mece horizontals and interlocking sections in the Curtainwall System, Stacking Joints shall not be located within the spandrel zone and should not involve movements of glass edges in their rebates. F. Submittals Prior to proceeding with any production, the following shall be submitted for review, approval, and selection by the Engineer. Product Data: Submit manufacturer’s specifications for materials and fabrication, installation instructions and recommendations for maintenance. Include certified test reports showing compliance with project requirements where test methods are indicated. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Submit procedures for re-glazing individual components. Shop drawings: wall elevations Full size details of all conditions, anchorage, glazing details, including provisions for vertical and horizontal expansion and contraction. •

Floor plans detailing lay-out and relationship of curtainwall to the structure.

•

Building sections coordinating wall to structure.

Structural Calculations Door hardware schedule and descriptive literature Structural calculations and shop drawings shall bear the seal and signature of a Professional Engineer. Samples: Glass samples for each type and thickness Paint colour chip samples Gasket and caulking color samples Aluminium powder coated samples of joint cover strips for each width Silicone Compatibility Certifications Certifications of Silicone Compatibility and Adhesion Test Results (covering aluminium sections, coated and uncoated glass, gaskets, aluminium spacer tubes, dessicant and butyl strips of double glazing, spandrel unit items, weather strips, sealants and other materials coming in contact with sealant, etc.) Sealant Stress Analysis Quality Control Programme Quality Control Programme covering production, assembly and structural glazing procedure. Glass stress analysis certifications Certification from glass manufacturer covering stress analysis including wind loading, thermal and bond line. G. Material 1. Aluminium Sizes, shapes, and profiles are to be basically as shown on the drawings. Wall thickness and profile depths to be required by calculations, to comply with structural loading. Alloy shall be to BS 1474 type HE9 or ISO Al, Mg S1 6063 or AA 6063 75. 2. Stainless Steel D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Stainless steel shall be Austenitic Stainless Steel as specified elsewhere in this Section. 3. Operating Windows Design and profile must be such that in the closed position, the vent and frame marry so as to match and have the same “sight line” and be basically imperceptible from the exterior and the interior of the curtainwall. Two (2) safety latch locks per vent are to control and limit opening of vent to 100mm with ability of mechanical over-ride to allow vent to open further to 400mm. Operating hinge mechanism to be continuous the full width of the vent, and to provide positive vent positioning both horizontally and vertically. Glass to match adjacent fixed glass area. Vent framing members to be hollow tubular extrusion with reinforcement mitered corners. Vents to have a double line of sponge rubber weatherseal continuous one-piece around perimeter with no joinery or mitering at corners. 4. Finish The Contractor shall submit samples of the Powder coating/Duranar coating to aluminium range of colour for selection and approval by the Engineer. Polyester powder coating and Duranar coating shall be as specified elsewhere in this section. 5. Glass Glass shall be of the types and minimum thickness, as shown on the drawings and specified herein, and as specified under relevant clauses in SECTION GLAZING. The Contractor shall provide certification from the glass producer/fabricator that the glass producer/fabricator has reviewed glass thickness and finds it suitable for the purpose intended in accordance with his published literature and in accordance with these specifications. Certifications shall include a written wind load and thermal stress analysis showing a probability of failure of no greater than 8 lights per thousand at the design loads and local climatic thermal conditions. Insulating glass units shall be installed in such manner as to prevent possible water accumulation within the glazing rebate. 6. Gaskets and Weather stripping All gaskets and weather stripping shall have continuous mechanical engagement to framing members. Gaskets and weather stripping shall be, EPDM or silicone rubber, as required for particular application. Where in contact with structural sealants compatibility shall be as established by ASTM C1087. 7. Cover Strips Cover strips to joints shall be of compatible aluminium to widths and powder coated to colours as indicated on the drawings. The thickness shall be as required and approved by the curtain wall system manufacturer and the Engineer. The method of mechanical fixing shall be in accordance with the system manufacturer and as approved by the Engineer. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



8. Sealants Non-Structural All joints, which are sealed with sealant as part of the fabrication or erection procedure, shall be sealed with an approved medium modulus silicone (exposed or concealed) sealant. All perimeter sealant (metal to adjacent construction) shall be non-staining medium modulus silicone sealant or urethane. Silicone sealants shall meet the requirements of ASTM C920 and shall be as manufactured by General Electric (Silpruf) or Dow Corning (791 or 795) or Tremco Spetrem 2 or equal and approved by the Engineer compatible with the system. In using specified sealants, written instructions of the sealant manufacturer and ASTM C962 shall be strictly observed with regards to the joint size, limitations, backer rod, mixing, cleaning, surface preparation, priming and application. A primer shall be used only if required by sealant manufacturer to obtain specified adhesion and performance. Sealant shall not be applied when substrates are wet or when the temperature is below 40 deg. F., unless special low temperature application procedures, as recommended by the sealant manufacturer are adhered to. Where required, care shall be exercised to prevent “three Surface Adhesion”. Bond breakers shall be provided where necessary. The Contractor shall provide certifications from the sealant manufacturer that the sealant manufacturer has reviewed the Contractor’s Shop Drawings and sealant details, and finds the same suitable for the purpose intended for , and has tested all components in contact with sealant for compatibility and will not stain the surfaces with which they are in contact with. Statement as to compatibility by ASTM C1087, adhesion by ASTM C794 and non-staining by manufacturers standard stain test shall be accompanied by actual test results on the production materials and finishes performed in accord with applicable test procedures. Structural Sealant All structural glazing, shall be done with an approved structural silicone sealant meeting the requirements of ASTM C920, black color, as General Electric Ultraglaze SSG 4200 and Dow Corning 983 or Tremco Proglaze II or equal and approved by the Engineer compatible with the system. All glazing with structural silicone sealant shall be accomplished in the shop under controlled conditions and with full-time quality control monitoring and testing taking place. No field glazing shall be allowed for structural sealant except for field replacements and for two sided structural work. In using specified sealants, written instructions of the sealant manufacturer and ASTM C962, shall be strictly observed with regards to joint size, limitations, backer rod, mixing, leaning, surface preparation, priming and application. A primer shall be used only if required by sealant manufacturer to obtain specified adhesion and performance. Sealant shall not be applied when substrates are wet or when temperature is below 40°. Units shall not be moved until structural silicone seal has achieved the established and confirmed parameters of cure (from the sealant manufacturer) before move by the silicone manufacturer in writing for the following stages: a) From the plane in which the unit is sealed (minimum 24 hours) b) Shipment to site (minimum 3 days from sealing) c) Erection on site (minimum 7 days from sealing) The stringiest of the confirmed cure parameter and the figures in brackets above shall be followed: The contractor shall provide certification from the sealant manufacturer that he has reviewed the Contractor’s shop drawings and sealant details and has tested all components, materials finishes, etc. in D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



contact with sealant, and finds the same compatible and suitable for the purpose intended for. Sealant manufacturer’s certification as to compatibility and adhesion shall be accompanied by actual test results on production substrates performed in accordance with applicable ASTM procedures and shall include the following based upon tests performed on the production run materials of the Project: Adhesion of each structural sealant to production samples of each metal finish and glass type, when tested in accordance with ASTM C794, establishing adhesion over the temperature range as described under performance criteria section of this specification. Compatibility of production samples of each material and finish in contact with the sealants such as other sealants, gaskets, spacers and setting blocks when tested in accordance with ASTM C1087. Stress statement for sealant profile (per shop details) that when exposed to the specified wind load, the design stress on the silicone sealant does not exceed 20 psi for a minimum 5:1 safety factor. Structural Sealant (cont.) Where structural silicone bonds to a coated metal or glass surface, the weakest element in the line of stress must have a minimum strength of 10 psi. For reach combination of substrates the Contractor shall submit a report from an approved laboratory for testing performd in the following manner: Assemble and fully cure as per the approved quality control programme procedures; 5 samples of each combination of actual substrates with a sample length of 75mm. All samples are to be pulled on a tensile machine at standard conditions at a rate of 50mm per minute until failure. Report measure minimum sealant contact area, tensile load and % cohesive failure for each sample. Calculate the tensile stress by dividing the tensile load by the minimum contact area and report value. All five samples must successfully achieve a minimum of 100psi tensile stress and 90% cohesive failure. If one or more samples of a combination do not meet this criteria, repeat test with five new samples. Repeat until all five samples are successfully tested. The Contractor shall establish and submit for review a “quality control programme covering the cleaning, priming, silicone sealant application, gaskets, spacers, setting blocks and other materials and finishes. Program shall cover the initial testing for adhesion/compatibility, and also regular periodic testing to be done during the production of the project on production run materials, etc. specifically including shop “peel and adhesion” test of silicone, prior to its use. Report of such tests shall be kept in file available for review by Building Department and/or the Engineers. Program shall include testing, at full negative design pressure, one full size off-the-line production unit per every one hundred units manufactured for the project. Also the methods which shall be employed to monitor workmanship such as substrate cleaning and priming and sealant application both for shop fabrication and necessary job site replacement glazing, repair and remedial work shall be included. No sealant or glazing work shall be performed prior to sealant manufacture’s written acceptance of the Quality Control Program. The sealant manufacturer shall be requested to make periodic inspections of glazing work, the initial one being at the start of glazing for job production units, to verify that sealant work is proceeding in accordance with its recommendations, including de-glazing of randomly selected units to inspect and verify quality of sealant and workmanship. Sealant manufacturer shall submit inspection reports covering his observations and any recommendations. 9. Glazing Accessories



T05-20/11/2013



Provide setting blocks at the sill quarter points of insulated glass units. Setting blocks shall meet ASTM C864 and shall be heat cured silicone rubber for structural glazing applications, 85 +/- 5shore “A” durometer with a minimum length of 100m, and a minimum width, which will permit full support of both lights of glass. Continuous, resilient spacer between glazing and aluminium framing members at structural sealant joints shall be provided. Spacers shall have continuous mechanical engagement to framing members and be tested for compatibility with structural sealant as per applicable ASTM procedures. 10. Miscellaneous Materials Provide straps, plates and brackets as required for support and anchorage of the fabricated items to adjacent surfaces. Where steel reinforcement is required for strength, the pieces after fabrication and cleaning shall have all surfaces painted with two heavy coats of zinc chromate primer. 11. Fasteners Provide type and size shown or as required for proper support and performance. Structural calculations to provide verification and grades of fasteners. 12. Insulating and Fire safing Where specifically indicated on drawings, U.S. Gypsum Co., “Thermafiber” wall insulation or approved equal with integral aluminium roll vapor barrier to room side shall be provided. All joints, edges, punctures, and tears in foil vapor barrier shall be sealed with self-adhesive foil tape as recommended by insulation manufacturer. 100mm deep compacted (in width) U.S. Gypsum Co., “thermafiber” 4lb. density firestop or approved equal shall be provided, between edge of floor slabs and interior faces of exterior walls. Support shall be provided by impaling clips. Fire proof sealant shall be used at fire stop joints. H. Fabrication 1. Workmanship All work shall be done by competent workmen thoroughly skilled in the trade, specifically as it applies to the structural glazing operation. Use no materials, equipment or practices that may adversely affect the functioning, appearance and durability of the completed work and related construction. The work shall be accomplished in compliance with the specified criteria without bucking, opening of joints, undue stress on fasteners, sealants, and gaskets, opening of welds, cracking of glass, leakage, noises or other harmful effects. 2. Joints in Metalwork All exposed work shall be carefully matched to produce continuity of line and design with all joints, unless otherwise shown or specified, being accurately fitted and rigidly secured. 3. Shop Assembly



T05-20/11/2013



All cutting, fitting, assembly and glazing work shall be done in the shop. 4. Protection of Metals Protection against galvanic action shall be provided wherever dissimilar metals are in contact except in the case of aluminium in contact with galvanized steel or nickel silver (white bronze) or stainless steel. This protection shall be provided by either painting the contact surfaces with two heavy coats of zinc chromate primer in different colors or by application of an appropriate sealant or tape or other approved galvanic isolator. All metals, except galvanized or stainless steel, which are to be in contact with concrete, mortar, or plaster shall have the contact surfaces protected with bituminous paint. 5. Structural Glazing All structural glazing must be done under the controlled condition of a production shop; the exception, (by necessity) being field replacement of broken glass. All structural glazing must be Quality Controlled and monitored on a full-time basis by experienced Quality Control supervisory personnel, qualified to do so by silicone manufacturer. No glazing is to proceed until all aspects of testing, certifications, compatibility, etc. as outlined herein have been performed and submitted and have satisfactorily met all requirements. I. Installation 1. Qualification of Workmen All work shall be performed by skilled workmen, especially trained and experienced in this type of work. 2. Lines and Grades Bench marks for elevations and building lines and offset for alignment shall be established on each floor level by the General Contractor. 3. Inspection of the Structure After lines and grades have been established and before beginning installation, Contractor shall examine all parts of the structure on which the works is to be placed. Should any conditions be found which, in his opinion, will prevent the proper execution of his work, he shall report such conditions in writing to the General Contractor. Installation work shall not proceed in that area until conditions have been adjusted to permit proper installation of the work. 4. Workmanship All parts of the work shall be erected, plumb and true, in proper alignment and relation to established lines and grades, and shown on accepted shop and/or erection drawings. 5. Use of Sealing Materials Sealing materials specified in this section shall be used in strict accordance with the manufacturer’s printed instructions and shall be applied only by mechanics especially trained or experienced in their use. Before applying sealing materials, all mortar, dirt, dust, moisture and other foreign matter shall be completely removed from surfaces it will contact.



T05-20/11/2013



Adjoining surfaces shall be masked, when required, to maintain a clean and neat appearance. Sealing compounds shall be tooled to fill joint and provide a smooth finished surface. 6. Anchorage Anchorage of the work to the structure shall be approved methods in strict accordance with approved shop and/or erection drawings. Supporting brackets shall be designed as to provide three dimensional adjustment and accurate location of al components. After the unit is properly positioned, all connections so designated on approved shop drawings shall be properly fixed, while still allowing for horizontal thermal expansion and contraction. 7. Field Glazing Job site structural sealant glazing shall be limited to necessary repair and remedial work . Structural sealant glazing work shall be in strict accord with the recommendations of the sealant manufacturers and the approved Quality Control Program. 8. Channel-lots for Cleaning Cradle The design and construction of the planet glazing panels shall provide for channel-slots for the cleaning cradle stabilizer stays. 9. Protection and Cleaning The Contactor shall be responsible for the protection of the work against damage by other trades as well as cleaning of the structural glazed curtainwall upon erection and attachment into place on the structure, shall be the responsibility of the General Contractor. This Contractor is to provide to the General Contractor and Owner specific written instructions from the glass and paint manufacturers on the proper method of cleaning and maintenance. J. Warranties 1. General Submit a written warranty signed by the Contractor, the manufacturer and installer warranting that portions of the work involving the structurally glazed curtainwall are good quality, free from defects, and in conformance with the requirements of the Contract Document and further undertake to repair or replace defective work, at no cost to the Employer, during a 10-year period following the date of issue of the Provisional Acceptance Certificate. Defective materials and workmanship is hereby defined to include, but not be limited to, the following: a) Glass breakage b) Glass discoloration c) Failure of the sealants d) Failure of the operational parts to function normally. e) Deterioration or discoloration of finishes. f) Failure of the system to meet performance requirements, including water penetration, air infiltration and structural failure of components resulting from forces within specified limits. 2. Structural Silicone Warranty The Contractor shall provide a warranty for the Structural Silicone against any form of deterioration, loss of adhesion, streaking, etc. for a period of 10 years from the date of issue of the Provisional Acceptance Certificate.



T05-20/11/2013



The Contractor shall also pass on to the Employer any and all Guarantees provided by the glass manufacturer covering insulated glass units and spandrel glass; portions of which exceed the ten (10) years provided by the Contractor. The warranties submitted under this section shall not deprive the Employer of other rights or remedies that the Employer may have under other provisions of the Contract Documents and is in addition to and runs concurrent with other warranties made by the Contractor under requirements of the Contract Documents. K.

DOCK LEVELLERS

General: Hydraulic Dock Leveller with steel Swing lip. Platform Size 3000x2000mm (LxW) or as required, to suit the site conditions and as per manufacturers recommendations. Standards: The Leveller shall be manufactured as per new European Standard EN 1398. a) Loading Capacity: 6000 kgs. Dynamic load. b) The operating range for this model shall be +430mm above loading platform level and – 350mm below platform level. c) The Leveller shall be equipped with 2 Nos. Lifting cylinders and separate cylinder for swing lip operation. d) The dock leveller shall be supplied with emergency stop buttons, and rupture valves and automatic safety systems to prevent collapse of the raised platform. e) The leveller shall be supplied with 2 Nos. rubber buffers Size 500x250x90mm(hxwxt) f) The length of the swing lip shall be 400mm. g) The standard paint finish will be blue RAL 5010. h) Main power supply 3phase, with motor power 1.5 K.W.

END OF SECTION



T05-20/11/2013



SECTION 6000

CARPENTRY AND JOINERY



T05-20/11/2013



SECTION 6000 CARPENTRY AND JOINERY 6000.1 SCOPE This specification covers Carpentry and Joinery Works intended for use in the Works in accordance with the Drawings and/or Bills of Quantities and as instructed in writing by the Engineer. 6000.2 MATERIAL A. Timber (Softwood & Hardwood) Timber shall comply in all respect with BS 7359:1990 for Nomenclature of Commercial Timber, including sources of supply and BS 1186 latest edition, Timber for and Workmanship in Joinery. Timber shall be an approved variety and quality suitable for the purpose for which it is to be used and equal to samples approved by the Engineer. All timber shall be properly seasoned and shall be planed square, straight and true and shall be free from the following defects: Sapwood, splits, ring shakes, soft pith Checks exceeding 300mm in length Checks exceeding one quarter of the thickness of the timber in depth Knots of any description in surfaces for staining or polishing Knots of any description in glazing bars Knots exceeding one half the width of the surface Knots exceeding 20mm mean in diameter Decayed or dead knots unless cut out and plugged Loose knots or knot holes unless cut out or plugged Pith pocket Decay and insect attack including pinworm holes. All timber shall be treated with a wood preservative as per “Cuprinol” or approved equal. In jointed panels each piece shall be of the same species. Joinery for staining or polishing shall have all surfaces of the same species and same character of grain running in the same direction. All plugs inserted after cutting gout defects shall be the full depth of the hole and the grain of the plug shall run in the same direction as the grain piece. Timber connectors where used shall be two single-sided toothed plates (round or square) for demountable joints or one double sided toothed plate(round or square) for permanent joints to conform with B.S. 1579 latest edition B. Moisture Content of Timber The softwood generally shall have a moisture content limit of 12%. The hardwood shall have a moisture content limit of 10% and shall have been kiln dried. The whole of the timber for joinery work shall be properly stacked and protected from rain and ground moisture. 6000.3 PLYWOOD Plywood shall consist of an odd number of piles arranged so that the grain of each layer is at right angles to the grain of the adjacent layer or layers. The plies shall be hot pressed during adhesion and shall have D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



a finished thickness as shown on Drawings, or shall be pre-finished plywood obtained from an approved supplier. In the case of plywood having 3 plies the core shall be not more than 60 percent of the total thickness. In plywood having more than 3 plies the faces and all plies with the grain running in the same direction as the faces shall have a combined thickness of between 40 percent and 65 percent of the total thickness of the plywood. The plywood shall be free from end joints (including scarf-joints in veneers), overlaps in core veneers, dead knots, patches and plugs, open defects, depressions due to defects in core, insect attack (except isolated pinworm holes through face veneers only), fungal attack and from discoloration differing from that normally associated with species. The Contractor will not be allowed to make up thickness by gluing or otherwise fixing together sheets of thinner previously formed plywood. Plywood adhesives shall comply with BS 1203, Grade 1. All plywood shall be of Exterior Grade and shall conform to the applicable requirements of BS 6566: Part 1-8, “Plywood” latest edition. 6000.4 BLOCK BOARD AND LAMIN BOARD Block board and lamin board shall be external WBP quality resin bonded from an approved manufacturer and guaranteed not to warp or change in size or suffer any kind of deformation. It shall be of timber specified and glued with anti-insect synthetic resin waterproof glue all though. All strengthening boards shall be fixed during manufacture. Blockboard and lamin board shall conform to the requirements of BS 3444:1972 “Blockboard and Lamin board”. Blockboard and Lamin board shall be free from defects as specified under “Plywood”. 6000.5 VENEERS Timber for face veneer shall generally be first grade hardwood as indicated on the Drawings and/or in the Schedule of Doors and obtained from an approved supplier. The minimum thickness of timber face veneers shall be 0.66mm thick. The face veneers shall be hard, durable, and capable of being finished easily to a smooth surface. They shall be free from knots, worm and beetle holes, splits, dots, glue stains, filling and inlay of any kind or other defects. The face veneers shall be applied to one or both sides of wood panels as shown on the Drawings. Where veneers are shown to be applied to one face only, the other side shall have a balancing veneer applied to prevent warping. Adhesives shall comply with the requirements of BS 1203:191 Synthetic Resin adhesives for plywood (phenolic and aminoplastic) and shall ensure proper adhesion between plies. 6000.6 PLASTIC LAMINATE



T05-20/11/2013



The plastic laminate facings shall conform to BS 2572:1990 Phenolic laminated sheets and shall be a minimum 0.9mm thick. Colour and pattern shall conform to the sample approved by the Engineer. Plastic laminate sheets shall be applied with a waterproof, heat-resistant adhesive of a type recommended by the plastic laminate manufacturer and applied in accordance with the manufacturer’s instructions. MANUFACTURE AND WORKMANSHIP 6000.7 GENERAL All carpentry and joinery work shall be accurately set out, framed and executed in accordance with the detailed Drawings. Joinery work shall be constructed to detailed drawings. Joints shall be made so as to comply with BS 1186, part 2:1988. Joinery shall be cut and framed at an early stage, but shall not be glued or wedged until the structure is ready to receive it. Framed work shall be properly mortised and toned, wedged, glued and cramped together and doweled where necessary. All external joinery work shall be put together with waterproof glue. The use of nails for fixing any items of joinery will not be permitted. Sprigs may be used for glazing beads only. All screws shall be countersunk and pelleted or puttied and all sprigs shall be punched and puttied. All joinery such as architraves, beads etc. required to fit against the contour of irregular surfaces shall be accurately scribed to ensure a close connection. All joinery which is to be polished, varnished or painted shall be finished smooth and clean by rubbing down with fine glasspaper. 6000.8 INSPECTION Facilities shall beg given to the Engineer for the inspection of al Joinery works in progress in the shops and on the site.

6000.9 MAKING GOOD ALL DEFECTS Should any shrinkage or warping occur or any other defects appear in the Joinery work before the end of the defects liability period, al defective work shall be taken down and renewed to the entire satisfaction of the Engineer and any work disturbed made good at the Contractor’s expense. 6000.10 IRONMONGERY Ironmongery for doors is under provisional sums. However, Ironmongery for cupboards shall be provided in keeping with the selection made for the door ironmongery. 6000.11 KITCHEN CABINETS A. Scope D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



This specification covers the supply and installation of the kitchen cabinets with all necessary accessories intended to be used for the works in accordance with the drawings, approved working drawings and to the satisfaction of the Engineer. Work under this section shall include but shall not be limited to the following: Floor and wall units with shelves, drawers, doors, hardware, etc. Work top and sink units including all accessories and associated works. Cooker hood re-circulating type with grease and carbon filters. B. Manufacture Kitchen cabinets shall be as indicated below: Carcasses shall be of 18mm thick MDF of Canadian Origin. All doors shall be 18mm thick MDF, PVC coated of Italian origin with rounded edges on all four sides. Units shall be assembled using white glue and wooden dowels. The base unit shall rest on adjustable aluminium legs and rubber shoes. Clip on type PVC skirting shall be provided. All hinges of 180 and 90 degrees to be clip-on and self-closing type. All hinges shall be of 180° opening unless it is not possible. Wall brackets shall be adjustable in three directions. Drawer sides shall run on steel epoxy coated runners with special plastic rollers. Knobs and handles shall be to the approval of the Engineer. Cooker hood shall be proprietary make re-circulating type through grease and carbon filters. Cooker hoods shall be provided for apartments only. Unless otherwise indicated the length of the cooker hood shall be 900mm and as approved by the Engineer. C. Worktop and sink Worktops shall be of 30mmm thick granite “Grey Sardo”. The dimensions and shape shall be as detailed on drawings and to the approval of the Engineer. The Contractor shall submit shop drawings for the same along with the necessary supports accompanied by calculations justifying the thickness, stability and sufficiency for the approval of the Engineer. Sinks shall be of Carysil of Acrysil Ltd. with mixers, bottle traps fittings and fixtures complete of configuration and as indicated on drawings.

D. Installation The installation of the kitchen cabinets, worktops with sink units shall be carried out in accordance with the approved drawings and the manufacturer’s written directions to the satisfaction of the Engineer. E. Working Drawings Detailed working drawings for the design of the Kitchen cabinets, based on the specification and drawing shall be submitted to the Engineer for approval prior to order. The drawings, when approved by the Engineer, shall constitute an integral part of the Contract Documents. 6000.12 DOORS, CUPBOARDS & OTHER ARCHITECTURAL WOODWORK A. Submittals



T05-20/11/2013



B. Production Data: Manufacturer’s technical data for each type of wood door, including details of core and edge construction, trim for openings and factory –finishing specifications shall be submitted. C. Fire-retardant materials: Manufacturer’s instructions for handling, storing, finishing and installation of fire-retardant treated material shall be included with the submittal. Certification that fire-retardant treated materials comply with the requirements indicated, and will not aesthetically and structurally be impaired by the treatment shall be provided. D. Shop Drawings: Shop drawings indicating location and size of each door, elevation of each kind of door, details of construction, location and extent of hardware blocking, factory finishing and other pertinent data shall be submitted. Doors and frames shall comply with tolerance requirements of BS, AWI and other International Standards for pre-fitting. Dimensions and alignment of hardware mortises in frames shall be verified before proceeding with factory pre-machining. E. Examination: The Contractor shall examine installed door frames prior to hanging to verify that frames comply with requirements for type, size, location & swing and are installed plumb and level. Doors with defects shall be rejected. Installation shall not be commenced until unsatisfactory conditions have been corrected. F. Adjusting and Protection: Doors which do not swing or operate freely shall be re-hung or replaced. Damaged doors shall be refinished or replaced. Wood doors shall be protected from damage during construction activities. Doors shall be protected as recommended by door manufacturer to ensure that wood doors are without damage or deterioration at time of issue of the Substantial Acceptance Certificate. G. Quality Assurance Manufacturer/Fabricator: Firm with not less than 5 years successful experience on projects of similar size and quality to that shown and specified. Fire retardant treatment: Fire-retardant treats those items required by applicable codes to be treated and those items shown or specified as “Fire retardant Treated Wood” or similar designation. Fire retardant marking: Each unit of fire-retardant treated wood and plywood shall be marked with producer’s label and a label showing grade and rating. Mark shall be on surface which will not be exposed after installation. H. Project Conditions Woodwork shall not be installed until required temperature and relative humidity have been stabilized and will be maintained in installation areas. It shall be ensured that the moisture content of installed woodwork is maintained within 1.0 percent of optimum moisture content, from date of installation through remainder of construction period. The fabricator of woodwork shall determine optimum moisture content and required temperature and humidity. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



I. Basic Materials And Fabrication Methods General: Except as otherwise indicated, the following requirements shall be complied with. Wood moisture content: Kiln-dried (KD) lumber with an average moisture content range of 6% to 11% shall be provided for interior work. Temperature and relative humidity shall be maintained so that moisture content values for woodwork at time of installation does not exceed 10%. Fire Retardant Treatment: The Contractor shall provide fire-retardant treated lumber and plywood which comply with applicable standards for pressure impregnation with fire-retardant chemicals and with the following requirements. Flame spread, fuel contribution and smoke developed ratings of 25 or less, with no increase in flame spread and no evidence of significant progressive combustion upon continuation of test for additional 20minutes. Fire retardant treatment which is relatively insoluble in water, will not adversely affect color and finishes indicated, and permits milling of lumber after treatment and kiln drying by a certified plant. Kiln-dry treated woodwork to required moisture content after treatment. Twisted, warped, bowed or otherwise damaged or defective wood shall not be used. Fire-retardant particle board panels with surface-burning characteristics of 20 for flame spread and 25 for smoke developed when tested in accordance with ASTM E 84 shall be provided. Solid Wood: AWI Section 100, grade 1. Colour and finish shall match samples on file with the Engineer. Plywood: Veneer core, minimum 20mm thick unless otherwise noted, interior grade using exterior type waterproof glue. The Contractor shall provide “A” face plies of 1.0 mm plain sliced, clear, paint grade veneers for exposed and semi-exposed surfaces to receive “painted finish”. The Contractor shall provide plywood for “painted” finish with “V” type hardwood edge banding on exposed edges and on all edges of adjustable shelves. Edges band shall be pressure glued to core with mitered corners. Panel products: AWI Section 200, particleboard core plywood, with face veneers matched as indicated. Transparent finish; grade I per AWI Section 200-S-8. Colour and finish shall match samples on file with the Engineer. Opaque finish: Species of hardwood veneer of Grade II per AWI Section 200-S-8 which, when finished will not show any grain, or defects when used with opaque finish. Lumber: AWI Section 100 with the following requirements: Panels with fire-retardant chemicals incorporated at time of manufacture to achieve surfaceburning characteristics of 20 for flame spread and 25 for smoke developed when tested in accordance with ASTM E 84 shall be provided. Miscellaneous products:



T05-20/11/2013



Fasteners: Wood Screws: Type, size, material and finish as required for the condition of use. Nails: Type, size, material and finish as required for the condition of use. Anchors: Type, size, material and finish as required for the condition of use. Staples: Type, size to provide sufficient strength to hold upholstered fabric taut and in place without sagging. Adhesive for laminating plastic laminate surfaces: Melamine, phenol-resin, or resorcinol-resin; type, grade and class best suited for the purpose. J. Fire Rated Doors It shall be responsibility of the Contractor to provide doors of fire rating indicated on drawings to the approval of the Civil Defense Authorities and the Engineer, in additions to meeting the relevant standards. All door sets shall follow the fire zoning and shall be of appropriate rating to the location they are situated in. The details shown on drawings are for purpose of architectural finish and layout only and not for achieving the required ratings. The construction of the door shall be as required to meet the required rating with the approval of the Engineer and the concerned authorities. Any approval accorded by the Engineer shall not relieve the Contractor of ay of his contractual obligations and responsibilities. K. Workmanship – General All fabrication shall be made from field measurement with provision for scribing as required to meet builtin conditions. Work of this section shall be coordinated with work of other trades. Units shall be fabricated in largest practicable sections. Trial fit shall be made in the shop, disassembled for shipment and reassembled with concealed fasteners as required. Relative humidity and temperature conditions shall be maintain during fabrication, storage and finishing operations matching that of the areas of installation. The details shown indicated the required type of construction. Modifications to conform to manufacturer’s standards, requirements of concerned authorities and standards may be considered providing they comply with the Contract documents, maintain the profiles shown and are subject to acceptance by the Engineer. Reinforcing as required shall be provided to ensure a rigid assembly. Exposed surfaces shall be free of dents, tool marks, warpage, buckle, glue, and open joints or other defects. All joints, corners and miters shall be fitted accurately. END SECTION



T05-20/11/2013



SECTION 7000

THERMAL AND MOISTURE PROTECTION



T05-20/11/2013



Section 7000 THERMAL AND MOISTURE PROTECTION 7000.1 SCOPE The scope of work covers the water tight roofing and water proofing system incorporating waterproofing membrane, liquid applied coating, screeds, thermal insulation, etc., all of which shall meet the requirements of the specification. Repairs and overlays shall be subject to approval/certification by the Engineer, prior to execution of each phase. The scope of work shall include water proofing to, but not limited to the following: • Services Roofs • Flat roofs and the glazed clay roofing tiles. • Mechanical Rooms • Toilets, kitchens, Ablution Area, wet areas, etc. • Facades. • UG Water tanks • Inside Manholes • All concrete work touched with soil 7000.2 QUALIFICATION The waterproofing systems including protection and all associated accessories and works shall be executed by a specialist firm(s) having at least 7 years experience in installation of materials described herewith in the U.A.E. The specialist(s) shall provide evidence of successful completion of similar works for the approval of the Engineer before commencing any work. The manufacturer’s qualified representative shall visit the job site immediately prior to commencement of works and as and when required and directed by the Engineer to satisfy the Engineer and to instruct the specialist(s) in the correct methods of execution of the Works. 7000.3 TESTING 7000.3.1. Waterproofing: The waterproofing system upon completion shall be subjected to testing by flooding with water up to a depth of 100mm above the highest point of the screed laid to slope but limiting the depth to ensure that the average weight of the water so flooded does not exceed 150 kg/m2. The water shall be retained for a period of 48 hours. The Contractor shall arrange for all, water, other materials and labour required for the execution of the test, inspection of works and for any making good of works or any associated works that may be required at no extra cost or time to the project. On complication of roofing works the Contractor is to leave the roof in a sound and water tight condition to the approval of the Engineer. 7000.3.2 Building Envelope Thermal Insulation & Tightness. The buildings envelop thermal insulation & tightness shall be subject to verifications as per authorities’ requirements. The contractor shall take all actions; but not limited to the following to conform to this item requirements: 1- The contractor will carry out a full building envelop verification procedures as per all authorities requirements. 2- The contractor shall submit for the engineer’s approval, at the inception of construction works before starting any of the insulating works all the qualifications of persons & their equipment that are proposed to carry out those works. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



3- The contractor will submit a detailed list of the required tasks & items showing locations & sequence with other related works. Locations should include building fabric & HVAC systems. 4- The qualifications of specialist to include a CV showing minimum experience of 2 years in similar works, specifications of equipment intended to be used added to references of experience. Equipment must include a high-tech infra-red camera & samples of imaging from previous works should be attached. 5- The contractor will submit for the engineer’s approval a detailed method statement showing using both “Visual Inspection” & “Thermal Imaging” techniques before & after each item as well as the final verification. The detailed procedure for rectifying defects should be included. 6- The contractor final submission for this item will include the following: •

Documentary evidence from the respective contractor / specialist confirming the compliance to the specific requirements.

•

Report of the thermo graphic test undertaken clearly showing the identified inconsistencies or leakage areas in the envelope.

•

Report of corrective actions undertaken to rectify the defects.

•

Thermal image should be provided to demonstrate compliance; before & after rectification.

7000.4 GUARANTEE The Contractor and sub-contractor shall provide the Employer with a written unconditional guarantee for the roofing system installed on site for a period of 10 (ten) years from the date of issue of the Final certificate at the completion of the maintenance period, stating that all Works have been carried out in accordance with the drawings and specifications and shall be guaranteed free from defects in material and workmanship and shall be leak proof for a period of ten (10) years from the date of issuance of the completion certificate. The Contractor shall agree to repair (including any replacement. The contractor shall bear the cost on any of the consequential damage or complete renewal as determined by Engineer during the above period as is provide for is same guarantee. The text of the guarantee shall be to the Engineer's approval. The Contractor shall submit to the Engineer/ Employer a guarantee of materials/ workmanship; any leaks resulting from defective materials or workmanship during the guarantee period at no additional cost to the Employer.

7000.5 MATERIALS 7000.5.1.1 Roof Waterproofing Membrane The water proofing membrane shall be torch bonded rubber/polyester membrane of total thickness of 4 mm. The membrane shall have a film of adhesive polyethylene on the lower face as prime coat as recommended by the approved manufacturer. Tensile strength Elongation at break

Extension min. 1000% Longitudinal and transverse



T05-20/11/2013



The membrane shall be of a type suitable for hot climate, high resistance to penetration, resistant to all chemicals of the atmosphere. The membrane shall be terminated in a 15mm x 15mm groove to concrete upstands with the least 300mm girth and shall be protected in vertical exposed faces with approved flashing. The waterproofing membrane shall be supplied in rolls clearly stating the manufacturer's name and type of material. The waterproofing membrane shall be obtained from a manufacturer approved by the Engineer. All grooves shall be sealed with two part polysulphide or polyurethane sealant. 7000.5.1.2 SBS Water Proofing Membrane • The roof water proofing membrane shall be SBS heavy laminate bituminous felt, reinforced with 180 gm/m2 of non woven polyester inlay and modified bituminous compound presenting high thermal stability, plasticity and flexibility characteristics. • The typical characteristics of a 4 mm thick membrane shall be as follows:

4 5.25

Toleranc e ±5% ±10%

900

±20%

800

±20%

50

±15%

%

50

±15%

N

170

≥170

N

180

≥180

°C °C Kpa °C Dmm

-25°C 100 400 115 32

≤ -25 ≥100 ≥400 ≥115 ±5

Tests

Unit

Thickness Aeric Mass

Mm Kg/m N/5 cm N/5 cm %

Tensile break

Strength

at

Elongation at break Tear Strength

Long Tran v Long Tran v Long Tran v

Cold Bending Form Stability Water pressure resistance Softening Point R&B Down Penetration 25 °C (77°F) •

Value

Test Method UEAtc UEAtc UEAtc

UEAtc UEAtc UEAtc UEAtc DIN 16935 ASTM D36 ASTM D5

The water proofing membrane for protection of concrete substructure shall be SBS heavy laminate bituminous felt, reinforced with 200 gm/m2 of non woven polyester inlay and modified bituminous compound presenting high thermal stability. The thickness of the membrane shall be 4 mm.

7000.5.1.3 Slip Sheets / Filter Membrane (TERRAM)) • A slip sheets/filter membrane shall be provided where it is called for and as shown on the drawings or as described elsewhere in the specification. The membrane shall be lap jointed with minimum of 200 mm over lap. Unit

Sizes



T05-20/11/2013



G/m2

Weight Thickness under 2 Kn/m2 pressure Permeability 100 mm head Pore size °90 °50

Mm Mm

Test Method ASTM D 3776

1/m2/s µm µm

140

200

280

250

1.6

1.8

2.6

2.4

100 70

60 40

40 20

50 30

• Slip Sheet/Filter membrane shall be of 140 g/m2. • The composition of the membrane shall be 70% polypropylene and 30% polyethylene. The membrane shall not be affected by salt water, oil and petrol and shall be fully ultra violet stabilized and resistant to growth of fungi and bacteria.

7000.5.2

Insulation

Insulation shall be a 50~ 100 mm thick (as per authority requirement) extruded polystyrene slab obtained from a manufacturer approved by the Engineer. Insulation boards shall have tongue and groove joints and a minimum density of 32 kg/m3 The thermal insulation material shall be preformed into rigid foam slabs by pressure extrusion method. The foaming and extrusion process shall ensure 100% closed cell formation. The insulation slabs shall be extruded polystyrene boards of thickness as per authority requirement, The material shall exhibit the following characteristics : • Thermal conductivity of maximum 0.032 W/mk when tested at 24° C, in accordance with DIN52612. • Compressive strength of 43 psi or 300 kps average when tested in accordance with DIN53421. Water absorption of maximum 1%, with min Density of 32 kg/m3 7000.5.3

Protection Boards

Protection boards for protection to water proofing/tanking membranes shall be from e reputed manufacturer compatible for application to bitumen or rubber tanking membrane. Protection boards shall be performed semi rigid asphalt boards 3 mm or 6 mm as indicated on drawings, thick formed of selected blend of asphalt and inorganic mineral fillers reinforced with asphalt saturated felt on one side and fibreglass mat weather coated and with a bond breaking film on other side. 7000.5.4 Liquid Applied Waterproofing – (Toilets, Kitchen, Ablusion, and Mechanical Rooms) High performance liquid bituminous solution modified with synthetic rubber latex with Rubber content 15% - 2 Coat on clean concrete slab face, and as per manufacturer recommendation -Bitprufe BLE 100 or equivalent.



T05-20/11/2013



7000.5.5 Liquid Applied for UG concrete (Footing, Tie Beams, water Tank from outside, Block work, Façade etc) Polymer modified bitumen emulsion with Rubber containe10 % - 2 Coat on clean concrete slab face, and as per manufacturer recommendation -Bitprufe BLE 65 or Equivalent 7000.5.6 Glass Reinforced Plastic (GRP) Lining for Water Tanks The materials for the GRP units shall be as follows: •

Gel coat Gel coat shall be a thixotropic isophthalic polyester gel coat resin ultra violet stabilized with resistant to water and chemicals.

•

Laminating Resin Laminating resin shall be polyester resin.

•

Glass Reinforcement Glass reinforcement shall be Chopped standard mat 450 gm/m2 piles.

•

GRP Elements GRP Elements shall consist wholly of glass reinforced polyester of minimum thickness with a tolerance of ± 1mm as indicated on drawings. It shall contain a minimum of 30% glass fibre reinforcement with the remaining 70% comprising of polyester resin and external gel coats of minimum 4 mm thickness. The concrete surfaces of floor, walls and ceiling shall be prepared to receive the GRP lining. The surface shall be free of dust pores, blow holes, honeycombs and other blemishes and shall be clean of any oil stains and any other adverse surface coating/droppings. The surfaces shall be prepared to the satisfaction of the applicator. The applicator shall bring any defects or unfit conditions to the notice of the Engineer before commencing any application. Approved certification to be provided that the material is not toxic and it's suitable for using as domestic water tank.

Note for Water Proofing 1-

DPC –Clay stabilized Liquid Bitumen water proofing membrane to be applied for periphery area at ground floor level only under 1st layer of the Block. -Spectite DPC or equivalent

2-

Any sleeves through the U.G wall/water tank (any wall penetration) should be throw UPVC paddle flange for U.G wall or electrical cables. (Akwa stop R × 101) or equivalent to be provided around the pipe from both side.

3-

Construction joints Vertical, Horizontal or at slope direction should be provided with water stopper (250 ECJ – 250 ICJ).

7000.5.7

Separation Layer

a) Separation layer shall have a thickness of 1200 gauge with overlap 20 cm minimum



T05-20/11/2013



as manufactured by DUPONT or approved equivalent. b) The material shall be Terram 700 or equivalent. 7000.5.8.1 Lightweight Concrete /Foam Concrete •

Screed shall be mixed from ingredients complying with the specifications in Ìn-situ Finishing' and `Concrete Work'. The density of light weight concrete shall be minimum 600 kg/m3 or as approved by the Engineer.

• The foaming emulsion shall be obtained from a specialist manufacturer approved by the Engineer. Indicated on the drawings with a minimum thickness of 50 mm. • The Foam concrete shall be laid in alternate bays not exceeding ten square meters and 300mm wide from the edge with joints between bays in 10mm thick compressible fiber material, Angle fillet 100x100mm shall be provided at junctions with vertical surfaces. 7000.5.8.2 Screed • The screed shall consist of one pert ordinary Portland cement to three parts sand by volume. Screeds shall be laid to slope and mixed and applied in 'In-Situ Finishing' the minimum thickness shall be (30 - 60mm). 7000.5.9

Polished White Cement Tiles

Tiles shall be fabricated from materials complying with the relevant specifications in `Concrete Work'. The tiles shall be 30 x 30 x 3 cm thick hydraulic pressed with smooth surface finish and factory polished. 7000.6 WORKMANSHIP Testing The Contractor is to test, to the satisfaction of the Engineer, all areas of roofing waterproofing terraces bathrooms and the like for water penetration. Theses tests are to be carried out after the members has been laid. The Contractor is to allow in his rate for such areas to be flooded with water. And left for a minimum of 48 hours .On complication of roofing works the Contractor is to leave the roof in a sound and water tight condition to the approval of the Engineer. Preparation of Surfaces All surfaces shall be clear of all deleterious matter and dry all in accordance with the manufacturer's written instructions .Prior to the application of any waterproofing /roofing materials or primer the Contractor shall gain the Engineer's written approval that may commence the said works .without the same ,all works will be rejected and replaced at the Contractor's expense.

7000.6.1 Waterproofing The membrane shall be handled and applied strictly in accordance with the manufacturer's written instructions. Surfaces to be covered shall be clean, flat, dry and free from any matter likely to adversely affect the performance of the waterproofing. The manufacturer's primer shall D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



be applied prior to laying the membrane.The waterproofing when satisfactorily laid shall be guaranteed for a period of 10 years minimum. 7000.6.2 Insulation Insulation shall be applied in accordance with the manufacturer's written instructions. Cutting and shaping shall be carried out in accordance with the manufacturer's recommendations. Surfaces to receive insulation shall not be contaminated with any matter likely to affect the performance of the material. 7000.6.3 Separation Layer Separation layer shall be cut and applied strictly in accordance with the manufacturer's written instruction. No air gap shall be left out while laying the separation layer. 7000.6.4 Light weight Concrete Screeds shall be mixed and applied in accordance with the specifications in Ìn-Situ Finishing'. Light weight concrete shall have a minimum thickness of 5cm and laid to a slope of 1:100 toward water outlets as detailed on drawings. Level and slope markings shall be made each at a maximum 2 meter apart and shall be checked by Engineer prior to laying of light weight concrete. The concrete supplier shall be obliged to certify the density of concrete for the sole approval of the Engineer. 7000.6.5 Polished White Cement Tiles Tiles shall be laid on sand cement screed as shown on drawing with expansion joints as instructed by the Engineer. Care shall be exercised to prevent damage to the underlying layers. 7000.7 Waterproofing Membrane The waterproofing membrane for protection of concrete substructure shall be a self-adhesive heavy laminate bituminous felt of a type suitable for hot climate, reinforced with 180 gm/m2 of non-woven polyester inlay and modified bituminous compound presenting high thermal stability, plasticity and flexibility characteristics as detailed on drawings and as specified in this Section. Whenever indicated on drawings mineral chipping faced membrane 4mm thick shall be provided. The membrane shall have the same characteristics as specified above. 7000.8 Slip Sheets/Filter Membrane A slip sheet/filter membrane shall be provided where it is called for and as shown on the drawings or as described elsewhere in the specification. For specifications of slip sheets/filter membrane refer to roofing system. 7000.9 Protection Boards Protection boards for protection to all water proofing/tanking membranes shall be from a reputed manufacturer compatible for application to bitumen or rubber tanking membrane. Protection boards shall be performed semi-rigid asphalt boards 3mm thick formed of selected blend of asphalt and inorganic mineral fillers reinforced with asphalt saturated felt on one side and a fiberglass matt weather coated and with a bond breaking film on the other side. 7000.10 Protection of Ground Slab, Steps, etc.



T05-20/11/2013



Ground slabs, steps, and the like which are in contact with soil shall be protected by an approved polythene sheet of 1000 gauge (0.254mm) thickness on blinding concrete as detailed on drawings or as directed by the Engineer. The continuity of the sheet shall be maintained by minimum laps of 100mm secured by approved adhesive or tape where necessary and/or as directed by the Engineer. Polythene sheet shall be as specified elsewhere in this section. 7000.11 Polythene Sheet Polythene sheets shall be provided to areas as indicated on the drawings either in transparent or black colour to gauges shown therein. Polyethylene sheets shall be manufactured from 100% prime first grade quality resins to BS 6515:1984. Materials manufactured from recycled, off spec. or waste materials shall not be accepted. The polyethylene sheet shall exhibit all the characteristics of BS 6515:1984 and the Contractor shall produce necessary test certificates to the Engineer to prove the same. Overlaps shall not be less than 100mm and shall be sealed together using an approved adhesive or tape. The materials shall be supplied, stored and installed in accordance with the manufacturers written instructions. 7000.12 Bituminous Paint The bituminous paint for damp proofing and protection to substructures shall be a high performance, thixotropic, cold applied bitumen emulsion with 10% added latex. It shall comply with the relevant section of BSCP 102:1973 – Protection of buildings against water from ground and BS 3690 – bitumens for building and civil engineering. It shall be easily flowing and applied cold in two or three coats by brush or squeegee suitable for use below ground level both for horizontal and vertical surfaces at temperature of 20°C to +100°C. The total thickness of the film on drying shall not be less than 1000 microns. END OF SECTION



T05-20/11/2013



.

SECTION 8800

GLAZING



T05-20/11/2013



SECTION 8800 GLAZING 8800.1 GENERAL Glass and glazing shall be provided as specified and as shown including entrances, curtainwall, windows, spandrels, skylights, glazed doors, transoms, sidelights, glazed partitions and mirror. 8800.2 DEFINITIONS Manufacturer as used in this section shall refer to a firm that produces primary glass or fabricated glass as defined in the referenced lazing standard. Deterioration of Coated Glass Defects developed from normal use that are attributed to the manufacturing process and assembly other than glass breakage and practices for maintaining and cleaning coated glass contrary to manufacturer’s directions. Defects include peeling, cracking, marking and discolouring and other indications of deterioration in metallic coating Deterioration of Metallic Glass Defects developed from normal use that are attributed to the manufacturing and assembly process other than glass breakage and practices for maintaining and cleaning laminated glass contrary to manufacturer’s directions. Defects include edge separation, delamination materially obstructing vision through glass, and blemishes exceeding those allowed by referenced laminated glass standard. Deterioration of Insulating Glass Failure of the hermetic seal under normal use due to causes other than glass breakage and improper practices for maintaining and cleaning insulating glass. Evidence of failure is the obstruction of vision by dust, moisture, or film on the interior surfaces of glass. Improper practices for maintaining and cleaning glass do not comply with the manufacturer’s direction. SYSTEM PERFORMANCE REQUIREMENTS 8800.3 General Glazing systems that are produced, fabricated and installed shall be provided to withstand normal thermal movement, wind loading and impact loading (where applicable), without failure including loss or glass breakage attributable to the following: defective manufacture, fabrication and installation; failure of sealants or gaskets to remain watertight and airtight, deterioration of glazing materials and other defects in construction. Glass Design Glass thicknesses indicated on the drawings and herein are the minimum thicknesses required. Contractor shall confirm glass thickness by analyzing project loads, and in service conditions. Provide glass lites for the various size openings in the thicknesses and strength (annealed or heat-treated or tempered) to meet or exceed the following criteria. Minimum glass thicknesses for exterior conditions shall be determined utilizing the structural performance criteria and the test methods of ASTM E997 and E998. Minimum thickness shall be determined using the most stringent of these requirements.



T05-20/11/2013



Minimum glass thicknesses of lites, whether composed of annealed or heat-treated or tempered glass, are selected so that the worst-case probability of failure does not exceed the following: a) 8 lites per 1000 lites set vertically or not over 15degrees off vertical and under wind action. Minimum thickness of monolithic annealed glass shall be determined according to ASTM E1300. Thicknesses of glass other than monolithic annealed glass shall be determined as per glass manufacturer’s standard method of analysis including applying adjustment factors to ASTM E1300 based on type of glass. b) 1 lite per 1000 lites set over 15degree off vertical and under action of wind. c) Normal thermal movement resulting from a maximum change (range) of 50 degree C in ambient and surface temperatures acting on glass-framing members and glazing components, based on engineering calculation on materials’ actual surface temperatures due to both solar heat gain and night time sky heat loss. 8800.4 SUBMITTALS The Contractor shall submit the following: Product Data: Manufacturer’s technical data for each glazing material fabricated glass product required, including installation and maintenance instructions. Indicate glass thicknesses to be used. Samples: Certificates:

300mm square samples of each type of glass indicated, and 300mm long samples of each colour of gasket and sealant. Certificates from respective manufacturers attesting that glass and glazing materials furnished for project comply with requirements of agencies having jurisdiction.

Separate certification will not be required for glazing materials bearing manufacturer’s permanent labels that represent a quality control program of a certification agency or independent testing laboratory acceptable to authorities having jurisdiction. Certification that glass does not exceed the permissible stress by analysis. Compatibility and Adhesion Test Report Statement from sealant manufacturer that glass and glazing materials have been tested for compatibility and adhesion, with interpretations and recommendations for primers and substrate preparation. 8800.5 QUALITY ASSURANCE Glazing Standards Recommendations of Flat Glass Marketing Association (FGMA) “Glazing Manual” shall be complied with except where more stringent requirements are indicated. This publication shall be referred for definitions of glass and glazing terms not otherwise defined. Safety Glazing Standard Required safety glass complying with ANSI 297.1 and testing requirements of 16CFR Part 1201 for Category II materials shall be provided. Insulating Glass Certification program



T05-20/11/2013



Insulating glass units permanently marked with appropriate certification label of Insulating Glass Certification Council (IGCC) for inspecting and testing shall be provided. Glazier Qualifications An experienced glazier who has completed glazing similar in material, design and extent to that indicated for this project with a record of successful in-service performance shall be employed. 8800.6 DELIVERY, STORAGE AND HANDLING Glass and glazing materials shall be protected during delivery, storage and handling to comply with manufacturer’s directions and to prevent damage to glass and glazing materials from moisture, temperature change, direct exposure to sun and from other causes. 8800.7 PROJECT CONDITIONS Environmental Conditions No glazing works shall be carried out when air and substrate temperatures are outside the limits permitted by glazing material manufacturer or when joint substrates are wet or dirty. 8800.8 WARRANTY General The Contractor shall submit warranties to repair or replace defective glass and glazing materials or workmanship for a period of 10 years after date of issue of the provisional Acceptance Certificate, or longer where specified. Defects include, but are not limited to the following: Failure of insulating glass edge seal as shown by moisture, dust, corrosion, or reflective coating damage within sealed air space. Insulating glass spacer migration Failure to meet specified performance requirements Failure of structural silicone seals Mirrors During warranty period, mirrors which developed defects in mirror coating due to normal conditions and not due to practices contrary to manufacturer’s instructions shall be replaced at no extra cost to the Employer Laminated Safety Glass The Contractor shall replace laminated glass which develop edge separation or delamination which obstructs vision through glass. Warranty period shall not be less than 10 years after date of issue of the Provisional Acceptance Certificate. Coated Glass The Contractor shall provide warranty agreeing to furnish to the Project site, within specified warranty period indicated below, replacements for those coated glass units which develop manufacturing defects. Manufacturing defects are defined as peeling, cracking or deterioration in metallic coating due to normal conditions and not due to handling or installation or cleaning practices contrary to glass manufacturer’s published instructions. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Spandrel Glass The Contractor shall arrange to provide a ten (10) year warranty from manufacturer against peeling, cracking, thermal breaking and deterioration of the metallic film and peeling or flaking of opacifiers as applicable. 8800.9 PRIMARY FLOAT GLASS PRODUCTS Float Glass ASTM C1036, Type I (Transparent glass, flat Class as indicated below, and quality q3 (glazing select)). Class 1 (Clear) unless otherwise indicated Class 2 (tinted, heat absorbing, and light-reducing where indicated) Refer to coated glass product requirements for tint colour and performance characteristics of coated tinted glass for monolithic glazing relative to visible light transmittance, U-values, shading coefficient and visible reflectance. 8800.10 HEAT-TREATED FLOAT GLASS PRODUCTS Fabrication Process: by horizontal (roller-hearth) process with roll-wave distortion parallel to bottom edge of glass as indicated, unless otherwise indicated. Tong-held method is not acceptable. Uncoated, Clear, Heat-Treated Float Glass: ASTM C1048, Condition A (uncoated sufaces), Type 1 (transparent glass, flat), Class 1 (clear), Quality q3 (glazing select), kind as indicated below: Kind HS (Heat Strengthened) where indicated Kind FT (Fully Tempered) where indicated Uncoated, Tinted, Heat-Treated Float Glass; ASTM C 1048, Condition A (uncoated surfaces), Type I (transparent glass, flat), Class 2 (tinted heat-absorbing and light reducing), Quality q3 (glazing select), with tint colour and performance characteristics for 6mm thick glass matching those indicated for annealed primary tinted float glass as indicated below: Kind HS (Heat Strengthened) where indicated Kind FT (Fully Tempered) where indicated Coated, Clear, Heat-treated Float Glass: ASTM C 1048, Condition C (other coated glass), Type 1 (transparent glass, flat), Class 1 (clear), Quality q3 (glazing select), with coating type and performance characteristics complying with requirements specified under coated glass products: kind as indicated below: Kind HS (Heat Strengthened) where indicated Kind FT (Fully Tempered) where indicated Coated, Tinted, Heat-Treated Float Glass: ASTM C 1048, Condition C (other coated glass), Type 1 (transparent glass, flat), Class 2 (tinted, heat-absorbing and light reducing), Quality q3 (glazing select), with kind, coating type, and performance characteristics complying with requirements specified under coated glass products. Tempered glass shall comply with ANSI Z97.1 and shall be heat checked or heat soaked. 8800.11 COATED MONOLITHIC GLASS PRODUCTS



T05-20/11/2013



General: Performance characteristics designated for coated monolithic glass products are nominal values based on manufacturer’s published test data for glass products 6.0mm thick, unless otherwise indicated. Comply with requirements specified including those for primary and heat-treated float glass products as they relate to properties of glass to which coatings are applied. Provide heat-treated coated float glass of kind indicated or, if not otherwise indicated, kind HS (Heat-Strengthened) where recommended by manufacturer to comply with system performance requirements specified and kind FT (fully tempered) where coated safety glass is designated or required. Provide kind HS coated float glass and Kind FT products where coated safely glass is designated or required Coated glass shall be hard coated so as to enable application of silicone sealant directly on the coated surface without requiring any descaling of the coating for the retainer strips and insulated glass. Coated, Heat-treated Spandrel Glass Kind HS (Heat Strengthened) Kind FT (Fully Tempered) Opacifier as indicated on drawings Low-Emissivity-Coated (low-E) Glass: Units coated with a durable, neutral-colored, low-emissivity metallic coating, of pyrolitic type and on surface indicated. 8800.12 LAMINATED GLASS PRODUCTS Comply with ASTM C 1172 for kinds of laminated glass indicated and other requirements specified. Kind LA: Two lites of annealed Type I glass Kind LHS: Two Lites of heat-strengthened Type I glass Kind LT: Two lites of full-tempered Type I glass. Interlayer: Interlayer materials as indicated below, and of thickness indicated with a proven record of no tendency to bubble, discolor or lose physical and mechanical properties after laminating glass lites and installation. Interlayer-Material: Polyvinyl butyral sheets, 0.76mm thick, clear. Laminating Process: Fabricate laminated glass to produce glass free of foreign substances and air or glass pockets as follows: Laminates lites with polyvinyl butyral interlayer in autoclave with heat plus pressure. 8800.13 INSULATING GLASS PRODUCTS Sealed Insulation Glass Units: Preassembled units consisting of organically sealed lites of glass separated by dehydrated air spaces complying with ASTM E774 and with other requirements indicated. Provide heat-treated, coated float glass of kind indicated or if not otherwise indicated, Kind HS (Heat Strengthened) where recommended by manufacturer to comply with system performance requirements specified and Kind FT (Fully Tempered) where safety glass is designated or required.



T05-20/11/2013



Performance characteristics designated for coated insulating glass are nominal values based on manufacturer’s published test data for units with lites 6.0mm thick and nominal 12mm dehydrated space between lites, unless otherwise indicate. Sealing System: Dual Seal; primary sealant (minimum width 3.0mm): Polyisobutylene; secondary sealant: silicone. Spacer Metal: Manufacturer’s standard metal Dessicant: Manufacturer’s standard; either molecular sieve or silica gel or blend or both. Corner Construction: Manufacturer’s bent and welded construction. Frosted Glass Frosted glass shall be 100 percent sandblasted using 120 grit material. Mirror Glass Clear Float glass conforming to specified standard, quality q1, 6mm thick. Cut glass to sizes indicated and complete edge treatment. Grind, polish and bevel mirror edges not framed. Coat back of glass with chemical deposited silver, covered by film of electrically or chemically deposited copper, and coated with manufacturer’s standards 0.05 mm dry film of organic coating. 8800.14 GLAZING SEALANTS General

:

Comply with the following requirements

Elastomeric Sealant Standard

:

Provide elastomeric sealant which complies with ASTM C 920 requirements

Colors

:

Provide color as selected by Engineer from manufacturer’s Standard colors.

8800.15 MISCELLANEOUS GLAZING MATERIALS Compatibility: Provide materials with proven record of compatibility with surfaces contacted in installation. Cleaners, Primers and Sealants: Type recommended by sealant manufacturer Setting Blocks: Neoprene, EPDM or silicone blocks as required for compatibility with glazing sealants, 80 to 90 shore A durometer hardness, 100mm minimum length by width to suit glass thickness. Shims and Spacers: Shims and spacers used with setting blocks shall be of same material, hardness, length and width as the setting blocks.



T05-20/11/2013



Edge Blocks: Same materials as setting blocks, of 50 to 60 Shore A durometer, of size to limit lateral movement of glass. 8800.16 GLASS TYPES Provide the following glass types subject to compliance with criteria specified herein and as detailed below: a) Insulated Reflective Glass Vision Panel As a reference the performance characteristics of a 1” (24mm) insulated glazed unit for typical vision panel with reflective glass is based on, 1/4” (6mm) Pyrolitic coated glass as Stopset Supersilver green of Claverbel or Eclipse Blue green of Libbey Owens Ford or Reflectasol Green of Saint Gobain or equal approved, tempered outer lite. 1/2” (12mm) Airspace. 1/4” (6mm) Clear inner lite, tempered to minimum height of 800mm from floor level as required to meet the safety standards. The typical Characteristics shall be: Light Transmittance Light Reflectance Out Solar Energy Trans Solar Energy Reflectance Out Summar ‘U’ value Shading Coefficient Relative Heat Gain

≥ 12% ≥ 9% < 8% > 8% ≤ 0.51 Btu/hr.ft² °F ≤ 0.24 < 0.54 Btu/hr.ft² °F

b) Spandrel Panel Exterior Glass - minimum 6mm thick tempered pyrolitic coated glass to match glass vision panel Air Space - as required Opacifier - Polyester film Insulation - 50mm rigid rockwool insulation of density 50 kg/m3 Vapour barrier - Aluminium foil 8800.17 WORKMANSHIP Verify compliance with applicable tolerances; for functioning of weep system; for face and edge clearances; and for effective sealing of joinery. Report conditions detrimental to glazing work. Perform glazing work after unsatisfactory conditions have been corrected. Clean glazing channels immediately before glazing. Remove coatings which are not firmly bonded to substrates. 8800.18 GENERAL Comply with the combined recommendations of glass manufacturers, of manufacturers of sealant and other glazing materials, except where more stringent requirements are indicated by referenced glazing standards. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Glazing channels are intended to provide for necessary bite on glass, minimum edge and face clearances and adequate sealant thickness, with reasonable tolerances. Adjust as required by Project conditions during installation. Protect glass from damage. Remove and dispose of glass units with damage or imperfections of kind that impairs performance or appearance. Prime joint surfaces as required for adhesion of sealant. Install setting blocks one quarter of glass width from each corner but with edge nearest corner not closer than 150m from one corner of 0.125 times glass width, whichever is greater. Install blocks to prevent movement. Provide spacers of correct size and spacing for clearances, for glass sizes larger than 1200 united mm (length plus height), except where gaskets or glazing tapes are used for glazing. Provide 3mm minimum bit of spacers on glass and use thickness equal to sealant width, or slightly less than final compressed thickness of tape. Provide edge blocking to comply with referenced glazing standard. Install edge blocks securely, between the mid-height and top corner of the glass and anti-walk as required. Set of units of glass in each series with uniformity of appearance. Provide compressible filler rods as recommended by sealant and glass manufacturers, to prevent sealant from clogging weep systems and from adhering to joints back surface and to control depth of sealant. Force sealants into glazing channels to eliminate voids and to ensure complete “wetting” or bond of sealant to glass and channel surfaces. Tool exposed surface of sealants to provide a “wash” away from glass. 8800.19 INSULATING GLASS Insulating glass units shall be 24mm thick, consisting of two panes of 6mm glass separated by a desiccant filled metal spacer with bent, welded or fused corners and welded or fused splices or joints to provide a continuous 12mm hermetically sealed and dehydrated space. Insulating glass seal shall be dual seal with polyisobutylene and silicone sealants and certified for compliance and certified for compliance with seal classification “CBA” by the Insulating Glass Certification Council (IGCC) and shall meet the requirements of ASTM E774 when tested in accordance with the following ASTM test methods. Secondary seal for structural silicone glazed units shall be a silicone edge seal certified for use in structural silicone glazing applications over the temperature range and structural loading as called for by the performance criteria section of this specification. E773 Test Method for Seal Durability of Sealed Insulating Glass Units E774 Specification for Sealed Insulating Glass units E546 Test Method for Frost Point of Sealed Insulating Glass Units E576 Test Method for Frost Point of Sealed Insulating Glass Units in Vertical Position The glass shall be fully heat strengthened or tempered as specified to assure adequate glass performance at the design pressures specified under the performance criteria. Glass manufacturer’s recommendations are to be accompanied by wind load and thermal stress analysis. The glass shall be fully heat strengthened or tempered as specified to assure adequate glass performance at the design pressures specified under the performance criteria. Glass manufacturer’s recommendations are to be accompanied by wind load and thermal stress analysis. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The contractor shall provide certification from the glass producer/fabricator that the glass producer/fabricator has reviewed glass thickness and finds it suitable for the purpose intended in accordance with his published literature and in accordance with these specifications. 8800.20 MIRRORS Apply one additional coat of backing paint and allow to dry. Apply mirror mastic or cover not more than 25% of back mirror. Set mirror on base support, on setting blocks or continuous gasket and press against substrate to ensure bond of adhesive. Leave open ventilation space, 3mm or more in thickness between mirror and substrate. Do not seal-off ventilation space at edge of mirror. 8800.21 TAPE GLAZING Position tapes on fixed stops so that when compressed by glass their exposed edges are flush with or protrude slightly above sightline of stops. Install tapes continuously but not in one continuous length. Do not stretch tapes to make them fit opening. Where framing joints are vertical, cover these joints by applying tapes to heads and sills first and then to jambs. Where framing joints are horizontal, cover these joints by applying tapes to jambs and then to heads and sills. Place joints in tapes at corners of opening with adjoining lengths butted together, not lapped. Seal joints in tapes with compatible sealant approved by tape manufacturer. Do not remove release paper from tape until just before each lite is installed. Apply heel bead of elastomeric sealant. Centre glass lites in openings on setting blocks and press firmly against tape by inserting dense compression gaskets formed and installed to lock in place against faces of removable stops. Start gasket applications at corners and work toward centre of openings. Apply cap bead of elastomeric sealant over exposed edge of tape. 8800.22 GASKET GLAZING (DRY) Fabricate compression gaskets in lengths recommended by gasket manufacturer to fit openings exactly, with stretch allowance during installation. Secure compression gaskets in place with joints located at corners to compress gaskets producing a weathertight seal without developing bending stresses in glass. Seal gasket joints with sealant recommended by gasket manufacturer. Gaskets shall have moulded corners. Install gaskets so they protrude past face of glazing stops. 8800.23 SEALANT GLAZING (WET) Install continuous spacers between glass lites and glazing stops to maintain glass face clearances and to prevent sealant from extruding into glass channel weep systems until sealants cure. Secure spacers in place and in position to control depth of installed sealant relative to edge clearance for optimum sealant performance. Force sealants into glazing channels to eliminate voids and to ensure complete wetting or bond of sealant to glass and channel surfaces. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Tool exposed surfaces of sealants to provide a substantial wash away from glass. Install pressurized gaskets to protrude slightly out of channel to eliminate dirt and moisture pockets. 8800.24 HEAT SOAKING OF TEMPERED GLASS All tempered glass shall be subject to heat soaking tested prior to delivery to site. 8800.25 PROTECTION AND CLEANING Promptly protect installed glass from breakage with crossed streamers attached to framing and held away from glass. Do not apply markers to surfaces of glass. Remove non-permanent labels and clean surface. Protect glass from contact with contaminating substances. If contaminating substances do come into contact with glass, remove immediately as recommended by glass manufacturer. Remove and replace glass which is broken, chipped, cracked, abraded or damaged in other ways during construction period, including natural causes, accidents and vandalism. Wash glass on both faces not more than 4 days prior to date scheduled for inspections to establish date of issue of the Provisional Acceptance Certificate in each area of the Project. Wash glass as recommended by glass manufacturer. 8800.26 GEORGIAN POLISHED WIRED GLASS Georgian polished wired glass. Do not apply markers to surfaces of glass. Remove non-permanent labels and clean surfaces. 8800.27 POLYCARBONATE GLASS The polycarbonate glass shall be of a colour to match the blue green Eclipse glass of Libbey Owens Ford. The continuous use temperature of the glass shall be 120 degrees C. The coefficient of linear expansion shall be 6.7m/m degree C x 10.5. Fire resistance according to BS 2782 shall be class O, self extinguishing. Sheet thickness shall be minimum 6mm and shall be bent by cold bending with proprietary patent glazing systems. Shell stability calculations to assess linear bucking under windload along with others calculations to cater to the design parameter requirements stated under Structural Glazing, shall be submitted for approval of the Engineer. Sheets shall be supplied with protective sheets of masking paper o polyethylene cling film on both surfaces. Prior to installation, shop drawings are to be prepared by the supplier to show all dimensions and fixing details of the sheets for approval of the Engineer.

END OF SECTION



T05-20/11/2013



SECTION 9000 FINISHES



T05-20/11/2013



Section 9000 FINISHES 9000.1 SCOPE These specifications cover all in-situ floor, wall and ceiling finishing’s to be incorporated into the works. 9000.2 GENERAL The Contractor shall perform all attendance upon other trades and protect all works specified under this section from damage during subsequent operations, make good any defects, clear away upon completion , clean throughout and leave all work in perfect condition to the approval of the Engineer. 9000.3 MATERIALS 9000.3.1 Cement Cement for all finishing’s shall be Ordinary Portland Cement complying with B.S. 12. White cement, where required, shall conform to the same specification standards. 9000.3.2 Coarse Aggregate Coarse aggregate for use in screed shall be as specified under `CONCRETE WORK'. Aggregate for use in granolithic shall be selected granite or quartz between 5 mm and 10 mm in size. 9000.3.3 Fine Aggregate (Sand) Sand for use in finishings shall be as specified under `CONCRETE WORK' and shall contain no more than 0.06% chlorides. Fine aggregate for use in tyrolean shall be specially selected for that purpose. 9000.3.4 Water Water shall be clean, free from any harmful matter, and free from any unusual proportions of dissolved salt. Sea water or brackish water shall not be used. Analysis by an independent testing body shall be made to determine the suitability of the water if required by the Engineer. 9000.3.5 Additives Additives for use in in-situ finishings shall only be used with the Engineer's approval. 9000.3.6 Metal Lathing Metal lathing for use in in-situ finishing shall be plain expanded metal type complying with B.S. 1369, weighing not less than 1.2 kg/m2. All metal lathing shall be zinc coated. Metal lathing shall be secured by means of galvanized steel nails and washers at 600 mm centres. If wire is to be used for securing metal lath it shall be zinc coated and not less than 1.2mm in diameter. Metal lath shall be provided over all junctions of concrete and blockwork or any other dissimilar materials which are to be rendered. The minimum overlap of the metal lath shall be 200 cm on each side of the joint. 9000.3.7 Angle beads, stop beads etc. All external angles to rendered finishings shall have external angle beads to ensure a true straight arris. Rendered finishings brought up to door frames, window frames and the like shall have architrave beads and where finishings end but do not abut other materials stop beads shall be used. All beads shall be coated and be of an approved type from an approved manufacturer. All beads shall be fixed in accordance with the manufacturer's instructions. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



9000.3.8 Metallic Surface Hardener for Concrete Where shown on the Drawings/ or Bill of Quantities a proprietary metallic surface hardener shall be applied to concrete floors. The hardener shall comprise of metallic aggregate cementitious binder, plasticizer and water-reducing admixtures. The hardener shall be a dry shake applied material such as Masterplate 200 or other equal and approved. The hardener shall be applied at the rate of 7.5 kg/m2. 9000.3.9 Levelling Compounds Levelling compounds for screeds which are to receive floor coverings shall be a blend of specially selected cements, graded aggregates, polymers and self control additives in powder form and capable of application by addition of water forming a smooth free flowing and self leveling material to smooth out surface irregularities. The mixtures shall set hard in ½ hour and allow the final covering to be laid after 8 hours. The surface preparation, mixing and application shall be strictly in accordance with the manufacturer’s instructions. 9000.3.10 Epoxy Resin Floor Finish Wherever shown on the drawings/Bill of Quantities, the epoxy resin based floor finish shall be a two component solvent-less coating obtained from an approved manufacturer. The coating shall be a hard, abrasion-resistant, inherently flexible finish with a non-slip surface obtained by the addition of clean sharp sand. The coating shall be suitable for service temperatures upto 90 deg.C and shall be applied at the rate of 1 kg/6-7 m2 (100-150 microns thick). The sand shall be applied at the rate of 1 kg/m2. 9000.3.11 Waterproofing to Baths, Toilets, Kitchens, Wet Areas, Etc. Waterproofing to floors of toilet and kitchens shall be cold applied, seamless, two component, extended polyurethane, elastomeric material in liquid form which when applied cures to a rubbery membrane in 24 hours. The membrane shall form a tough durable, resilient, impermeable barrier to water and most aqueous reagents, adhering to the structural surface. A primer or bonding shall be used (if required) as recommended by the manufacturer of the membrane. The minimum thickness of the membrane shall be 1.5m and shall be suitable for hot climates. The membrane shall meet the requirements indicated in the table below: Property Unit Value Method of Test Tensile Strength Kg/cm2 40 ASTM D412 Elongation at Break % 500 ASTM D412 Tear Strength Kg/cm 20 ASTM D624 Dic “C” Softening Point (Ring & Bell) °C 163 ASTM D2398 Low Temp. Brittleness °C -50 ASTM D648 50 min ASTM D2240 Hardness (Shore A) Perms 0.555 ASTM E96 Permeability (100 mill sheet at 100°F) Adhesion to Concrete Kg/cm2 25 Elcometer Abrasion Resistance, Wt. Loss, mg 1.2 ASTM C501 Taber Abraser CS-17 Wheel, 1000gr/1000rev. Recovery (from 100% extension



T05-20/11/2013



after 5mins.) 99 Concrete, screed or blockwall surface that are to be applied with the membrane shall be fully cured before the application of the membrane. The membrane shall be applied on the concrete/screed floors before any tiling operations are carried out. The membrane shall be carried up walls, columns, abutments, etc. to at least 100mm above the finished floor level for all areas and up to 100mm above the bathtub rim before application of wall plaster. A layer of metal lathing shall be provided over the wall area covered by the waterproofing membrane before plastering the walls. Tiles shall then be glued to the plastered wall surface. Screed shall be laid over the membrane as protection against any damage from site traffic and other causes. Extreme care shall be exercised to prevent any damage to the waterproofing membrane during the application of floor and wall finishes. 9000.3.12 Liquid Applied Facade Damproofing Dam proofing for surfaces of façade to receive cladding or curtain wall shall be carried out by application of a solvent free SBS elastomeric bitumen gelified emulsion with an elongation at break of at least 100% elastic recover, having thixotropic performances. The cured membrane shall be waterproof but shall have a water vapor permeability of at least 0.3 g/m2/24H. The damproofing shall be applied over clean, dry and smooth concrete or blockworks surface. All pipes, details, anchors, etc. which have to penetrate the structure must be in place prior to any damproofing application. The damproofing shall be applied over clean, dry and smooth concrete or blockworks surface. All pipes, details, anchors, etc. which have to penetrate the structure must be in place prior to any damprofing application. Damproofing system shall be applied with brush or roller, in one coat at a rate of 650 g/sq.m minimum (on blockwork and concrete surfaces) and allowed to cure for at least 12 hours. Before erection of cladding or curtain wall, precautions shall be taken to ensure the membrane not to be damaged. 9000.4 WORKMANSHIP 9000.4.1 Mixing of Render and Screed Mechanical mixers of an approved type shall be used for mixing except where hand mixing of small batches is approved by the Engineer. Mechanical mixers, mixing boxes and tools shall be cleaned after mixing each batch and kept free of material from previous mixes. All tools, implements, vessels and surfaces shall at all times be kept scrupulously clean and strict precautions shall be taken to avoid materials becoming contaminated by pieces and partially set material which would tend to retard or accelerate the setting time. Retempering will not be permitted and all render or screed which has begun to stiffen shall be discarded. Frozen, caked or lumped materials shall be be used. 9000.4.2 Preparation of Surfaces D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Walls and Ceilings All surfaces to be rendered shall be clean and free from dust and grease. Projecting mortar and concrete fins and run shall be removed. Traces of salts shall be thoroughly sprayed with water, but all free water shall be allowed to dry and disappear from the surface before the render is applied. Rendering shall not commence until the background has been suitably prepared. Blockwork joints shall be deeply raked out, efflorescence brushed off and all dust and foreign matters removed. On all external surfaces and on all smooth internal surfaces a spatter dash of cement and sand which shall contain 500 kg of cement per one metre cube of sand shall be applied and allowed to dry before rendering is commenced. Alternatively, an approved bonding agent may be used. All surfaces of walls and ceilings shall be wetted immediately prior to applying the rendering. The Contractor shall form vertical guide screeds 50 mm wide on wall. The spacing shall not exceed 1.50 metres. The screeds shall be plumb and shall all be in the same plane. The sides of the screed shall be left rough to bond with plaster. The finished surface shall be true to shape and angle, even in all directions, with straight arises free of cracks and trowel marks and to the entire satisfaction of the Engineer. Floors All surfaces to receive screeds shall be clean and free from projections, dust, grease and other deleterious matter. Free water shall be allowed to dry out before screeding commences. The surface to be screeded shall provide a good bond for the screed. If in the opinion of the Engineer, the surface does not provide a good surface, it shall be hacked to his satisfaction. 9000.4.3 Application of Finishes Render Render shall not be applied within 24 hours of the spatter coat application, if used. Render shall be floated to a true, even surface. If the surface is to be a smooth finish then it shall be further trowelled in a manner which forces the sand particles down into the render. All render surfaces shall be free from rough areas, trowel marks, checks or other blemishes. Work shall be executed in a neat workmanlike manner and internal and external angles shall be true, straight and plumb. Render shall be made good to adjacent finishings, frames, skirtings etc. sleeves and other fittings.

and around pipes

Render shall be worked into expanded metal lathing, where used, and into beads to form a neat edge or arris. Screed Screed shall be laid by competent workmen to the thicknesses indicated on the drawings or directed by the Engineer. Screed shall be laid in bays, if required by the Engineer, in which case joints shall coincide with those in the base as nearly as possible. Curing of screeds shall be carried out by covering with sacking, canvas, hessian or similar material and keeping them constantly wet for a period of at least three days. The screed shall be D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



protected from all traffic until set. Screed to falls shall be to perfect gradients so that no ponding may occur. Surfaces shall either be floated or trowelled depending upon the nature of the finish to be applied, and shall be as indicated on the drawings or directed by the Engineer. 9000.5 Mix Proportions A. Render Render to surfaces shall be mixed in the following proportions:Internal render and backing to tiles : 1 part cement and 4 parts sand measured by volume External render : 1 part cement and

4 parts sand measured by volume

B. Screed Screed to floors shall be mixed in the following proportions:1 part cement 1 1/2 parts fine aggregate (sand) 3 parts coarse aggregate Water content shall be kept to minimum with a maximum allowable slump of 50 mm. 9000.6 TILE, SLAB AND SHEET FINISHING 9000.6.1 Scope These specifications cover tile, slab and flexible sheet finishing to floors and walls intended to be used in the works. 9000.6.2

General

The Contractor shall perform all attendance upon other trades and protect all works specified under this section from damage during subsequent operations, make good any defects, clean throughout and leave all works in a perfect condition to the approval of the Engineer All materials and manufactured items that are liable to damage shall be delivered in the original packages, containers, etc. bearing the name of the manufacturer and the brand, and shall be carefully loaded, transported, unloaded, stored in an approved manner, protected from damage and exposure to weather or dampness during transit and after delivery to the Site. Damaged materials and manufactured items shall not be used in the works specified under this Section. Any materials and manufactured items damaged during and after bedding or setting in position shall be removed and replaced by and at the Contractor's expense 9000.6.3 Materials and Manufacture 9000.6.3.1 Cement D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Cement shall be Ordinary Portland Cement to B.S. 12. White cement shall conform to the same specification standards. 9000.6.3.2 Sand (Fine Aggregate) Sand (Fine Aggregate) for use in tile and slab finishings shall be as specified under `CONCRETE WORK'. 9000.6.3.3 Water Water shall be as specified under `CONCRETE WORK'. 9000.6.3.4 Colour Pigments Colour pigments shall conform to BS 1014. 9000.6.3.5 Precast Terrazzo Tiles, Skirting, etc. The precast terrazzo tiles and skirtings shall be formed of white cement and granular marble chippings of large grades in order to obtain good wearing surfaces. The thickness of wearing surface shall be around half of the tile thickness. Precast terrazzo skirtings shall have fair square top edges. Precast terrazzo treads, risers strings, thresholds, etc. shall be of the design, dimensions and thicknesses shown on the drawings and they shall be formed in the same proportions and mixes as for tiles. Where required, terrazzo units shall be reinforced with bars and treads shall have either a non-slip aggregate (carborundum) incorporated into the top surface or a non-slip nosing recessed into the surface near the edge as directed by the Engineer. Grinding shall be done wet by means of a No. 8 carborundum stone. Filling shall be with a neat cement grout of the same colour as the facing mix and this shall be worked into the surface with a wooden scraper to fill all voids and air holes. After a minimum period of 24 hours, polishing shall be carried out as described in `WORKMANSHIP'. Samples of terrazzo shall be provided for the Engineer to choose from 9000.6.3.6 Ceramic Floor Tiles Ceramic floor tiles shall be matt finish plain clay tiles manufactured in accordance with B. S. 1286 type B. Skirtings shall be coved edge type 100 mm high. Acid resistant tiles shall be used where specified. Pattern and colour shall be to the Engineer's approval 9000.6.3.7 Glazed Wall Tiles Glazed wall tiles shall conform to the requirements of B.S. 1287 and to the sizes shown on the schedules of finishes and the drawings. Single edge and double edge rounded tiles, coved and corner tiles shall be used where required. Acid-resistant tiles shall be used where specified. Patterns and colours shall be to the Engineer's approval. 9000.6.3.8 Plasticizer Plasticisers proposed by the Contractor and approved by the Engineer shall be used.



T05-20/11/2013



9000.6.3.9 Sealant to Terrazo After completion of the polishing and cleaning of the terrazzo the tile floors the surface shall be sealed with an approved industrial quality acrylic clear seal buffed to give a high gloss finish but with a non-slip surface. 9000.6.3.10 Adhesive Adhesive shall be a suitable cement based adhesive complying with BS 5980:1980, from a manufacturer approved by the Engineer. 9000.6.3.11 Joint Sealant Sealant shall be a suitable cement based adhesive complying with BS 5980:1980, from a manufacturer approved by the Engineer. 9000.6.3.12 Sealants The treatment of external/internal, moving and static joints to prevent penetration of moisture. The sealant shall be one part high modules silicon sealant type-B to BS 5889:1989. The colour shall be to the Engineer approval. BACKING STRIP Backing strip/backing rod for joint sealant shall be round, closed cell, impermeable, extruded polyethylene foam, from a manufacturer approved by the Engineer. The diameter of the rod shall be about 25% greater than the width of the joint to provide a tight fit. Continuous lengths shall be used as far as possible. Aluminium cover strips, where indicated on the drawings, junctions of different floor finishes shall be provided with extruded aluminium cover strips. Cover strips shall be of type, and from the manufacturer approved by the Engineer and shall be fixed in accordance with the manufacturer's instructions. Workman Ship, Generally All required openings, chassis, or other apertures are cut and prepared. The likes of pipes, fixtures, fixing pads and plugs, have been fixed. Making well has been completed and the surface is checked by the Engineer. Surfaces are too wetted and re-wetted as required to equalize suction before the first coat of plaster or the like is applied. Particularly dense concrete surfaces are to be wetted and re-wetted as required before bonding plaster is applied. Where surfaces are out of line, they are to be brought to level by hacking or dubbing out in similar mix to the undercoat prior to commencement of finishing. Standards: BS 2499 BS 3712 BS 3712: Part 1:1991 BS 3712:Part 3:1994 BS 3712:Part 4: 1991

Hot applied joint sealants for concrete pavements Method of test for building sealants Homogeneity, relative, density and penetration. Application life skinning properties and tack free time. Adhesion in peel



T05-20/11/2013



BS 4254:1991 BS 5212 BS 5212:1986 BS 5385:Part 2:1991

Two-part polysulphide-based sealants Cold applied joint sealants systems for concrete pavements One-part gun-grade polysulphide-based sealants Code of practice for design and installation of External, ceramic wall tiling and mosaic. BS 5889:1989 One part gun grade silicone-based sealants BS 6100 Sec.1.5.2:1987 Glossary of Terms relating to joints & jointing a) General: Joint fillers shall be cellular preformed and low density capable of 50 percent compression at 4 newtons per sq.mm. Backing strips shall be foamed polyethylene joint filler of suitable size and surface finish to act as bond breaker. Primers shall be fully in accordance with the requirements and recommendations of the sealant manufacturer. Sealants shall be to dimensions shown placed against firm preformed backing strips. Sealant shall have hard adhesion to parent material and shall not harden or become brittle over a temperature range of -5 to 55°C and shall not degrade in strong sunlight. Sealant shall be clean and dry at time of priming. Concrete shall be wire brushed and blown clean with oil free compressed air. Metal surfaces shall be cleaned with an oil and paraffin free solvent to remove all surface oils. Such solvent shall be wiped dry by clean rags. Joints shall be primed in accordance with the manufacturer’s standards and requirements of the sealant manufacturers. Joints shall be sealed as soon as the primer is tack dry. Joints shall be sealed at an ambient dry bulb shade temperature of 25 to 35°C. Protect adjacent surfaces as necessary. Joints shall be fully filled and finished with a smooth even surface. To roads, hardstandings and ground slabs the sealant shall be placed such that when compressed they will not depress more than 3mm below the surface. b) Application of sealants 1. 2. 3. 4.

All external joints shall be sealed. All wet joints shall be sealed. All visible vertical joints between concrete and/or masonry elements shall be sealed. All joints between ceramic tiles and abutting materials such as cabinets, baths, sinks, door frames, floor drains shall be sealed.

Joints in offices and other accommodation shall be sealed as specified but with cover strips specifically designed to conceal expansion joints while allowing expansion to take place. c) Sealant Type: Type A Structural Expansion and isolation joints. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Floors and walls will have proprietary elastomeric joints. The sealant shall be a two part polysulphide sealant, to BS 4254:1991 and capable of plus or minus 25% movement (minimum). The colour and sealant shall be to the Engineer’s approval. Type B Crack-Control joints in medium and heavy duty floors. The sealant shall be a two-part chemical-fuel and oil-resistant and abrasion-resistant elastomeric sealant capable of plus or minus 5% movement (minimum) and to the Engineer’s approval. In areas subject to spillage of hydraulic fluid or other aggressive agents, suitable alternatives which will not be subject to attack shall be used as agreed with the Engineer, e.g. to mechanical workshops. Type C Sealant for Windows, doors, sanitary fittings, ceramic tiling and general builders work. The sealant shall be a one-part high-modules silicone sealant, type B to BS 5889:1989. the colour shall be to the Engineer’s approval. Type D Glazing and Bedding Compound The sealant shall be an oil-bassed material containing synthetic polymer, manufactured specifically for glazing bedding to be to the Engineer’s approval. Type E Roads and Hardstandings The sealant shall be a chemical-fuel-and-oil resistant cold-applied two-part elastomeric compound to BS 5212 to the Engineer’s approval. It shall be capable of plus or minus 1.5 percent movement (minimum). 9000.6.3.13 Backing Strip/Backer Rod Backing strip/backer rod for joint sealant shall be round, closed cell, impermeable, extruded polyethylene foam, from a manufacturer approved by the Engineer. The diameter of the rod shall be about 25% greater than the width of the joint to provide a tight fit. As far as possible continuous length shall be used. 9000.6.3.14 Joint Filling Material Filling material movement joints shall be flexible bitumen impregnated mineral fiber board from a manufacturer approved by the Engineer. 9000.6.3.15 Plasticisers Plasticisers shall be from a manufacturer approved by the Engineer. 9000.6.3.16 Mastic Mastic for waterproofing and damp proofing membrane shall be rubber/bitumen based from a manufacturer approved by the Engineer. 9000.6.3.17 Marble or Granite Slabs



T05-20/11/2013



Marble or granite slabs for flooring, skirting, treads, risers, door thresholds, column and wall cladding shall be first quality, uniform in colour and texture, free from voids, earth veins and lamination or structural weakness and of an approve texture and colour. The pattern, dimensions, and thickness of marble or granite slabs shall be as shown on the drawings or as stated in the Bills of Quantities. Samples of marble or granite slabs shall be submitted to the Engineer for approval prior to order. All marble shall be applied with an approved non-yellowing penetrative protective sealant to back and sides. Metal anchorage consisting of cramps, bolts, dowels, etc. shall be of approved proprietary make of stainless steel. 9000.7 WORKMANSHIP 9000.7.1. Precast Cement and Terrazzo Tiles The precast concrete and terrazzo tiles shall be laid on a (1:3) mix of cement and sand mortar and any admixtures approved by the Engineer. All tiles shall be laid with square joints and shall be grouted upon completion, care being taken to fill all joints completely. The grout shall consist of neat cement of a colour to match the tiling. Any surplus grout shall be cleaned off the face of the tiling and surrounding surfaces immediately and all tiling shall be carefully cleaned off. All terrazzo surfaces shall be polished on completion. Large areas such as floors shall be wet polished by means of approved machines using a No. 140 carborundum wheel. Any narrow surfaces which cannot be polished conveniently by the machine, may be polished by hand using a No. 140 carborundum stone and water. Care must be taken during any polishing operation not to damage any angles or arises. Tiles shall be cut with a suitable cutting tool and rough edges shall be rubbed smooth. Cut-tile misfits shall be replaced with properly cut-tiles. Straight edges shall be accurately set to the lines established and reset at suitable intervals to keep the joints parallel over the entire area. Broken tiles or tiles showing least signs of defects will not be accepted and if laid by the Contractor shall be removed and replaced with sound tiles, at his own expense Tiles shall be laid out from the centreline of each space outward and adjustments made along walls, partitions, and border, so as to symmetrize the pattern with a minimum of cut tiles. Tiles of less than half of their full size along one side after cutting shall be avoided. 9000.7.2 Ceramic Floor Tiles Ceramic floor tiles shall be laid in a mortar bed on top of screed as described in ÌN-SITU FINISHINGS' so that the total thickness of tiles, mortar and screed is 70 mm. The ceramic tiles shall be thoroughly soaked in water for a minimum of twenty four (24) hours before laying. Tiles and skirtings shall be bedded in cement and sand (1:3) mix with addition of approved plasticizer. All joints shall be as close as possible and shall in no case exceed half (0.5) mm in width on face. A thick creamy slurry of neat white or tinted cement mixed with water shall be brushed over the floor until all joints are thoroughly filled. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Acid-resistant tiles shall be grouted in a suitable acid-resistant grout to the Engineer's approval. The surface of the floor shall be very gently rubbed with a wood block to bring tile surface to true planes, excess slurry shall be removed, and the floor shall be rubbed with burlap to clean the tiles and finish the joints to the satisfaction of the Engineer. Walking on tiles shall not be allowed for five (5) days after laying. 9000.7.3 Glazed Wall Tiles – Fixing with Adhesive Wall tiling shall be carried out in compliance with BS 5385:Part 11976 for Internal Work and BS 5385: Part 2: 1976 for External Work and/or BS 8000: Section 11.1: 1989, as applicable and as directed by the Engineer. The background for tiling shall be suitably prepared free from oil, grease, loose or triable materials and shall provide an adequate key for bedding. The maximum deviation of background shall not exceed 3mm when measured under a two meter straight edge. Tiling work shall be carefully set out prior to starting to minimize the amount of tile cutting and to ensure alignment of vertical and horizontal joints. Tiles shall be dry when fixed, using adhesive, mixed and used strictly in accordance with manufacture’s written instructions and within the stated working time of the adhesive. The manufacturer’s recommendations for safe handling and ventilation of working area shall be carefully removed. Adhesive shall be applied as a floated coat to a thickness of 5 to 6mm. Tiles shall be firmly pressed into position within the stated working time of the adhesive. Tiles and fittings shall be set I adhesive to true vertical face with continuous horizontal and vertical joints. Joints shall be straight, level, perpendicular and of even width not exceeding 1.5mm. The vertical joints shall be maintained plumb for the entire true level and plane by uniformly applied pressure under a straight edge of a rubber faced block. Misfits as well as damaged or defective tiles shall be removed and replaced at the Contractor’s own expense Special tile fittings shall be located as shown on detail drawings and as directed by the Engineer. Bedding shall be allowed to set before grouting to avoid disturbance to tiles. Grout shall be applied in matching colour according to manufacturer’s written instructions and worked in until joints are thoroughly filled flush with the finished face of joint. Surplus grout shall be removed with a damp cloth and joints tooled to a smooth finish. Acid resistant tiles shall be grouted with a suitable avid resistant grout to the Engineer’s approval. Immediately after the grouting has set, tiled surface shall be given a protective coat of noncorrosive soap or other approved method of protection and joints shall be cured for 72 hours. Wall tiling operations shall be started until the floor tiling in the same area has been completed. 9000.7.4 Glazed Wall Tiles – Fixing with Cement: Sand Mortar



T05-20/11/2013



Wall tiling shall be carried out in compliance with BS 5385: Part 1:1976 for Internal Work and BS 5385:Part 2:1976 for External work and/or BS 8000:Section 11.1:1989, as applicable and as directed by the Engineer. Cement and sand mortar (1:4) ten (10)mm thick shall be laid as base for wall tiling. The surface of the mortar shall be scratched in an approved manner when nearly set, to form key and shall be cured for five (5) days before tiling starts. The surface shall be well wetted before the actual operation is commenced. Tiles and fittings shall be set in cement and sand mortar (1:4) mix, 6mm thick to a true vertical face with continuous horizontal and vertical joints. Joints shall be straight, level, perpendicular and of even width not exceeding 1.5mm. The vertical joints shall be maintained plumb for the entire true level and plane by uniformly applied pressure under a straight edge of a rubber-faced block. Misfits as well as damaged or defective tiles shall be removed and replaced by and at the Contractor’s expense. The external and internal angles and side edges of glazed wall tiling shall be formed with angle beads whereas top edges of tiles, shall be formed with rounded edge tiles. Joints shall match the general tiling and special fittings shall be used. Joints in glazed wall tiles and fittings, after the edges of tiles have been thoroughly wet, shall be grouted with a plastic mix of neat white or coloured cement immediately after a suitable area of tile has been laid. The joints shall be tooled slightly concave and the excess mortar shall be cut off and wipes off with a damp cloth from the face of the tile, before it sets hard. Interstices or depressions found in the mortar joints after the grout has been cleaned from the surface shall be roughened at once and filled to the spring line of the cushion edge before the mortar begins to harden. Immediately after the grout has had it initial set glazed wall tiles surfaces shall be given a protective coat of a non corrosive soap or other approved method of protection and joints cured for 72 hours. Wall tiles operation in spaces requiring floor tiles shall not be started until the floor tiles installation had been completed. 9000.7.5 Marble or Granite Slabs Marble or granite floor slabs shall be laid on a bed of cement: sand mortar 1:3 mix. The back of the slab shall be properly sealed to ensure good bonding between the slab and mortar. All slabs shall be tight butt jointed. Joints shall be thoroughly grouted with matching coloured cement and wiped clean before setting hard. All exposed faces and edges of marble or granite shall be polished smooth free from scratches or other defects. Marble or granite wall cladding shall be fixed in accordance with B 8298:1989 and/or BS 8000:Section 11-2:1990 as applicable and as directed by the Engineer. Cladding shall be fixed to solid background by mechanical means such as cramps, dowels and similar fixings in accordance with working drawings. The cladding shall be supported at its lower edge and securely tied back at the top. The thickness of the material behind the cramp should be 20mm. the fixing cramps shall be adequately inset in to the supporting background, preferably with undercut holes and secured in place with 1:3 cement/sand or epoxy/polyester resin mortar dabs. The back surface of the cladding shall be coated with an approved quality sealant. Cladding shall be butt jointed with maximum 3mm gaps. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The length and height dimensions of individual slabs shall be worked to within plus or minus 1mm from those specified. Thickness shall be within 3mm from that specified. For wall cladding, all block work, concrete or other backing must be formed so as to allow a minimum of 20mm clearance between the backing and the back of the cladding. Cramp holes and mortises shall be carefully drilled or cut to avoid stunning or fracture of the material adjacent to the hole or mortise. The Contractor shall be responsible for providing and fixing protection against weather or damage and staining by other trades. Particular care must be taken against staining from timber, oil, wet straw, washings from steel work or scaffolding or from any other injurious substances. On completion of adjacent building operations the completed marble work shall be cleaned down and any defects in the pointing and polishing shall be rectified. All marble works shall be carried out by an approved specialist Sub-Contractor with a proven track record of at least 7 years. Detailed shop drawings and design calculations shall be submitted to the Engineer for approval . The design criteria shall be similar to those specified for the curtain walling system as applicable. Shop drawings shall be dimensioned and developed from details shown on working drawings supplied by the Engineer and from site survey. Key numbers of each slab shall be shown, together with details of metal anchorages. No marble or granite shall be worked until these drawings are approved by the Engineer. The Contractor shall layout very 50m2 of the marble or granite as per the approved shop drawings/key numbers to be approved by the Engineer just prior to placing in position. Any rejections will be promptly replaced and applied after approval. Any approval accorded by the Engineer shall not relieve the Contractor of any of his contractual obligations and responsibilities. Suspended Ceilings 9000.7.6 Scope These specifications cover suspended ceilings and other proprietary finishing system to be incorporated in the works. 9000.7.7 General The Contractor shall perform all attendance upon other trades and protect all works specified under this section from damage during subsequent operations, make good any defects, clear away upon completion, clean throughout and leave all work imperfect condition to the approval of the Engineer. All materials and manufactured items shall be delivered in their original packages, containers, etc. bearing the name of the manufacturer and the brand. All items shall be carefully loaded, transported, unloaded and stored in an approved manner, protected from damage and exposure to weather or dampness during transit and after delivery to site. Damaged items shall be rejected. The contractor shall supply shop drawings to the Engineer prior to commencing the work for his approval and the Contractor shall modify or amend such drawings as directed by the Engineer. Such modifications, amendments and approval by the Engineer of shop drawings shall not relieve the Contractor of his responsibility for the design and sufficiency of those works. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



9000.7.8 Aluminium Tiles Suspended Ceiling Aluminium ceiling tiles shall be 600x600mm plain tiles manufactured from 0.7mm thick aluminium sheets and shall be factory finished with polyester powder coating by electro static spraying to not less than 60 microns as per BS 6496:1991 to a colour shown on the Drawings or as directed by the Engineer. The ceiling shall be fire rated to class 1, when tested in accordance with BS 476: Part 7: 1987 surface spread of flame and classified as Class 0 in accordance with BS 476: part 6 : 1989 fire protection. The tiles shall be fixed direct to a cold rolled galvanized sheet clip-in runner coupler, in a clip in runner, suspended by a proprietary suspension system comprising galvanized rigid tension spring hangers, runner and wall brackets, matching perimeter trims with hold down clips, etc. fixed and spaced strictly in accordance with the manufacturer’s instructions and/or as directed by the Engineer. The suspended ceiling system shall be from a manufacturer with a proven record of at least 5 years and to the approval of the Engineer. 9000.7.9 Decorative Gypsum Board Suspended Ceiling Gypsum board suspended ceiling system shall be installed as detailed on the drawings to the approval of the Engineer. Gypsum board suspended ceiling system shall be manufactured and installed as detailed on the drawings by an approved sub-contractor who has successfully engaged himself in similar works for at least 7 years. Plaster board ceiling shall comprise of 12.7 mm thick layer of approved proprietary plaster board screw fastened to approved support framing at 600mm centres both ways. Joints shall be sealed with vinyl based cement and perforated paper type and all caulkings shall be with vermiculite plaster (1 ½ parts exfoliated vermiculite to 1 part plaster). The suspension system shall be designed to suit the layout , spans and the design loads and al substantiating design calculations and details shall be submitted to the Engineer for his approval. Approval accorded by the Engineer shall nor relieve the Contractor of his obligations to provide a safe and aesthetic ceiling. Plaster boards shall be provided with mouldings at all edges, corners, etc. to achieve the desired effect as detailed on the drawings and to the approval of the Engineer. Fibrous gypsum suspended ceiling, moldings, cornices, etc. shall be formed using the approved design mix with all constituent materials being gauged, batched or weighed accurately. Moulds shall be dimensionally and geometrically accurate and release agents/waxes that will allow a clean release of the casting without adversely affecting the component surfaces shall be used. The moulding and castings shall include all necessary fixing holes, brackets, etc. Moulding and coating shall be individually inspected for any surface blemishes shall be rectified in an approved manner. The components shall be true in shape and free from cup and bow. The dimensional accuracy shall be ±2mm per m and the horizontal plane deviation shall not exceed 0.3% of the component length. The squareness of rectangular components shall be such that the difference between the diagonals shall not exceed 0.5% of the shorter diagonal. The formed components shall be asbestos free, antistatic and shall have a density not exceeding 1500kg/m3, be unaffected by ultraviolet light and not support fungous attack. Their thermal D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



conductivity (k) value shall not be greater than 0.375 W/m2/deg. C and shall have a thermal coefficient of expansion not exceeding 14.94 x 10-6mm deg. C. They shall not absorb moisture present in internal locations through excessive humidity. Components shall have an ultimate tensile strength or not less than 8.27 N/mm2. Component thickness shall be as recommended by the manufacturer or as directed by the Engineer. The contractor shall form necessary opening for various services including any access panels as required and finish them appropriately to the satisfaction of the Engineer. The Contractor shall prepare detailed shop drawings after verifying the dimensions at site, of the component and fixings and submit them for the approval of the Engineer prior to casting. The shop drawings shall also detail the various suspension materials and the methods of fixing the casting along with hi proposed method of erecting each compact. The Contractor hall prepare for the Engineers approval samples of the various mouldings cornices and decoration works. The Contractor shall protect all Gypsum works from damage until the completion of the Works. Should any damages be caused it shall be made good to the satisfaction of the Engineer at the Contractor’s expense. All inlaid materials, mirrors, air conditioning grilles and the like shall be cleaned and left in perfect condition. 9000.7.10 Calcium Silicate Suspended Ceiling Calcium silicate suspended ceiling shall consist of 600 x 600 x6 mm thick calcium silicate vinyl faced tiles laid in to a proprietary exposed grid metal suspension system with matching edge trims. Calcium silicate non-combustible boards shall be produced from a laminar board consisting of a calcium silicate matrix reinforced with vermiculite and natural organic fibers. It shall not contain any asbestos or other inorganic materials. The board shall be semi-compressed and cured in a high pressure autoclave to provide a high degree of dimensional and chemical stability. The calcium silicate tiles shall be vinyl faced factory finished and of pattern approved by the Engineer. The suspended ceiling including the suspension system shall be installed strictly accordance with the manufacturer’s written instructions and to the approval of the Engineer. END OF SECTION



T05-20/11/2013



SECTION 9900

PAINTING AND DECORATING



T05-20/11/2013



Section 9900 PAINTING AND DECORATING 9900.1 SCOPE OF WORK The specifications cover paint work and other decoration of concrete and rendered surfaces, wood, ferrous and non-ferrous surfaces in accordance with the Schedule of Finishes, Drawings, Bills of Quantities and as directed in writing by the Engineer. The term "Paint" as used herein includes emulsions, enamels, lacquers, sealers and other coatings, organic or inorganic, whether used as prime, intermediate or finish coats. All painting works shall be applied by skilled workmen experienced in this work. 9900.2 MATERIALS The materials to be used, shall be of the best quality and of approved types, obtained from an approved manufacturer(s). All paints shall comply with the following requirements: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii.

The product shall be thoroughly mixed and ground. The colour of the paint shall match the approved sample. Paint shall show no evidence of cracking, chipping, flaking or other defects. Paint in the containers during and after application shall not be abnormally pungent, offensive or disagreeable. Paint shall show easy brushing, good flowing and spreading and levelling properties. The properties shall be demonstrated on test specimens at the request of the Engineer. Coats that have any noticeable pull under a large brush and that show poor spreading and flowing properties will not be acceptable. Paint shall dry to a uniform, smooth, flat or semigloss finish under ordinary conditions of illumination and wearing. There shall be no laps, skips, highlights or brush marks. Tinted paints shall dry to a uniform colour. Recoating of previous painted surface shall produce no lightening softening or other irregularities.

9900.2.1 Knotting Knotting shall be composed of dissolving shellac or other resin which remains unaffected by the resinous materials in the wood or the following paint coating, thereby preventing the resinous materials in the timber leaching into the paint film and causing discolouration or defective drying and shall be in accordance with BS 1336, latest edition. 9900.2.2 Mordant Solution Mordant solution shall be composed of a solution usually slightly acidic in nature and containing solvents, for applying to new smooth metallic surface to remove grease organic soaps and provide a physical key, and shall be obtained from a approved supplier. 9900.2.3 Fillers D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Fillers shall be "Polyfilla", "Alabastine" or approved equal. 9900.2.4 Stopping Stopping shall be hard stopping compound of white lead paste, gold size (oleo resinous medium) and other fillers obtained from an approved supplier. 9900.2.5 Putty Filler Putty filler shall be composed of white lead and dry filler mixed with pure linseed oil, the content of the white lead shall be not less than ten percent (10%) of the mixture by volume and shall be obtained from an approved supplier. 9900.2.6 Thinners Thinners shall be an approved turpentine or white spirit. Where the paints are specified to be water thinned, fresh water shall be used. 9900.2.7 Pigments Pigments shall be pure colours that will easily dissolve and mix with the various coating and shall conform to the requirements of BS 1014 - 1961 "Pigments for cement, magnesium oxychloride and concrete". 9900.2.8 Rust Inhibitor Rust inhibitor shall be Galvafroid primer, manufactured by Secomtastic Ltd., Bracknell, Berks, England, or Crown Chlorinated Rubber Zinc Rich Primer manufactured by the Walpamur Co. Ltd., Darwen Lancs., or approved equivalent. 9900.2.9 Primers Primers applied to surfaces of different materials shall be as follows: a) b)

Interior or exterior General ferrous

Alkali-resistant primer rendered surfaces Lead based, zinc chromate or surfaces calcium plumbate as recommended by the manufacturer of the finishing paint.

c)

General non-ferrous

Mordant solution of an surfaces approved brand and rust inhibiting primer.

d)

Structural steel work

One component, epoxy resin based anticorrosive zinc rich primer (Dry film thickness 35 microns) followed by a high-build primer based on chlorinated rubber pigmented with micaceous iron-ore and inert pigments (Dry film thickness 75-100 mic e) Woodwork surfaces Low lead primer in (to receive paint)accordance with BS5080 or BS 5358. 9900.2.10 Undercoating Paints



T05-20/11/2013



Undercoating paints shall generally be as recommended by the manufacturer of the finishing coat. Structural steel work undercoating paint shall be a high-build coating based on chlorinated rubber and pigmented with inert pigments (Dry film thickness 75-100 microns). 9900.2.11 Finishing Paints Finishing paints shall be as follows: a)

a) Interior rendered and concrete surfaces as shown on the Schedule of Finishes and on the Drawings

Approved emulsion paint for interior use of the colour indicated on the Drawings or directed by the Engineer.

b) General interior and exterior ferrous and non-ferrous metal surfaces, ditto.

Chlorinated rubber paint, interior or exterior grade, of an approved manufacture.

c) Structural Steel work

Semi-gloss finishing coat based on chlorinated rubber and pigmented with inert pigments.

d)Interior woodwork surfaces other than hardwood.

Oil paint, semi-gloss finish, of an approved manufacture.

e)Hardwood surface

Ditto

. 9900.2.12 Rough - Textured Paint The rough textured paint shall be based on an acrylic binder containing small mineral particles. The paint shall be waterbased and the colour and manufacturer shall be to the approval of the Engineer. The primer to be used shall be as recommended by the paint's manufacturer. 9900.2.13 Light - Textured Paint The light textured paint shall be a high quality decorative emulsion paint based on a copolymer resin reinforced with coarse rock-hard aggregate (of dolomite) to give a tough but flexible film. The paint shall be of a colour and shall be from a manufacturer approved by the Engineer. The primer/sealer to be used shall be as recommended by the paint's manufacturer. 9900.2.14 Varnish Varnish quality shall be Alkyd based, flat, durable, clear and transparent, spray applied on very dry and clean surface, and shall be from an approved manufacturer as Jotun, National paint or other approved equivalent. 9900.2.15 Fire Protection Interior exposed structural steel shall be coated with a thin film intumescent coating 2 hour fire protection such as steelmaster 120 by OMNIFIRE and supplied by Jotun or approved equal.



T05-20/11/2013



Surface preparation, DFT and paint application shall be strictly adhered to as recommended by the paint manufacturer. 9900.3 WORKMANSHIP 9900.3.1 General The Contractor shall submit to the Engineer for approval the brand and quality of the paints he proposes to use. If approval is given to a brand of paint the Contractor shall use the primers, undercoats, etc. manufactured or recommended by the manufacturer of that brand. All paints to be used under this contract shall be delivered and stored on the site in sealed, labeled containers, a minimum of 30 days prior to application. Upon notification by the Contractor that the material is at site, samples of each materials shall be obtained at random from sealed containers by the Engineer in the presence of an authorized representative of the Contractor. Samples shall be clearly identified by commercial name, type of paint and intended use. If judged necessary by the Engineer the paint samples may be tested in a laboratory designated by the Engineer at the Contractor's expense. Complete colour charts for the paints to be used shall be submitted to the Engineer for approval. Pigmented paints shall be furnished in containers not larger than 25 kgs. products that have a minimum of 2 years satisfactory field service.

All paints shall be

Mixing and application of paint shall be in accordance with the specifications of the manufacturers concerned and to the approval of the Engineer. The mixing of paints, etc. of different brands before or during application will not be permitted. No dilution of painting materials shall be allowed except strictly as detailed by the manufacturers and as approved by the Engineer. Hardware, hardware accessories, machine surfaces, plates, lighting fixtures and similar items in place prior to cleaning and painting, which are not intended to be painted, shall be removed or protected prior to painting operations and repositioned upon completion of painting work as directed by the Engineer. Equipment adjacent to or against walls shall be disconnected by workmen skilled in these trades and moved to permit the wall surfaces to be painted, and following completion of painting shall be replaced and reconnected. Cleaning solvents shall be of low toxicity. Cleaning and painting shall be so programmed that dust and other contaminants from the cleaning process will not fall on wet or newly painted surfaces. Brushes, pails, kettles, etc. used in carrying out the work shall be clean and free from foreign matter. They shall be thoroughly cleaned before being used for different types or classes of materials. No exterior or exposed painting shall be carried out under adverse weather conditions such as rain, extreme humidity, dust storms, etc.



T05-20/11/2013



Painting work shall be shaded from direct sunlight to avoid blistering and wrinkling. Wherever possible, painting of exterior surfaces shall "follow" the sun such that it is carried out in shadow. Edges, corners, crevices, welds and rivets shall receive special attention to ensure that they receive an adequate thickness of paint. All cracks and holes shall be cut out properly square and made good with suitable filler or cement/sand mix as appropriate, such repaired portions being allowed to dry out and sandpapered smooth. 9900.3.2 Rendered Surfaces Rendered surfaces shall be allowed to dry out completely before carrying out painting operations. Render shall be at least five weeks old before commencing painting operations. Preparation of surfaces shall consist of vigorous brushing and rubbing down to remove loose surface material and dust. Surfaces shall then be left for a week to determine whether efflorescence reappears in which case it shall be brushed off dry and a further waiting period on one week allowed. Alternatively, the surfaces may be neutralized by brushing on a solution of 3 percent phosphoric acid and 2 percent zinc chloride and removing all loose particles after drying. No painting shall be carried out until the Engineer is satisfied that no efflorescence is occurring. Where required by the Engineer one or two coats of Alkali-resistant primer shall be applied, sufficiently thinned to penetrate the surface. All rendered and concrete surfaces shall be twice stopped with approved putty filler. The first coat of stopping shall be applied after the primer coat is dried out completely and the second coat after the first undercoat application. Each coat of stopping shall be allowed to dry and harden thoroughly and shall then be rubbed with sandpaper until a smooth surface is achieved. A minimum of two approved undercoats recommended by the manufacturers of finishing coat shall be applied by brushing well into the surface. Each coat shall be allowed to dry and harden thoroughly before the next coat is applied. The finishing coat of paint shall be applied after the completion and testing of the mechanical and electrical works. 9900.3.3 General Ferrous Surfaces Surfaces shall be thoroughly cleaned to remove grease and dirt, wire brushed and scraped to remove scale and rust. One coat of approved putty shall be applied on the surfaces and left to dry for at least twenty four hours. Surfaces shall then be rubbed by sandpaper or other approved means before primer is applied. One coat of rust inhibiting primer shall be applied by brushing well into the surface and shall be allowed to dry and harden thoroughly before the application of subsequent coats. If ferrous works are delivered primed, the surfaces shall be examined to ascertain that the primer coat is hard. If not satisfactory the prime coat shall be removed and the surfaces cleaned to remove grease and dirt and re-primed as described above. Abraded spots on shopcoated surfaces shall be wire-brushed and touched up with same materials as the shopcoat.



T05-20/11/2013



The under-coat and finishing coat shall be chlorinated rubber paint, interior or exterior grades and used all in accordance with the directions of the approved manufacturer. Chlorinated rubber paint, interior or exterior grades, shall not be applied in damp or foggy weather or to any surface which is not perfectly dry. Brush application is recommended although this material may be sprayed if desired. Only special thinners produced by the approved manufacturer may be added to achieve the spraying consistency required. Special approved thinners shall be used for cleaning brushes after use. Ferrous works such as frames, covers to expansion joints, etc. which are to be built into walls shall be primed before installation. 9900.3.4 General Non-Ferrous Metal Surfaces Galvanized steel and other non-ferrous metal surfaces to be painted shall be solvent cleaned or painted with mordant solution before the application of paints as described above for ferrous surfaces. 9900.3.5 Structural Steelwork Surfaces Prior to the application of the paint system all structural steelwork shall be blast-cleaned. a) The blast cleaning and protective painting of structural steelwork shall be carried out in accordance with the recommendations of British Standard Code of Practice 5493. The surface finish of blast-cleaned steel work for painting shall be in accordance with British Standard 4232:1967 (or to an absolute minimum of S.A. 2.5 as defined in Swedish Standard SIS 05 59 00) b) The steel to be blast cleaned shall be dry and the operating conditions shall be such that condensation does not occur during the work. When compressed air is used, it shall be dry and free from oil. Any oil or grease shall be removed from the steel surface before blast cleaning is begun. If the steel is heavily rusted, particularly if scaly rust is present, a preliminary cleaning shall be carried out with power-driven impact tools. After shot blasting all spent, shot or grit must be removed. If an instantaneous-recovery blasting machine is not employed, the cleaned surface shall be air-blasted, vaccum-cleaned or otherwise freed from abrasive residues and dust immediately after the blast cleaning. In the event of any shot or grit being found under or embodied in the paint film, the affected areas shall be reblasted and the complete painting system reapplied. Following the removal of abrasive material, the surface shall be rubbed over briefly with a nylon scraper or scourer to reduce the number of `Rogue Peaks'. The application of at least the first coat of paint shall follow with the least possible delay and in any case within 2 hours of blasting and before visible deterioration has occurred as compared with a freshly blast-cleaned area. c)

After blast cleaning the entire surface shall show blast cleaning pattern and shall be completely free from contamination by oil, grease, dirt or other matter, except that tightly bonded residues of mill scale or rust shall be permissible up to the following limits. For the whole surface an average of not more than 5%, i.e. at least 95% of the surface shall be



T05-20/11/2013



clean bare steel. For any single square of 25 mm side, not more than 10%, i.e. at least 90% of the square shall be clean bare steel. Areas that appear shadowed solely because of differences in the blast cleaning pattern or the structure of steel shall be classed as clean steel. d) Surface roughness shall be as follows: After using metallic abrasives : Maximum permissible amplitude* shall be 0.10 mm. After using non-metallic abrasives : Maximum permissible amplitude shall be 0.18 mm. Method of Measurement: In case of disagreement regarding an acceptable surface finish, one of the four methods described in BS 4232:1967 shall be employed. * Maximum Amplitude : Greatest vertical distance between the summit of any peak on the blast-cleaned surface and the bottom of an immediately adjacent through, but without taking into account any exceptionally high `Rogue Peaks', i.e. Embedded particles of abrasive. Wood surfaces where specified to be painted shall be primed, undercoated twice and finally coated with semi-gloss paint of approved manufacturer. Wood surfaces shall be rubbed with abrasive paper to obtain a smooth surface. Surface mould where present shall be removed by washing, rubbing down or burning off as necessary. Resinous exudation and large knots shall be removed and replaced by approved filler or knot sealer and the surface shall be primed. Blacks of frames and wood to be built-in shall be primed unless already impregnated with preservative. Priming shall be brushed on and a minimum of two coats applied to end grain. After the primer coat is hard, all cracks, holes, open joints, etc. shall be made good with hard stopping and rubbed with fine abrasive paper. In the first process of stopping is found to be unsatisfactory it shall be repeated after the first undercoating is applied and well dried. Priming of joinery shall be applied only on the site after the Engineer has approved such joinery and before it is fixed. The two undercoat paints shall be applied on wood doors, panels, etc. before they are fixed, to ensure that the bottom and top edge and sides are thoroughly painted. The finishing coat of paint to such wood doors, panels, etc. shall be applied after fixing in position and as directed by the Engineer. Wood surfaces specified as stained shall be rubbed down with fine abrasive paper and two coats of oil stain applied to the satisfaction of the Engineer. Wood surfaces specified as varnished shall be thoroughly cleaned down of all dirt, oil, grease, etc. and rubbed to a smooth finish. Knots shall be treated with knotting and two coats of approved oil varnish applied. End of Section



T05-20/11/2013



SECTION 15400

PLUMBING INSTALLATIONS



T05-20/11/2013



Section 15400 PLUMBING 15400.1 Scope Of Work The Contractor shall furnish all labour, materials, equipment, tools, appurtenances, services and temporary work to provide complete plumbing works all in perfect working order. This work shall include but not to limited to the following: • • • • • •

Sanitary fixture. Water supply system. Soil, waste and venting system. Rain water services. Pumps, calorifiers, etc. Testing: of all piping systems and equipment and other devices to demonstrate that the entire installations are in perfect working order. • As-built drawings. • Builders work: s required. All materials shall be brand new bearing stamped ratings as required and must be approved by the Engineer prior to their use. The foregoing sub paragraphs are not intended to itemize all works required by this section of the specification and are only for the purpose of outlining the extent of work. 15400.2 Description Of Work Individual water heater shall be used to generate hot water to kitchen and toilets as indicated on drawings. All floors are supplied through pressurizing unit to maintain 3 bar at all points. Soil and waste water from all fixtures discharge to the outside and carried in a set of concrete manholes to the public areas to connect with D.M. drainage system. Storm water from all roofs is discharged outside through a network of roof drain and riser pipes. 15400.3 Testing The Contractor shall submit to the Engineer prior to the date of commencement of the tests his proposed test procedure. The procedure method and points of measurement as well as the method of calculation, shall be approved by the Engineer before any test is carried out. The Contractor shall supply skilled staff and all necessary instruments and carry out any test of any kind on a piece of equipment, apparatus, part of a system or on a complete system if the Engineer requests such a test for determining specified or guaranteed date as given in the specifications. Any damage resulting from the test shall be repaired and/or damaged material replaced, all to the satisfaction of the Engineer. In the event of any repair or any adjustment having to be made, other than normal running adjustment, the test shall be void and shall be recommenced after the adjustment or repairs have been completed. The test shall not be made void due to circumstances beyond the Contractor’s control. 15400.3.1 Water Supply System



T05-20/11/2013



All testing, balancing and final adjustment shall be in accordance with the provision of the applicable B.S. code of practice. All water installations shall be flushed out with clean water. This shall be preceded by chemical cleaning, while flushing out all times which could be damaged (like fillers...) shall be excluded. Disinfection of portable water system shall be as follows: Thoroughly flush the pipework and storage system to remove all debris and dirt. Once the water runs clear close all taps. Refill the tank with water and add suffiecient quantity of approved manufacturers hypochloride solution to achieve 50ppm of residual chlorine in the following water. The water should be tested from the most distant point before closing the taps. Once the desired 50ppm of chlorine is achieved close all taps and allow system to remain sterilized for 24 hours. From the preiously chosen sample points test the water to ensure that minimum of 10ppm of chlorine is present. Once 10ppm is available flush the piping until chlorine is removed. Check for the absence of bacteria from a minimum two points using total bacterial dip slides. All water supply piping shall be tested under hydrostatic pressure of not less than 1 ½ times working pressure or 100psi whichever is greater and shall be maintained for twelve hours. This test shall be applied to separate lengths of pipework before final connection of equipment and appliances but after all piping is complete systems shall also be flushed. Test shall be completed and approved before pipe valves and fittings have been concealed. 15400.3.2 Drainage, Soil Waste and Venting Systems These systems shall be subject to a water test prior to being covered and also tested for water tightness after backfilling. On any section of the pipe under test the head of water applied shall not be less than 3.00 meters and not greater than 6.00 meters. Test shall be maintained for eight hours, and any defects shall be rectified and the test reapplied to the complete satisfaction of the Engineer. Pipes shall UPVC to BS 4514/5255, brown for underground and gray for above ground. All condensable piping shall be installed with foam rubber tape insulation throughout. Manhole covers shall be to BS 497. Duty as per drawings. All soil and waste stacks to be extended to roof level for ventilation purpose. 15400.3.3 Pumps & Control The pumps shall be tested for actual gpm against design gpm, actual shut off head against design shut off head, operating suction and discharge pressure, r.p.m. and b.h.p. All control shall be tested for proper functioning in accordance with the requirements of the specifications. 15400.3.4 Final Testing D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



In addition to the above, final tests shall be carried out as directed by the Engineer just before final completion of the works and during the maintenance period. 15400.4 SHOP DRAWINGS Immediately after the Contract has been awarded the Contractor shall prepare workshop drawings showing exact position of all sanitary fixtures and position and size of all pipe work and drainage soil, waste and vent piping, clearly indicating fittings proposed. Drawing scale shall be minimum 1/50. These drawings, when approved by the Engineer, shall used for ordering purposes. 15400.5 SANITARY FIXTURES The Contractor shall, unless otherwise stated in the bill of quantities, install and commission all sanitary fixtures, appliances, fittings and accessories such as mixers, bottle traps, shelves, mirrors, towel and soap holders anal spray etc. including silicon applications and install in position as shown on the drawings. Any of the above items not included in B.O.Q. shall be covered under this contract without any additional cost. Fixtures shall be set in a neat, finished and uniform manner making the connection to all fixtures at right angles to the wall, unless otherwise directed by the Engineer. Roughing for this work must be accurately laid out so as to conform with finished wall materials. Fixtures are not to be set until so directed by the Engineer. Fixture and accessories shall be of the colour approved by the Engineer. Ample application of petroleum jelly shall be applied to all surfaces of exposed chromium plated piping, valves and fittings and stainless steel fixtures immediately after installation. Concealed brackets, hangers and plates shall have a shop coat of paint. All exposed chrome plated piping and trim shall be fully protected during installation. Strap or padded wrenches shall be used on chrome pipe fittings and valves. All exposed metal parts in toilet rooms and bathrooms shall be chromium plated. All valves in toilets and kitchens shall be chrome plated recessed type. 15400.6 PIPES, VALVES & FITTINGS Supply and install all pipework as shown on the drawings. Pipework shall be installed in a manner to allow for ease or air escape and system drainage. It shall be endeavoured to obtain this naturally by gravity. However, where conditions do not permit it, an automatic air vent shall be installed at all air pocket locations and 1/2” drain grate valve shall be supplied and installed at all low points and riser legs. Drainage pipes of dia. 4” or less shall be installed with a slope of not less than 2%. Drainage pipes of dia. larger than 4” shall have a slope of 1%. Before installing any pipe, it shall be internally cleaned from dirt, sand, debris, etc. Pipes shall be installed in a neat way with runs parallel and branching and change in directions at 90 degrees or at 45 degrees. Elbows shall be used for changes in directions, pipe handing shall be resorted to in extreme cases and only after the Engineer’s written approval. Sleeves shall be supplied and installed wherever pipes cross slabs, walls, partitions, etc. Sleeves shall be cuts of pipes having an internal diameter of not less than 1cm larger than bare sleeved pipe or the insulated sleeved pipe depending on the particular situation. Floor sleeves shall protrude



T05-20/11/2013



about 2cm above the finished floor level. All gaps shall be plugged with a non-flowing, plastic and water proof paste. 15400.7 INTERNAL COLD & HOT WATER PIPES For hot and cold water distribution inside the apartments, system is to be composed of: Crossed linked polyethylene pipe pulled in a black corrugated conduit or ordinary polyethylene. Distributors, fittings and valves of bronze construction. 15400.7.1 PIPES The inner pipe is a cross linked polythylene pipe withstanding upto 95oC. All pipes to be stamped on equal intervals showing clearly the name of the manufacturer along with the pressure and temperature rating of these pipes. All pipes should be laid so that the 16mm pex water pipe can be replaced, if necessary. Pipes should satisfy the requirement for drinking water installation and approved by a recognized health organization for this particular usage. 15400.7.2 FITTINGS & ACCESSORIES The single line plastic XLPE pipe in pipe will supply the water to the different accessories as shown on the drawing from a main draw off point (a distribution valve or a distribution header fitted with isolating valve. Pipe to be connected to the different fittings via a wall box of reinforced plastic fitted with bronze elbow suitable for ½” or ¾” threaded connection. The box should be suitably designed in order to enable the replacement of existing pipes in the event of their damage (puncturing). All distributors, valves, box elbows, tees, bends should be of red brass (bronze). Connections to be of a cone grip unions type allowing : full flow capacity, minimum pressure loss, easily detachable with torque wrench, cutters, etc. Distribution valve of distribution header will be located inside an access box of galvanized steel suitably located in each toilet or inside the false ceiling as indicated on the drawings. Access covers to be submitted for Consultant’s approval. Approved Manufacturer : System to be as per supplier recommendation or equally approved. All pipes shall be installed complete with: -

Metallic supports

-

Union, flanges, couplings, elbows, tees, crosses, reducers, caps, etc.

-

Automatic air vents

-

Drain valves

-

All cutting, patching and making good of walls slabs, partitions, etc., due to fixing, supporting and anchoring of pipes. All connections and fixings to equipment and accessories.

EXTERNAL COLD WATER PIPES External cold water pipes shall be hard temper copper tubing conforming to B.S. 864 part 2.



T05-20/11/2013



Copper fittings shall be streamlined wrought copper solder type of pattern to suit requirements. Flanges shall be cast bronze with raised ground face and bolt holes spot faced. Flanges shall be for Mpa water working pressure. Gaskets shall be of a material suitable for the fluid, temperature, and pressure for which they will be used. Approved Manufacturers : Fittings :Conex or equivalent heavy duty compression fittings. Provided all supply lines to bidets with check valves. Provide cold water supply to water heaters with check valves. Provide angle valves for incoming water supply to all fittings. Where hot and cold water supply pipes connect to a combination supply fittings with a shut-off valve on its discharge, or the combination supply fitting is equipped with manual or thermostatic mixing valve, equip each hot and cold water supply pipe with a composition disc, swing check valve ahead of the supply fitting. Provided at all water points, such as lavatory basins, WC, hose taps etc., stop cocks which shall be adjusted so that the taps, ball valves, etc. operate quietly and efficiently before final acceptance by the Owner. 15400.8 INSULATION FOR COLD & HOT WATER SERVICE PIPES Insulation to hot water service pipes recessed in walls shall be in the form of factory applied PVC sheath, to be suitable as thermal insulation. For hot water pipes above false ceiling and all hot and cold water pipes exposed to sun, insulation shall be 3/4” thick, sectional, cellular neoprene, covered with 6 OZ canvas cloth and 2 coats of waterproof sealant. Hot water pipes run underground shall be insulated with 50mm polyisocyanurate of 60Kg/cu.m densitly, aluminum foil backed, vapour sealed and finished with a minimum of 3mm fiber glass matting and resin (3 layers) giving a continuous protective layer to the insulation. The fiber glass coating shall consist of laminations of minimum 1200 gm/sq.m. of ‘E’ glass GSM plus ‘C’ glass tissue to the outer surface all impregnated with isophthalic resin to give a resin to glass ratio of between 2.5/1 and 3/1. After curing all surfaces shall be given a flow coat of isophthalic resin incorporating 2% paraffin wax to ensure a tackfree cure. For underground pipes, fibre glass matting is to be applied or as recommended by the manufacturer for protection of pipe directly buried in soil. 15400.9 MAIN COLD WATER SUPPLY PIPE The Contractor shall furnish and install the main water supply pipe from the water meter box close to the boundary line as shown on the drawings. The main, shall be buried with a minimum cover of 1000mm. All underground piping shall be UPVC Class E type to BS-3505. 15400.10

VALVES

15400.10.1 General D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Supply and install all valves as shown on the drawings and as required. All valves shall be designed for a working pressure of 150 p.s.i. except for fire fighting application, it shall be 175 p.s.i. gate, globe and check valves shall be of the same diameter as the pipe served. A union shall be used with all threaded gate, globe check and float valves. 15400.10.2 Gate Valves Gate valves, 2 1/2” and smaller, shall be all bronze, screwed ends, union bonnet, wedge disc type to B.S. 5154/B. Gate valves 3” and larger, shall be cast iron, outside screw and yoke, flanged ends bronze wedge disc faces and seats. 15400.10.2 Gate Valves (cont.) One gate valve shall be supplied and installed: 1. At the supply and return from each equipment except pumps. 2. At the suction and discharges of each pump. 3. At the bottom of each riser and all low points to be drained. 4. In general at all points shown on the drawings and/or specified. 15400.10.3 Check Valves Check valves shall be used in the discharge line of each pump. Check valves 2 1/2” and smaller shall be all bronze, screwed ends, screwed cap with check, renewable composite disc and seat to B.S. 5154/B. Check valves 3” and larger, shall be cast-iron, flanged ends, bolted cap with lift check renewable composite disc and seat. 15400.10.4 Float Valves Float valves shall be all bronze, screwed ends, float operated. Float shall be all copper and mounted at the end of a brass or copper rod, which actuates valve operation. Float valves shall be to B.S. 1212. 15400.10.5 Strainers Strainers shall be suitable for a working pressure of 200 psi non-shock provided suction pipe of each and all pumps. Strainers 2 1/2” and smaller shall be Y-pattern type with bronze body, screwed cover, brass basket, and screwed ends. Strainers 3” and larger shall be of cast iron body, brass basket and flanged ends. Strainer basket shall have 0.8mm perforations for water service. One strainer shall be installed at the suction of each pump. 15400.10.6 Automatic Vents D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Supply and install all automatic air vents as shown on the drawings and as required. Automatic air vents of the ball float type shall be installed at all high points in the piping. A 1/2” lock shield valve shall be directly installed ahead of each automatic air vent, and a 1/2” drain line shall be provided to discharge at a convenient point. 15400.10.7 Vent Caps Vent caps shall be UPVC with open slots all around cowl and shall be commented into the waste or vent stack pipe at least 150cm above roof level. 15400.10.8 Flexible Pipe Connectors Flexible pipe connectors shall have a stainless steel or copper bellows with a woven flexible bronze wire reinforcing protective jacket length with threads male or flanged ends as required for proper installations. Sweat and connections are not acceptable. Connectors shall be rated for 1 Mpa water working pressure, 120 deg. c. operating temperature and suitable for upto maximum 20mm misalignment. 15400.10.9 Pipe Expansion Joints Supply and install at all civil expansion joints pipe expansion joints of the bellow type. All joints shall have flanged ends and stainless steel elbow suitable for a working pressure of 150 p.s.i. 15400.10.10 Union & Flanges Union and flanges shall be installed at all equipment inlets and outlets, at all valves inlets and outlets, on all pipe branches and in general every 10 meters of pipe run. Unions shall be used on all screwed pipes and shall be of the same quality and service. Flanges, suitable for welding, shall be used on all welded pipes, and shall be all steel construction. Threaded flanges shall be used on all threaded pipes when flanged valves and equipment are connected to the pipes, flanges shall be of the same quality and service as the pipe served, and shall conform to ASTM or B.S. standards. 15400.10.11 Hangers & Supports The pipe hangers shall be of the individual or trapeze type as conditions require, and shall be constructed of structural steel and steel hanger rods with adjusting nuts. Horizontal PVC and copper pipes shall be supported, at not more than 90cm and all horizontal pipes shall be supported at all changes in direction to be sure a maximum deflection of 3mm. Vertical pipes shall be provided with heavy iron clamps, one at every floor level and shall be supported at not more than 1.5m apart. Piping shall not be hung from other piping, and no wire, tape or metal bands shall be used as substitute for hangers. Hangers and supports shall be secured to the structure by providing inserts in the concrete, or by means of fish plates in case of heavy loads and as detailed in the drawings. 15400.10.12 Temperature & Pressure Relief Valves Valves shall be used on domestic hot water lines wherever applicable and shall be self closing type with test lever and screwed connections.



T05-20/11/2013



Each valve shall be suitable for a pressure of 75 to 150 psi service and shall be supplied with temperature relief set at 200 deg. F. Each valve shall be AGA (American Gas Association) rated. 15400.11

PIPE INSULATION

Insulation for exposed cold water piping running on roof and all hot water piping shall be unbounded fine fibred glass wool of high resilience. 3/4” thick, 3/4 pcf density, 0.25 thermal conductivity at 100 deg. F. insulation shall be canvas finished, painted and secured with bands. Insulation shall be applied after hydrostatic tests have been completed. Before applying the insulation, surface shall be thoroughly clean and dry. All dirt, scale, rust, oil grease or water shall be adequately removed. Surfaces not galvanized shall receive two coats of lead primer. Valves, strainers, fittings and flanges shall be insulated with insulating cement applied over galvanized wire mesh reinforcement, fixed on to the fitting. Insulation shall not be applied on valves above the honnets, on strainer basket plugs, nor on nameplates. Pipes shall be individually insulated. Insulated pipes running on roof shall be covered with aluminium sheet metal jacket, on top of insulation, of 22 gauge. 15400.12

ABLUTION SPRAY

Shall be 3/4” diameter polished chrome plasted compression type with standard male hose connection (heavy duty type). Trigger operated.

15400.13 ELECTRIC WATER HEATERS Each electric water heater shall be of the cylindrical storage type constructed of heavy gauge steel with white enamel finish externally and glass lining from inside. Heater shall have polyurethane foam insulation wall between the outer casing and the glass lining all around top and bottom of cylinder. Heater shall be suitable for a working pressure of 100 psi and shall be certified by UL. Each electric water heater shall be complete with the following : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Fast acting surface mounted thermostat for automatic temperature control. Factory installed sensitive high limit energy cut-off (for safety to prevent overheating) preset at 210oF. Electric element of capacity as indicated on the Drawings shall be constructed of highest quality resistance wire sheathed in mineral filling and the whole encased in a copper tube and subjected to a high voltage test. A non-return valve at the cold water inlet to the heater. Pressure relief valve installed between heater and non return valve. Removable access panel to the heating element and thermostat. Factory installed nipples. Chrome plated gate valves at inlet and outlet of heater. Wall fixing brackets and support / Free standing support. A minimum of 5 year warranty.



T05-20/11/2013



15400.14 PUMPS 15400.14.1 Pressurizing Unit For Water Supply Supply and install wherever shown on the drawings a pressurizing set comprising a pressure vessel, two main pumps (one is standby) and one jockey pump, interconnecting pipes and valves and all necessary control to perform proper operation, all as shown on the drawings. The unit shall be designed for intermittent operation and shall be mounted on a base and shall be fully tested at the factory dispatch. 15400.14.2 Pressure Vessel The pressure vessel shall be constructed of welded steel with rubber diaphragm, epoxy lined section tested at 1030 kpa to BS 487. The vessel shall be pre-charged with air at the factory and should require no further charging on site. 15400.14.3 Pumps Pumps shall be end suction close coupled centrifugal pumps with stainless steel casing and stainless steel impeller (316 L) of the self priming type. The base and the pump head cover shall be made from stainless steel. Pump flanges shall be stainless steel with stainless steel sleeve of ample size to carry any axial and radial thrust complete with electric motor of the totally enclosed from cooled type with class F insulation and rated to IP 54’. 15400.14.4 Control Panel Pressurizing unit shall be supplied with a sheet steel dust proof and jet roof to minimum IP55 type control panel, complete with: • Starter with over load protection. • Hand/Auto control switch. • Cyclic change over switch, to automatically alternate, duty and standby pump to equalize time of pumps. • Alarm circuit with muting button, to provide audible warning of low suction water level. • Low level cut-out installed in the lower water reservoir. • Pressure switches, to control starting and stopping of pumps. The control panel shall be complete with circuit breakers, indicating lights for “Mains On”, “Pump Running” and “Motor Tripped”, and mains isolator fully interlocked with the front cover. An electric alternator shall alternator the duty and standby pump on every cycle. In case of failure of duty pump to start, the standby shall be automatically started. 15400.15 END SUCTION WATER SUPPLY Each pump set, for water supply application, shall be complete with the following: • Electric control panel complete with circuit breakers, starters, automatic electric alternators, indicating lights and selector switches. Panel shall be made of sheet steel of dust and jet proof to minimum IP 55 type with lockable door. Panel and door shall be rust proof. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



• Float switches, installed in both domestic water reservoirs, and control cables between the float switches and the electric control panel. 15400.16 CONTROL OF PUMPS • One pump shall act as a standby (as indicated in the pump schedule). • A low water level float switch installed in the lower water tank shall prevent either of the pumps to run dry if the lower tank is empty. • A float switch installed in the roof water tank with two predetermine levels. The high level when reached shall stop the pump automatically and the low level when reached shall start the pump automatically. • An electric alternator shall alternate the duty and standby pumps on every cycle. In case of failure of the duty pump to start, the standby shall be automatically started. 15400.17

GRP SECTIONAL TANK

The Contractor shall supply and install insulated GRP sectional water tanks as shown in the drawings. The panels shall be made of hot pressed GRP with uniform and stable contraction making them free from corrosion, bacteria growth, accumulation of algae. The panels shall be highly durable, meeting all requirements maintaining clean water. The net value of the water in the tank is specified and the size shall be approved by the Engineer. The panels shall be insulated to the standards. Accessories like air vent, GRP corner angle, rubber sealant, stainless steel nuts and bolts, tie rods, struts roof support, struts etc. shall be from the same manufacturer and shall be approved by the Engineer. External ladder shall be of aluminium and internal ladder shall be of UPVC. Water tank foundation shall be as per the recommendation of the manufacturer and as approved by Engineer. 15400.18 UNDERGROUND TANK The Contractor shall supply and install the fibre glass moulded cylindrical water tank as shown on the drawings. The size of the tank shall be as per the drawing. Accessories like air vent, sealant, drain, over flow, ladder to be provided with access for ball valves and other provisions. The tank shall be highly durable with thermex insulation and all requirements to maintain clean water free from corrosions bacteria growth. Water tank make shall be to the approval of the engineer. END OF SECTION



T05-20/11/2013



SPECIFICATION 15500

FIRE FIGHTING SYSTEM



T05-20/11/2013



Section 15500.1 GENERAL DESCRIPTION Supply and install, wherever shown on the Drawings, a complete fire fighting system of the hose reel, dry riser and sprinkler types. The system shall be supplied and installed complete with: • • • • • • • • •

Landing Valves Siamese connection Hose Cabinets Fire Pumps Sprinklers Flow switch and Necessary Piping Network Necessary Fire Alarm Bells Portable Fire Extinguishers Fire blankets

All as specified hereinafter 15500.2 GENERAL REQUIREMENTS • • • • • •

Piping shall be pitched to permit complete draining of the system. Fire standpipe shall not be used in any way to provide water for other purposes. All valves shall be readily accessible and risers shall be securely supported at each floor. All valves shall be located where readily accessible. No item shall be installed in breach of any of the existing local fire Department regulations. In all cases, however, installation shall comply with LPC and BS 5306:Part2: Latest Edition. All local alarms shall be linked with the electrical fire control panel whenever shown on drawings and or specified in such a way that whenever any local alarm is initiated, a corresponding pilot light and alarm shall be actuated on the main fire control panel to indicate occurrence of fire in the particular zone.

15500.3 TESTS • •

Fire line piping shall be tested at 50 psi in excess of the maximum working pressure or at 200-psi (1380 Kpa) hydrostatic pressure whichever is greater. Prescribed test shall be maintained for two hours without any perceptible drop in pressure Test shall be performed in the presence of, and to the satisfaction of the Engineer.

15500.4 DRY RISER Dry riser system shall comprise a dry standpipe, fire brigade Siamese connection, and landing valves. 15500.4.1 Siamese Connection Siamese connection shall be installed where shown on Drawings at a convenient height from finished side walk level and shall be chrome plated extra heavy cast brass complete with the following: • •

6” X 2 ½” X 2 ½” (150 X 65 X 65 mm) Siamese connection with drain cock and check valves to suit local practice All chains, caps and screws used for fixing.



T05-20/11/2013



•

Recessed wall box housing the Siamese connection with wired glass door marked in red from inside: “FIRE BRIGADE CONNECTION” in both English and Arabic. 15500.4.2 Fire Hose Landing Valve Fire hose landing valve shall be angle type, 300-psi (2070 Kpa) glove valve with polished, chrome-plated brass body and trim, red cast iron wheel handle, bronze stem, renewable composition disc, FLANGED 2 ½” (65 mm) inlet and quick coupling outlet with polished brass chrome plated cap and chain. For valves with integral pressure reducing valve, the pressure regulator shall be spring-loaded with springs made of zinc-plated steel and chamber of chrome-plated bronze. The regulator shall have stainless steel adjusting and lock screw and ball, bronze piston and Nitrile rubber lowpressure seal. 15500.5 FIRE HOSE CABINET Cabinets are as detailed on Architectural Drawings. 15500.5.1 General Supply and install fire hose cabinets wherever shown and to the details indicated on the Drawings. Cabinet shall receive an approved shop coat of paint inside and outside. 15500.5.2 Hose Cabinet Each fire hose cabinet shall include the following: • • • • • • • • 15500.6

Fire hose diameter ¾” (20 mm), 100 Ft. (30 m.) long, lightweight made of red rubber with a working pressure of 150 psi. (1030 Kpa). Hose shall comply with BS 3169 Type A. Hose reel of the swinging type, up to 180 degrees full swing complete with guide arm. Chromium plated diameter ¾” (20 mm) fog nozzle capable of complete shut off, straight stream or any degree of solid conical fog. Diameter ¾” (20 mm) gate valve with die cast nonferrous alloy housing with machined waterway. Diameter 2 1/” (65 mm) bronze landing valve with quick press-type coupling adaptor cap and chain. 6 kgs. Dry chemical fire extinguisher with spray hose and nozzle. 2.5 kg. Co2 fire extinguisher with spray hose and nozzle.

FIRE SPRINKLER SYSTEM

15500.6.1 General Requirements Sprinkler installations shall comply fully with the requirements of NFPA section 13 and /or the BS 5306: Part 2: 1990. Provision shall be made for flushing the system. All piping shall be installed so that the system may be thoroughly drained. The piping shall be pitched in the direction of drainage. Drain valves shall be provided where necessary, where shown on the Drawings and at all sectional valves to help draining the major part of the system. On all risers 4” (100 mm) or larger, drain valve shall be 2” (50 mm) size, on 2 ½” (65 mm) and 3” (80 mm) risers, 1 ¼” (32 mm) valves shall be used and on small risers, ¾” (20 mm) drain valves shall be provided. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



No direct interconnections shall be made between sewers and sprinkler drain systems. Sprinkler piping shall not be used, in any way, for domestic water supply purposes. All valves controlling the water supply shall be located where readily accessible. Provision shall be made for test connections and valves. Isolation valves shall be of the indicating type. 15500.6.2 Tests The system shall be subjected to a hydrostatic pressure test, to the satisfaction and in the presence of the Engineer. Pressure shall not be less than 200 psi (1380 Kpa) or at 50 psi (345 Kpa) in excess of the maximum static pressure when the maximum static pressure is in excess of 150 psi (1030 Kpa) and the test shall be maintained for two hours. If leaks develop during the test, the contractor shall make all necessary repairs and shall retest the system at no additional cost to the Employer. 15500.6.3 Signs Provide at sprinkler test valve a metal sign 100 X 200 mm size with white letters on red background, reading “SPRINKLER TEST VALVE”. Letters shall not be less than 50 mm in height. 15500.6.4 Sprinkler Head-Upright Sprinkler heads shall be all bronze, spray type 135 deg .F (57 deg. C) rating, with bulb operating element of “Quartzoid”. Head located in finished areas shall be chrome-plated. Not less than 12 spare sprinkler heads shall be provided together with sprinkler head wrenches, all supported on steel clip in a suitable steel cabinet with hinged door and latch. Cabinets shall be wall hung and in compliance with all authorities having jurisdiction. Location of cabinet shall be as directed by the Engineer. 15500.6.5 Sprinkler Heads-Pendant (Recessed) As above, but with maximum 3” (76 mm) diameter chromium-plated escutcheon, adjustable for a minimum of ½” (13 mm) for ceiling variations. Sprinklers shall be chromium-plated with maximum projection of ½” (13 mm) below ceiling. Not less than 12 spare sprinkler heads shall be provided together with sprinkler head wrenches, all supported on steel clip in a suitable steel cabinet with hinged door and latch. Cabinets shall be all finished in red enamel with white letters on door reading: “SPARE SPRINKLER PARTS”. Cabinets shall be wall hung and in compliance with all authorities having jurisdiction. Location of cabinet shall be as directed by the Engineer. 15500.6.6 Flow Switch – Electric Type The water flow alarm device shall consist of an electrical switching device actuated by means of a vane extending inside the pipe so designed that when water flows inside the pipe the moving vane shall close the circuit in the motor switch which shall complete the circuit and actuate an alarm in the BMS and main fire control panel. 15500.6.7 Sprinkler Control Valve Supply and install control valves wherever shown on the drawings and as specified in these specifications and as detailed on the drawings. The control valve shall include: •

Stop valve – Located in such a location as to be always readily visible and



T05-20/11/2013



accessible to authorized person. riveted strap.

It must be secured open by a padlocked or

• Alarm valve. – Fixed on the main supply pipe immediately above the stop valve. • Water motor alarm and gong. – Must be installed not higher than six (6) meters • above the valve. Alarm must be tested at least once a week. • Combined drain and test valve. • Retard chamber • Pressure gauges at inlet and outlet of alarm check valve. • Alarm motor stop valve. • Electrical pressure switch. • Strainer. – Installed in the supply pipe to water motor. 15500.6.8 Alarm Valve This valve is part of the control valve and shall comprise a bronze seating and valve guide, alarm valve clack (Clapper) resting on the seating. The clack is a flat circular bronze plate faced with special composition disc. When water flows through the control valve, the water will raise the clack disk, and flows to the system with a small amount passing thru a special groove to the alarm motor and gong and initiating the alarm. The clack will remain in the raised position until there is no flow of water thru the control valve then the stop valve will be closed. When sprinklers are in operation during a fire the alarm gong may be shut off by closing alarm motor stop valve. An electrical pressure switch connected in the flow of the alarm gong shall also initiate an electric alarm in the main fire control panel and the BMS. 15500.6.9 Drain & Test valve The drain and test valve is to drain the sprinkler installation of water after a fire has been extinguished and before replacing the sprinklers that have operated. It is also used to test the running pressure of the water supplies. 15500.7

FIRE FIGHTING PUMPS (HOSE REEL SYSTEM)

15500.7.1 General Supply and install, wherever shown on the Drawings, and of capacities indicated there upon fire fighting pumping units. Pumping unit shall consist of two pumps, (Electric and Diesel Driven) electric control skid. Each pump shall be of the centrifugal, type coupled to a totally enclosed fan – cooled motor and the other one to a driven engine. Pumps shall be of the bronze fitted construction with cast iron casing, and renewable bronze casing – wearing rings, impeller shall be of the enclosed type cast bronze dynamically balanced and keyed to shaft with stainless steel keys. Each pumping unit shall be complete with the following: a-Concrete foundation block with vibration isolators. b-Combined pressure switch gauge at the discharge side. 15500.7.2 Operation of the Fire Pumps The system is always wet and pressurized by means of the fire pumps and the small diaphragm vessel. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



When a hose reel valve is opened, the pressure in the pipeline will fall and when it reaches the set point, the duty pump will operate by the action of the pressure switch. At the same time an alarm shall be initiated in the main fire control panel. In case the duty pump fails to operate, or found insufficient to provide the required pressure, the second pump will operate after ten (10) seconds and will continue for at least three (3) minutes. The pump will close afterwards when all the hose reels valves are closed. The pressure vessel provides a small reserve of water to prevent the frequent operation of the pump in case of a small water leakage in the system. 15500.7.3 Electrical Controller Supply and install electric controller completely assembled, tested and wired at the factory before shipping and shall be marked “Fire Pump Controller”, and shall be mounted on the same skid of the pumping unit, and shall include volt free contacts for connection to be BMS. The controller shall be of the manual and automatic control type and shall be complete with the following: Heavy gauge sheet steel enclosure protected to IP54 fitted with lockable access door and finished in high quality stove enamel Externally operable disconnect switches. Circuit breakers and starters. Earth leakage sensor with annunciation as required by Authorities. Pressure switch. Pilot lights to indicate circuit breaker closed and power available, pump operating or off Ammeter test link and voltmeter test studs. Two-position selector switch marked ‘Auto-Manual’. Time delay relay to delay the starting of the standby pump in case the duty pump fails. Low level float switch, in the fire storage reservoir to be interconnected with the control panel to prevent pumps from starting and initiate an alarm in case water level drops to the level of the float switch. An automatic warning of power failure to the motor starting switch shall be given visually and audibly at the fire control pump. Power for this warning system shall be taken from a separately switched sub circuit to that feeding the motor. Control power transformer as applicable to limit control voltage to 240 volts maximum. No phase-to-neutral voltage shall be required. 15500.7.4 Electric Motor Motor shall comply with the provisions of the National Electrical Code and with the requirements of the Electrical Specifications. Motor shall be rated for continuous duty and shall not be used to voltages exceeding 110 percent of rated voltage. Motor shall be of such capacity that at rated voltage and rated frequency, the full load ampere rating will not be exceeded under any conditions of pump load. Motor shall be derated according to NEMA Standard MGI part 14 of for altitudes. Motor shall be provided with watertight conduit boxes. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



15500.7.5 Diesel Engine Diesel engine shall be compression ignition, mechanical injection type rated to operate continuously for a period of 2 hours on full load. Diesel engine shall be automatic or manual starting with its own set of battery. Starter motor shall incorporate axial displacement type pinion and shall be capable of cranking the engine for not less than six cycles of 15 seconds crank separated by 5 second dwell. Diesel engine shall be direct air-cooled. Diesel engine air intake shall be fitted with a filter designed to prevent ingress of water directed from above. Diesel engine shall be fitted with a tank providing fuel for running time of 2 hours and complete with sediment trap, contents gauge, access hole, filter, lockable isolating valve and hand filling pump. Diesel engine exhaust system shall be fitted with a silencer with flexible and rigid mild steel exhaust pipes. Diesel engine shall incorporate a manually operated engine shutdown mechanism, returning automatically to the “Start” position after use. Diesel engine pump set shall be shop tested for full performance test in accordance with LPC requirements on the assembled pump/engine set and test certificate provided. 15500.7.6 Approvals The Contractor shall be responsible to confirm the total dynamic head of the fire pumps and seek the approval of the fire department or persons having jurisdiction and the approval of the Engineer before ordering the pumps. 15500.8 FIRE FIGHTING PUMPS (SPRINKLER SYSTEM) Supply and install wherever shown on the Drawings and of capacities as indicated on drawings two fire fighting pumps, one diesel driven acting as standby and the other one electric driven as a duty pump. Each pump shall be of the centrifugal type. Each pump shall be specially “Tested” for fire service application. Pump and driver shall be mounted on an extra heavy cast iron drip rim ring base. Stop/reset push-button. Supply healthy indicating lights. Volt free normally closed contacts should be provided for remote alarm to signal the following conditions: a-Pump on demand b-Pump running c-A.C. Phase failure 15500.9 DESCRIPTION OF OPERATION OF FIRE FIGHTING SYSTEM The Low-level water reservoir shall be used as a water storage reservoir for domestic and fire fighting purposes. The lower volume is kept for fire fighting usage.



T05-20/11/2013



The network is always wet and under pressure, where a jockey fire pump is used to pressurize the system and to operate whenever water leakage in the system occurs. Whenever a fire valve is opened or a sprinkler head is actuated automatically, water under pressure from the network will flow automatically and the jockey pump runs automatically for a preset time, after which it stops, and one of the fire pumps starts automatically if the following two conditions are satisfied simultaneously: The flow switch, in the main fire water stream senses the flow, and The Contracts of the pressure switch, in the suction line of the pump, are closed. The operation of the fire pumps will ring two alarm bells one in the pump room and the other in the main control panel located wherever shown on drawings. A flow switch is installed in the main supply line to each zone; when this switch senses any flow it should give a visual and audible alarm in the main fire control panel. In addition the signal should be linked with the fire alarm system (supplied under Electric Section). So that an alarm shall be initiated in that particular zone. If the first pump fails to start, the second pump shall start automatically. When all the fire valves are closed, the flow switch shall automatically stop the operating fire pump. 15500.10 ELECTRICAL MOTOR DRIVEN PUMP Electrically driven pump shall be coupled to a totally enclosed fan cooled motor through a flexible coupling. Motor shall comply with the provisions of the International Electro Technical Commissioning (IEC) and with the Requirements of the Electrical specifications. Motor shall be rated for continuous duty and shall not be used to voltages exceeding 110 percent of rated voltage. Motor shall be of such capacity that at rated voltage and rated frequency, the full load ampere rating will not be exceeded under any conditions of pump load. Motor shall be provided with watertight conduit boxes. The power supply circuit for the motor shall be separate from all other circuits in the premises. Each connection to the power supply shall be via an isolating protective device, e.g. an isolating switch-fuse, reserved solely for sprinkler service and independent of any other main or sub-main circuit. Such devices shall be secured against unauthorized operation and shall, except for maintenance, be kept locked on. Switch rooms supplying power to sprinkler pump motors shall be situated where access by the fire brigade is readily available. Duplicate indicator lamps shall be provided in the vicinity of the pump to show that power is available for the motor. Where the supply is A.C. the failure of any one phase of the supply shall be indicated. Visual and audible automatic warning of power failure to the motor starting switch, or in the case of an A.C. supply failure of any one phase, shall be given at an area with responsible manning. The alarms should be located at a continuously manned location such as a gatehouse. The electricity supply shall be fitted with high rupturing capacity fuses capable of carrying the stalled motor current for a period of not less than 75% of the period needed for the motor windings to fail. Any no-volt release mechanism shall be of the automatic resetting type so that on restoration of the supply the motor can be restarted automatically if the trunk main pressure falls. Magnetic and thermal overload trips shall not be used. Motor supply cables inside buildings shall be: -



T05-20/11/2013


a) b) c)


Category AWX of SWX cables complying with BS 6387; or Mineral-insulated copper-sheathed cables complying with BS 6207; or Protected from direct exposure to fire.

External overhead cables shall not be used within 6 m of any window, door or other opening in: 1) 2)

Any sprinkler protected building or Any building within 15 m of sprinkler protected building.

Where there are two or three electrically driven pumps, failure (by mechanical breakdown or fire damage) of equipment or cables supplying any pump shall not affect the supply to the other pumps. Pumps shall be of the bronze fitted construction with cast iron casing, and renewable bronze casingwearing rings. Impeller shall be of the enclosed type cast bronze, dynamically balanced and keyed to shaft with stainless steel keys. Pump shaft shall be carbon steel with stainless steel shaft sleeves. Pumps shall be complete with the following: Eccentric tapered suction reducer and concentric tapered discharge increaser. Concrete foundation blocks with cork isolation pads Casing automatic relief valve at casing discharge set to open higher than design discharge pressure and lower than shut-off discharge pressure to prevent overheating when pump operates at shut-off with no discharge. Open drip cone to collect and drain water dripping from the casing relief valve. A flow water-measuring device to test the pump capacity of water flow of not less than 175% of pump rated capacity. 15500.10.1 Electric Control Panel for Electrical Driven Pump The controller should be designed in accordance with the current Technical aspect of FOC. Rules, 29th Edition (LPC) covering electrically driven Fire Pumps. Enclosure is of substantial gauge sheet steel protected to IP54 fitted with lockable access door and finished in high quality stove enamel. The following components are mounted within the Enclosure: •

Triple pole fully mechanically interlocked on load isolating switch to prevent access door being opened when switch is in ‘On’ position.

•

Main HRC cartridge fuses complying with the current LPC regulations.

• • • • • • •

Control circuit fuses. Control circuit Neutral Link. Set of phase failure relays. Start relay. Accelerating Period Timer. Line Contactor. Pair of electrically interlocked Start and Delta contactors (not in contradiction with authority requirements)

•

Set of fully identified outgoing terminals.

The following Components are mounted on the Enclosure Door D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



• • • •

Isolator handle. Stop / reset push-button. Supply healthy indicating lights. All wiring associated with the electric motor driven pump, including the monitoring circuits should be in accordance with the Regulations for Electrical Installations (Wiring Regulations) (15th Edition, 1981, IEE). To protect cables from direct exposure to fire they should be run outside the building or through those parts of the building where the fire risk is negligible and which are separated from any significant fire risk by walls, partitions or floors with a fire resistance of not less than 30 min. or they should be given additional direct protection. 15500.10.2 Operation of Electric Driven Pump The starting circuit is arranged to fail-safe by utilizing a separate fused starting relay, which under normal standby conditions is energized so that it remains in the ‘hold’ position. If the pressure in the fire main falls to a pre-set value the pressure switch in the main operation and releases this relay by causing it to de-energize thus starting the pump. Should the wiring to the pressure switch be disconnected or an earth fault condition occur on the wiring then the relay would release to start the pump. 15500.11 DIESEL ENGINE DRIVEN PUMP 15500.11.1 General The diesel internal combustion engine driving the fire pump shall be of the compression ignition type, and shall be specifically “LISTED” for fire pump service. The Engine rating shall be in accordance with (LPC)/ BS 5514 and corrected for altitude and ambient temperature. The Engine shall be capable of operating continuously at full load at site elevation for a period of 6 hours at its rated outpoint. The minimum engine rated output should have 10% greater than the maximum brake horse power required to drive the pump at of flow of 1.1 times the maximum protected flow. The Engine shall be connected to horizontal shaft pumps by means of flexible coupling and shall be connected to vertical shaft pumps by means of a right angle gear drive with suitable universal joints. 15500.11.2 The Engine and Equipment shall: a)

Be of the mechanical injection type starting without the use of wicks, cartridges, heater plugs, or ether at engine room temperature of 4 degree C. b) Accept full load within 15 seconds, of the initiation of the start signal. c) Be naturally aspirated, super charged or turbo-charged. d) Have manually operated shutdown mechanism. e) Be provided with governor to control engine speed within ± 4.5% of rated speed under any condition of load up to the full load rating. f)

Be fitted with a device to measure running time and a tachometer. g.)

Have the facility that any manual device fitted to the engine which could prevent the engine starting automatically, shall return automatically to the normal position after manual application.



T05-20/11/2013



The Engine air intake shall be fitted with filter of adequate size to prevent the entry of foreign matter; and protected from water discharge from sprinkler fitter on the engine room. The engine shall have cooling system necessary to prevent the pump overheating whilst churning and any water necessary for charge air-cooling. Cooling water pipes shall be of steel or copper. The cooling system of the engine shall be by a closed circuit water system, cooled by water taken from the pump to heat the exchanger. This water supply shall be fed to the heat exchange via a pressure-reducing device where the safe operating pressure of the heat exchanger is less than the pump churning pressuring with the pump water source at the highest level. The device shall be provided with manually operated bypass. The water shall be circulated by an auxiliary pump bolt driven from the engine. The capacity of the coast circuits shall be not less than that recommended by the engine manufacturer. The Engine exhaust system shall be fitted with silencer. The total backpressure of the exhaust system shall not exceed the engine manufacturer recommendation. Where the exhaust system rises above the engine manifold, means shall be provided to prevent any condensation flowing into the engine. The diesel engine shall have a separate fuel pump from a separate welded steel fuel tank complying with BS 814. When filled to capacity there shall be sufficient fuel in the tank to run the engine on full load for not less than the following periods: a) b) c) However there shall further 6 hours.

3 hours in a light-hazard installation. 4 hours in an ordinary –hazard installation. 6 hours in a high-hazard installation. be a reverse supply sufficient to run the engine on full load for not less than a

The fuel tank shall be fitted with the following: a) b) c)

a sludge and sediment trap; A fuel gauge in readily visible position. The fuel gauge shall not be of the glass or plastics tube type. Damage or fracture of any part of the fuel gauge system shall not result in fuel spillage; An inspection and cleaning hole normally sealed.

Any valve in the fuel feed pipe between the fuel tank and the engine shall be adjacent to the tank and shall normally be locked in the open position. A Filter, accessible for cleaning, shall be fitted in the fuel line between the tank and the fuel pump. Fuel pipes shall be metal. Soldered joints shall not be used. Suitable means such, as screwed plugs shall be provided to bleed the entire fuel system of air. Air relief cocks shall not be used. Pipes carrying lubricating oil shall be of steel or copper. Soldered joints shall not be used. Arrangements should be made to prevent leakage or spillage during filling, of fuel or lubricant, onto electrical control panels, or parts of exhaust system, which may become hot. The Engine starting mechanism shall be as follows: a)

General. Independent automatic and manual starting systems shall be provided except that the starter motor may be common. The rated voltage of the batteries and starter motor shall be either: i)

24 V for engines of capacity more than 1640 cc; or



T05-20/11/2013


ii) b)


24 V or 12 V for engines of capacity not more than 1640 cc.

The automatic starting system shall normally draw power from a battery reserved for this purpose. If at any stage during the starting sequence the battery has in sufficient output to crank the engine, further cranking shall be provided automatically from the battery, which is normally connected to provide the manual starting system. A manual facility shall be provided to permit the pre-selection either better for the automatic starting system. The automatic start facility shall remain functional at all times except when the engine is rotating under its own power, and shall be initiated by the opening of normally closed circuit by a device responding to a fall in water pressure in the trunk main or supply pipe.

c)

Emergency manual start facilities shall be provided. Starting power shall be drawn from both sets of batteries in parallel.

d)

A manual start test button and indicator lamp shall be provided to permit periodic testing of the manual electric start system without breaking the frangible cover over the emergency start button. The starter panel shall be marked, adjacent to the lamp, with the working: ‘Operate manual start test button if lamp is lit’. The manual start test button shall only be brought on line after an automatic engine start followed by a shut down or after six repeated unsuccessful attempts to start automatically. Either of the two conditions shall cause the indicator lamp to light and bring the manual start test button on line in parallel with the emergency manual start push button. The power shall only be drawn from the manual start battery. When a test manual start has been carried out, the circuit used for this purpose shall automatically become inoperable and the indicator lamp shall be extinguished. The automatic start facility shall e available, even when the manual start test button circuit is activated.

e)

The electric starter motor shall incorporate a movable pinion, which will engage automatically with the flywheel gear ring. To avoid shock loading, the system shall not apply full power to the starting motor until the pinion is fully engaged. The pinion shall not be ejected from engagement by spasmodic engine firing. There shall be a means to prevent attempted engagement when the engine is rotating. The starter motor shall cease to operate and shall return to the rest position if the pinion fails to engage with the flywheel gear ring. After a failure to engage, the starter motor shall automatically make repeated attempts to achieve engagement. When the engine starts the starter motor pinion shall withdraw from the flywheel gear ring automatically by means initiated by an electro-mechanical speed sensor. Pressure switches, for example on the engine lubricating system or water pump outlet, shall not be used as a means of de-energizing the starter motor. Centrifugal speed switches or voltage generators used for sensing shall have a direct coupling to, or be gear driven by, the engine; flexible drives shall not be used. Each starter batteries and chargers shall be as follows: a) Batteries. Two separate battery power supplies shall be provided and shall be used for no other purpose. Batteries shall be either open nickel-cadmium prismatic rechargeable cells



T05-20/11/2013



complying with BS 6260 or lead acid Plante positive batteries complying with BS 6290: Parts 1 and 2. The electrolyte for lead acid Plant batteries shall comply with Bs 3031. Batteries shall be selected, used, charged and maintained in accordance with the requirements of these specifications and with any manufacturer’s instructions. Hydrometer, suitable for checking the density of the electrolyte, shall be provided. Battery chargers. Each starter battery shall be provided with an independent continuously connected fully automatic constant potential charger. It shall be possible to remove either charger whilst leaving the other operational. Chargers for lead acid Plant batteries shall provide a float voltage of 2.25± 0.05 V per cell. The nominal charging voltage shall be suitable for local conditions (climate, regular maintenance, etc.) a boost charge facility shall be provided for charging to a higher voltage not exceeding 2.7 V per cell. The charger output shall be between 3½ % and 7½ % of the 10 hours capacity of the battery. Chargers for open nickel-cadmium prismatic batteries shall provide a float voltage of 1.445± 0.025 V per cell. The nominal charging voltage shall be suitable for local conditions (climate, regular maintenance, etc.) a boost charge facility shall be provided for charging to a higher voltage not exceeding 1.75 V per cell. The charger output shall be between 25% and 167% of the 5 hours capacity of the battery. Batteries shall be mounted on stands. The following conditions shall each be indicated both locally and at a responsibly manned location by both a red warning light and an audible alarm: a) The use of any switch which prevents the pump starting automatically; and /or b) The failure of the engine to start by the end of the six cyclic attempts. And c) Pump running. The warning lights shall be appropriately marked. Engine fuel oil. equivalent

The engine fuel oil shall be class A2 in accordance with BS 2869 or

A standard kit of tools as recommended by the engine and pump manufacturers shall be provided together with the following spare parts: a) b) c) d) e)

Two sets of fuel filters, elements and seals; Two sets of lubricating oil filter elements and seals; Two sets of belts (where used); One complete set of engine joints, gaskets and hoses; Two injector holes.

Engine tests and exercising shall be as follows: a)

Each complete engine and pump set shall be tested on the supplier’s test bed for note less than 1.5 hour at the rated flow. The following shall be recorded on the test certificate: i)

The engine speed with the pump churning.

ii) iii)

The engine speed with pump delivering water at the rated flow, The pump churning pressure;



T05-20/11/2013


iv) v) vi) vii) viii) ix)


The suction head at the pump inlet; The pump outlet pressure at the rated flow (downstream of any outlet orifice plate); The ambient temperature; The cooling water flow rate; The lubricating oil temperature rise at the end of the test run; Where the engine is fitted with a heat exchanger the initial temperature and the temperature rise of the engine closed circuit cooling water.

When commissioning an installation the automatic starting system of any diesel engine driven pump set shall be activated with the fuel supply isolated for the six cycles each of not less than 15 s cranking and not more than 15 s or less than 10 s rest. After completion of the six starting cycles the fail to start alarm shall operate. The fuel supply shall then be restored and the pump set shall start when the manual start test button is operated. 15500.11.3 DIESEL ENGINE CONTROLLER The controller should be designed in accordance with the current technical aspect of F.O.C. Rules 29th Edition for Diesel Engine Controller, (L.P.C.) arranged for automatic and manual starting, with a 24 volt dual battery system. Enclosure is of substantial gauge sheet steel protected IP54 fitted with lockable access door and finished in high quality stove enamel. The following Components are Mounted Within the Enclosure: •

Fully mechanical interlocked on load a.c. isolating switch prevent access door being opened when switched is in ‘on’ position.

• Dual independent solid state controlled battery charges. • Circuit Breakers • Control circuit relays • Cam Timer • Control circuit module housing, voltage stabilizer and Diodes • Batteries disconnected buzzer • Set of fully identified outgoing terminals • Failed to Start Buzzer • Starter motor pinion tooth abutment circuit The following Components are mounted on the Enclosure Door: • • • • • • • • • • • • • • •

A.C. Isolator D.C. Isolator A.C. Supply Healthy Light Manual start control circuit healthy light Automatic start control circuit healthy light Pump on demand indicating light Pump running indicating light Failed to start indicating light Test manual start indicating Battery ‘A’ healthy light Battery ’B’ healthy light Batteries isolated indicating light Test manual start pushbutton Break glass pattern manual start pushbutton Charge rate ammeters



T05-20/11/2013



• Tachometer • Hours run counter • Oil Pressure gauge • Water temperature gauge (water-cooled engines only) • Battery auto/manual selector switch light. Volt free normally closed contacts should be provided for remote alarm to signal the following conditions: • • •

Pump on demand Pump running Fault on Controller

15500.12 OPERATION OF DIESEL ENGINE PUMP The automatic starting circuit is arranged to fail-safe by utilizing a separately fused starting relay, which under normal standby conditions is energized so that it remains in the “hold” position. If the pressure is the fire main falls to a pre-set value the pressure switch in the main operates and releases this relay by causing it to de-energize thus starting the pump. Should the wiring to the pressure switch be disconnected or an earth fault condition occurs on the wiring then the relay would release to start the pump. 15500.13 JOCKEY FIRE PUMP Supply and install wherever shown on the Drawings and of capacities indicated there upon a jockey fire pump. Pump shall be of the vertical multistage type with a cast iron casing and stainless steel stages and impeller. Pump shall be vertically split case design with removable housings and the channel rings shall be replaceable without replacing the bearing housings. Pump shall be self-venting. The impeller shall be hydraulically self-centering and no external adjustment shall be necessary The shaft shall be of stainless steel construction and the bearings shall be grease lubricated ball type. The pump shall be supplied complete with: Electric motor of totally enclosed type, flexibly coupled to the pump. Motor shall be sized to prevent overloading at the highest operating head specified. Jockey pump controller factory wired and tested in one unit to (IEC) Standards. Controller shall include hand-off-auto switch, a fusible 3-pole disconnect switch, magnetic motor contactor and thermal overload relays with external reset. The controller shall be furnished in a sturdy, wall-mounted enclosure with hinged door. A pressure switch installed in the piping system and set for approximately 0.35 bars greater than the pressure switch for the main fire pump when pressure in the system drops below the preset level. Controller shall include a minimum-run timer, to insure a 3 minute minimum pump operation, to prevent the jockey pump from frequent operations and shall include volt free contacts for connection to BMS. 15500.14 APPROVALS The Contractor shall be responsible to confirm the total dynamic head of the fire pumps and seek the approval of the fire departments or persons having jurisdiction and the approval of the Engineer before ordering the pumps.



T05-20/11/2013



15500.15 PORTABLE FIRE EXTINGUISHERS Supply and install wherever shown on the drawings portable fire extinguishers of the capacities and ratings indicated on the drawings. Extinguisher shall be rechargeable multipurpose ABC dry chemical type or Co2 type as shown on drawings. Each dry chemical unit shall be complete with a frame for hanging, to the wall, 36 cm. long hose, discharge valve and pressure gauge. Extinguishers shall be tested to BS 5423 and approved by F.O.C. or equivalent. Co2 extinguishers shall be lightweight aluminium construction to BS 5423 and approved by F.O.C. or equivalent. Extinguishers shall have permanent leak proof shut-off safety disc, non-metallic horn, flexible hose and wall hooks. Maintenance schedules shall be provided with each type of extinguishers. The schedules shall be in protective covers and shall detail all aspects of maintenance of extinguishers including details of weight checks, pressure test, discharge tests, internal and external visual checks, time periods for checks and action to be taken on finding a fault. The schedules will also contain full details for repairing, recharging and resetting extinguisher. Contents and re-ordering instructions. 15500.16 FIRE BLANKET Fire blanket shall be made from textures woven glass fibre, impregnated both sides with a special high temperature resistant silicon rubber. The fire blanket shall have an approximate finished weight of 565 gm/m2, and shall conform to BS 6575. The blankets shall be packed in white rigid selfextinguishing PVC container, with instantaneous release tape to function as handle when the blanket is pulled for the container.

End of Section



T05-20/11/2013



SECTION 15600

FIRE DETECTION & ALARM SYSTEM



T05-20/11/2013



Section 15600 FIRE DETECTION AND ALARM SYSTEMS 15600.1.1

General

Fire Detection and Alarm Systems shall be installed in accordance with BS 5839 Part 1 : 1980 “The Installation and Servicing of Electrical Fire Alarm Systems”, and BS 5444-P Part 5. The Contractor shall supply, install and commission the complete Fire Detection and Alarm System including manual and automatic fire detectors, alarm sounders and control and indication equipment as detailed for each building and when complete the Contractor shall arrange for tests at his expense to satisfy the Civil Defence Authority, the Client and the engineer that the system is operating correctly. The system shall be composed of a soft addressable system with latest technology in the field to achieve maximum facilities in identifying the spot of fire outbreak and with minimum annunciation of false fire phenomena. All the system components such as Control Panel, Detectors, Manual Push buttons, Sounders etc., shall be produced by the same manufacturer who has at least five (5) years experience in Design, Manufacturing, Installation, Commissioning and Maintenance of fire Alarm System. The Fire Alarm Contractor shall be registered in the approval list of Local Authorities approving the system. 15600.1.2 1) 2)

3) 4) 5) 6) 7) 8)

Design Criteria The system shall comply with BS 5839, Part 1 except where this is in conflict with the specification. The system shall include : i) Fire Alarm Control Panel ii) Ionisation/Optical type smoke detectors iii) Rate of Rise heat detectors iv) Manual , break glass push buttons v) Electronic sounders and alarm horn The fire alarm enunciators shall be fixed in the building in a position indicated by Local Authorities. Once an alarm is initiated it shall continue until normal conditions are restored. Manually operated silencing devices shall allow transfer of the alarm to a control sounder. The operation of a silencing device shall not cancel the usual indication etc. The system shall be suitable for operation on 24V supply and shall be complete with all necessary batteries, battery chargers and the like. All materials, equipment and accessories for detection and alarm system shall be obtained from a single supplier and shall meet the approval of Local Authorities. Contractor submit complete list of materials and equipment of fire Alarm and Detection System for Engineer’s approval.

The Contractor shall provide five copies of a manual giving complete instructions for the operation, inspection, testing and maintenance of the system including wiring diagrams of units and main control panel. It shall also include the following. 1) 2)

Manufacturer’s instructions for testing and frequency of cleaning for automatic smoke detector heads. Manufacturer’s instructions for any control adjustment and maintenance of battery/charger units.



T05-20/11/2013



15600.1.3 As-Built Drawings Upon completion of the installation and prior to final inspection, the Contractor shall provide “As Built” drawings. Where detectors are used, the “As Built” drawings shall show the number and the exact sequence in which the detectors are installed on the circuit. Contractor shall submit for Engineer’s approval, reports and production and field tests. 15600.1.4 a)

Maintenance and Service Provide maintenance and call back service for two (2) years following final acceptance date of the fire alarm and detection works. Maintenance shall include the visit of Contractor’s competent personnel to site, necessary adjustment, cleaning and replacement of parts.

b)

15600.1.5 a) b)

Spare Parts The contractor shall list the spare parts required for a period of two years with prices. Provide two complete sets of special tools necessary for the routine maintenance and testing of the complete Fire Alarm System.

15600.1.6

Product Delivery a) b)

15600.1.7

Do not store equipment outside exposed to atmosphere. Physically protect all equipment and materials against damage from any other trades. Training

The Contractor shall organize training courses on the maintenance of the Fire Alarm System for the personnel designated by the employer. 15600.2

System Description a)

Provide a complete high quality fire alarm and detection system composed of fully electronic hardware to achieve maximum facilities in identifying the source of fire outbreak in its very early stages and minimize unwanted false alarm. The System shall include but not limited to the following :-

b)

1) Addressable Main Fire Alarm Control Panel with Analogue Detection Technique with integral battery and charger, in built keyboard (function keys). 2) Addressable Manual call Points 3) Addressable Fire sensors 4) Addressable Electronic Sounders and Alarm Horn 5) Fire Alarm Interface units 6) Other accessories required for wiring 7) Auxiliary components 15600.2.1

System Hardware Construction

15600.2.1.1 1) i)

Main Fire Alarm Control Panel The Soft addressable fire alarm control panel with analogue detection technique shall have the following features: Panel shall be multi-tasking micro computer controlled.



T05-20/11/2013



ii) iii) iv) v) vi) 2)

Self contained and wall mountable. Integral switch mode power supply and battery charger. 24 hour battery back-up. Twin 24 hour master alarm circuit. Twin auxiliary relays configurable for fire fault and or warning operations. Control panel shall be fully electronic of modular design based on logic circuitry by microprocessor to allow programmed control and operation. The panel shall have alarm acknowledgement, reset, Day/Night organization and program operating controls as well as indications for all identified alarms, troubles, and display of alarm staging duration. The whole equipment of the panel with emergency power batteries shall be housed in the same housing, any alarm signal shall have an automatic priority over any trouble signal received in the control panel , i.e., alarm signals shall over-ride the trouble information. Upon resetting the alarm, the trouble signal will appear again until repair is completed.

3)

The control panel shall be able to handle up to 6 addressable loops, with extension panels available as required.

4)

No address shall be set neither on the detector nor in the detector base. All detectors and base electronics shall be identical. The base electronics shall be fixed and all assignments of zones and positions shall be programmed at the control panel.

5)

All detection and alarm lines shall start and end in the main fire alarm control panel.

6)

Single fibre optic cable and multiple fire counts shall be used for linking fire detection/alarm system.

7)

Control Panel shall have the following indications (i)

Alphanumeric liquid crystal display for fire, fault and warning messages. Display shall be in 4 lines with 40 characters per line.

(ii)

Back light facility on liquid crystal display.

Two tone buzzer for fire/fault. (iii)

Audible bleep for keyboard pres confirmation.

(iv)

Modules for light emitting diodes : Red Green Yellow

8)

-

Fire Power on Warning and Fault

Fire Monitoring i)

Fire events shall be detected at the fire alarm control panel and shall provide a visual indication with the illumination of the red light emitting diode module marked ‘FIRE’ complemented with messages on the LCD. In addition, event messages shall be printed simultaneously upon occurrence of each event. An audible indication shall also be given by a non-cancellable low tone fire buzzer, which shall be automatically operated by the control panel



T05-20/11/2013



together with the external Master Alarm circuits. All fire events shall be given a high priority for display, indication and control at the panel, with fault, warning and other status events registered during a fire condition, however their indications shall be inhibited until the fire condition is reset. ii)

The control panel shall be interrupted by any detection element on its loop holding Fire or Fault threshold. The panel shall immediately perform a fast scan to locate the de vice requesting attention and when it is located, data bits shall be taken from it and used in conjunction with background readings to analyse the event. The background readings of each analogue channel on any device shall be taken at 1.3 minutes intervals to create a table of slow ‘Running Time Average’. A slow drift of analogue channel readings from a sensor requiring maintenance shall be reflected by changes to the time average values, allowing alarm level off-set values to be created for event analysis, maintaining the sensors sensitivity and allowing the early detection of slow burning fires.

9)

FAULT AND WARNING MONITORING i)

Fault event All fault events shall be automatically detected at the fire alarm control panel giving visual indications by the illumination of the yellow light emitting diode module marked ‘FAULT’, complemented with messages on the display giving details of each event occurrence. An audible indication shall also be given with the operation of a cancelable high tone fault buzzer from within the control panel.

ii)

Warning event A warning shall be given when the disabling facilities of the control panel is automatically or manually operated. The automatic disabling operation shall be activated by the time zone facilities, which shall disable detection elements over a preprogrammed time period to prevent inadvertent alarms being raised. The manual disabling operation shall be activated only by personnel carrying out commissioning, service or maintenance. Warning events shall be automatically shown at the control panel giving visual indications by the illumination of a yellow light emitting diode module marked ‘WARNING’ and shall be complemented with messages on the liquid crystal display giving details of each event occurrence.

iii)

All Fault and Warning events shall be immediately logged as originally displayed. They shall also be printed at the printer using information retrieval facilities or simultaneously upon occurrence of each event. The details of each event shall include information on the type of event, its time and date of occurrence with other relevant data such as card slot number,



T05-20/11/2013



detection element number, channel number or zone number depending upon the origin of the event. The visual and current log information shall be automatically cancelled when the condition is removed. 10)

USER CONTROLS i) All controls shall be behind a lockable cover. ii) Essential controls for fire and evacuate - Start Sounders - Stop Sounders - Reset. iii) iv) v) vi) vii) viii)

11

Engineering 1. i) ii) iii)

iv) v) vi)

2.

Silence fault buzzer facility Tune and date setting facility Master Alarm START/STOP Controls Liquid crystal display, light emitting diodes and fault buzzer test. Printer ON, OFF, Line Feed and Test facilities. Disabling facilities for - Fire sensors and manual call points - Zones - Sectors - Auxiliary relays - Master Alarms Loop configuration System shall comprise of loop wiring with a loop length of maximum 1km if required. Addressable sensors, addressable manual call points, remote LEDs, addressable electronic sounders, repeat panels and interface units shall be on the same loop. Soft addressing i.e., automatic allocation of addresses to detection elements shall be done once they are installed thus eliminating the need for setting address switches at each such elements. 32 character label per each detection element shall be provided. Sub-looping and spurring off facility from the main loop shall be available. Each and every detection element shall have a loop breaker relay to maintain its integrity and keep the entire loop functional isolating only the particular faulty element. A single short or open circuit fault on a loop wiring shall not disable any detection element on it and the system shall remain fully functional. System Monitoring Loop communication shall be monitored for :-

errors including communication errors short circuit with response time of 0.5 second open circuit every 10 seconds or less disconnection of detection elements from loop every 10 seconds or less supply fault



T05-20/11/2013


3.


Event Log 1) 2) 3) 4)

4.

A log of upto 255 previous fire, fault, warning and status events. Separate log of 100 previous fire events Fault event log (current) Warning event log (current)

Time zone Programme over 7 days operation and delay programme of duration 0-10 minutes shall be available.

5.

Other features 1) Automatic or manual correction facilities for fast or slow clock. Information retrieval facilities for engineering set-up and system status. 2) 3) 4)

Memory of configuration and engineering set up. Clearing fault and warning facilities Password protected access to engineering controls.

12

POWER SUPPLY

a)

The power supply unit shall be integrated into the fire alarm control panel to power the electronics within the panel and also provide for detection elements connected to the panel’s loops. The unit normally shall derive its supply from the standard mains of 415V 50Hz, protected with a 5A fuse. In the even of a mains failure the panel’s battery back-up facility shall maintain all power requirement for 24 hours and then have sufficient power to ring all bells for 30 minutes continuously afterwards.

b)

The method used for transforming the power shall involve the switching of power devices at high speed and to chop unregulated d.c.voltage into pulses at a rate determined by the load requirement. Efficient computer grade energy storage devices shall modulate the pulses into stabilised d.c. voltage, which shall be chopped yet again to create a number of other isolated d.c. voltages which shall be chopped yet again to create a number of other isolated d.c. voltages for use by the control panel, so that there shall be considerable reduction of heat loss at all power devices compared to dissipation of a linear power supply of similar capacity.

c)

There shall be two charger circuits for the sealed lead acid battery banks integrated with the power supply design and each charger shall be protected by a 5A fuse. Each charger shall have a negative temperature compensation characteristic giving a 48mV/deg C reduction in charge voltage with an increase in temperature. This shall allow the batteries within the control panel to be correctly charged in temperature environment under normal conditions. In addition, a load test shall be performed at 4 second intervals to monitor the battery disconnection, fuse failure and low discharge voltage.

d)

Other facilities built into the power supply assembly shall provide for panel and system control. These shall include two auxiliary relays, two



T05-20/11/2013



master alarm circuits rated 1A and 24V and a two tone FIRE/FAULT buzzer. Extensive faults monitoring shall performed at the unit to cover the main supply, loop voltage, earth fault and monitoring of all stabilised d.c. voltages A fan assisted thermostatically controlled cooling system shall be built into the power supply design for reliable operation throughout the product life. To add further security, there shall be protection against known causes of power supply failure such as main supply interference, electrical transient, inrush current and saturation of energy storage devices. Memory of configuration and engineering set up. Clearing fault and warning facilities Password protected access to engineering controls. 15600.2.2

AUTOMATIC FIRE SENSORS a)

b)

c) d) e)

Automatic Fire Sensors shall include ionization smoke sensors, optical smoke sensors, rate of rise with maximum temperature limit heat sensors and combined optical and heat sensors. Any of these sensors shall fit in the same sensor base so that only the sensor head shall be changed at any time without changing the base disconnecting the wiring. The Fire Sensors shall be protected against transient interference. Sensor base shall have the facility of a 3 way base in order to facilitate sub looping or spurring facility. Also it shall be equipped with an integrated module for individual addressing with built-in alarm indicator and provision for connecting remote indicator. The fire sensors shall be designed to lock into a sensor base assembly housing terminations for loop cable connections. The fire sensors shall be tested for extremes of radio-frequency interference, temperature and humidity, wind, electrical transient, shock and insect infestation. Ionisation Smoke Sensor Smoking sensing design to BS 5445 Part 7.

Monitoring fires -

smoke threshold response of less

Monitoring faults

-

than 1 second.

loop and local, connection and communication.

The smoke chamber shall employ a low energy alpha emitting ionizing radiation source (Americium 241 of 0.8 Mc). Ionisation smoke detectors shall be dual chamber type with sampling reference chambers for high reliability and shall have an adjustable opening size of smoke entry, built-in response integration of circuitry to cut down alarm signals due to false fire phenomena and it shall be possible to disable the circuitry in the same detector by corresponding mark which can be seen while detector head is mounted. Radio frequency interference Temperature

:

10-20 MHz upto r/m , with and without modulation

: 0-80 deg C

Humidity : 0- 100% RH D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Mechanical Impact /Shock/Vibration

:

EN 54 requirements

Electrical transient

:

Upto 7 KV tested

Wind Speed : Upto 5 m/s steady, or 10 m/s gusting. 15600.2.2.1

Optical Smoke Sensor

Scattered light (optical) smoke detector shall have sampling chamber of symmetrical optical system, adjustable opening size of smoke entry, full compensation for dust accumulation (soiling) and built-in response integration circuit as mentioned in ionization smoke detector. Radio frequency interference

:

10-20 MHz upto r/m , with and without modulation

Ambient Temperature

: 0-75 deg C

Permissible Humidity

: upto 95%

Mechanical Impact /Shock/Vibration :

EN 54 requirements


Upto 7 KV tested

:

Wind Speed : Upto 5 m/s steady, or 10 m/s gusting. 15600.2.2.2

Heat Sensor

Heat Sensing design to BS 5445, Part 5 Monitoring Fires Faults

Smoke threshold response of less than 1 second Loop and local connections and communications.

Heat detector shall be able to measure the ambient temperature and its rate of rise by thermally insulated thermistor, with removable protective cover for cleaning, of full electronic parts, self holding alarm activation and restorable type (not fused type) Automatic reset time

:

2 Seconds max.

Nominal response sensitivity : 58 deg C Rate of temperature rise

: 10 deg C / starting above 25 deg C

Radio Frequency Interference : 10-520 MHz upto 10 r/m with and without modulation. Humidity

:



0-95% RH

T05-20/11/2013



Mechanical Impact /Shock/Vibration

: EN 54 requirement


:

Upto 7KV tested

Wind speed

:

Upto 5 m/s

15600.2.2.3

Combined Optical and Heat Sensor

Smoke and heat sensing element in one head Smoke sensing design to BSS 5445, Part 7. Heat sensing design to BS 5445, Part 5 Micro computer controlled. Monitors Fires

-

Faults

-

heat or smoke threshold response of less than 1 second. loop and local connections and communications.

Smoke sensing shall be by pulses of an infra-red beam projected across a dark sensor chamber by the LED emitter. A photodiode receiver fitted at an obtuse angle to the IR Beam shall normally sense some standing like scatter. When smoke enters the smoke chamber through entry slots around the sensor head, more light shall be scattered towards photodiode Receiver thus enabling the micro processor and measurement circuits on the PCB to pick up a fire threshold. Hear sensing shall be done by the two thermostats in close contact with the Mesh which shall prevent foreign bodies entering the sensor chamber and shall serve as a heat sink for the Thermostats to allow even heat distribution. Radio

:10-520 MHz upto 10 r/m with and without modulation.

Temperature

:

0 - 70oC

Humidity

:

0 – 95% RH

Mechanical Impact/Shock/Vibration

:

EN 54 requirement


:

Upto 7KV tested

Wind speed

:

Upto 5 m/s

15600.2.3 Addressable Manual Alarm Call Points a) Manual alarm station shall be addressable push-button type which can be individually allocated as an independent zone on the same detection line connecting other zones, with built-in response indicator which shall light up when activated. b)

Monitors Fires

-

Glass break Keyswitch operation



T05-20/11/2013



Faults -

Loop and local connection and communication

c)

It shall be electrically compatible with standard range of fire sensors so that it can be connected directly into a supervised two wire loop.

d)

Shall be designed to permanently withstand corrosion.

15600.2.4

Addressable Electronic Sounder

a)

Shall meet requirements of BS 5839 Part 1

b)

Micro computer controlled and shall be flush mounted.

c)

Shall have a 2 way loop connection for spur and sub-loop option.

d)

15 mA current consumption.

e)

Two link selectable volume:-

95 Hz low sound 104 Hz high sound

g)

Shall be compatible to be connected on the same loop alongwith addressable sensors and addressable manual call points.

h)

Alarm programming features shall be possible by entering user data via the builtin keyboard.

15600.2.5

Fire Alarm Interface Unit

a) Fire alarm interface unit shall be compatible to be connected on the same loop and along with addressable sensors, addressable manual call points and addressable sounder. It shall have the following the features: 1) 2) 3) 4) 5)

1)

6)

Integral battery and charger. 24 hour battery back-up. Shall accommodate upto 4 input or output lines. Micro computer controlled. No use of relays required when any form of low current output devices are connected. Shall have capacity to drive 4 special outlets to be controlled via relays.

7) 8) 9)

1 A maximum shared sector load. 2 mA maximum per input line. Input monitoring of conventional detection and manual call points shall be done.

b)

It shall monitor:

Output

-

open circuit fault short circuit fault

with a response time of less than 1 second. 2)

Local power supply and battery back-up failure.



T05-20/11/2013



3)

Local communication failure.

4)

Loop communication failure.

15600.2.6

Cable for Loop Circuit and Product Interconnection

a)

The cables shall have a continuous metal sheath encapsulation 2 cores of conductors, each having a 1.5mm square cross sectional area. For a loop circuit the length of cable used shall not exceed 1Km., including the cable length used on its sub-loops and spurs.

b)

Multicore cables having more that 2 cores shall not be used for loop wiring, due to inadequate separation and possible electrical interference problems.

15600.2.7

Execution

Fire alarm components shall be installed directly to conduit outlet boxes at the following mounting heights above finished floor level, measures to the above center of box unless stated otherwise. a)

Fix manual call station semi-recessed at 1.50mm height above finished floor.

b)

Automatic smoke and heat detectors : ceiling mounted.

c)

Alarm sounders : 2.20m above finished floor.

d)

External response indicators : fix beside or over doors as directed by the Engineer or shown on the drawings.

15600.2.8 a)

Wiring and Wiring Facilities Supply and install the necessary conduit, enclosed trucking or MICS and accessories and wiring for the fire alarm system. System shall operate on two wire lines for detection, alarm and control functions. Wire size termination and other details shall be as per Fire Alarm Detection System manufacturer’s recommendations.. Wiring shall be MICS cable indicated on the drawings.

c)

All wiring shall be installed to provide a complete and satisfactory functional system in all respects. All cable terminations at components and junction boxes shall have identification tags, indicating polarity and function in a manner which is consistent throughout the system.

d)

The fire Alarm / Detection System wiring shall be completely independent from other system wiring in all respects in accordance with the IEE Regulations.

e)

Joints in Fire Alarm System wiring shall be avoided. Where joints cable are unavoidable the joints shall be enclosed in a suitable junction box labeled ‘Fire Alarm’ and joints shall not be such as to reduce the reliability and resistance to fire of the cable below that of an un-joined cable.



T05-20/11/2013


f)

15600.2.9


Supply and install multiple count fibre optic cable from main control panel at control room to offshore control panels / control rooms. Testing and Commissioning

a)

After the installation is complete, the Contractor shall conduct operating and commissioning tests. The equipment shall be demonstrated to operate in accordance with the requirements of this specification. The system installation, testing and commissioning shall be as per Dubai Local Authorities approval and requirements.

b)

The Fire Alarm System shall be completely programmed in accordance with Local Authorities requirement and a specialist from the manufacturer shall attend and demonstrate the complete system.

15600.2.10

Extinguishing System Contractor shall supply and install the following extinguishing system in the various location as for the drawing attached:

a)

b)

Carbon Dioxide Systems: The minimum design concentration of gas shall generally be 34% by volume achieved within one minute. The minimum design concentration shall however, be increased to suit the risk in accordance with BS 5306:Part 4:1979. Dry powder System (ABC) The dry powder system shall designed to BS 5306.

15600.3

INTEGRATED VOICE EVACUATION SYSTEM

System Description: 1.1 The integrated PAVA system shall cover all normally accessible areas with the

exception of car-parks, service areas, stair cores etc or areas where a high level of background noise at present. In these areas loop powered loop signaled electronic sounders connected to the fire alarm system shall be used 1.2 The system shall be capable of being used for everyday background music and

public announcement duties with the fire announcements overriding all other facilities.

alarm

initiated

emergency

1.3 The Distributed Amplifier Units shall include amplifiers for local areas. The DAU's shall be capable of complete standalone operation for the areas it is assigned should the network/interface connections fail. In the event of a catastrophic failure occurring on any individual component within the DAU. 1.4 The speakers inside the shops and certain other areas (please refer the layout Fire Alarm PAVA layout drawings) shall broadcast voice alarm signals only. Before proceeding with the procurement and execution of work at site, proposal for the zoning of such areas shall be submitted to the Engineer for study and approval.



T05-20/11/2013



1.5 Initiation of voice alarm shall take immediate priority and shall cancel all other PA operations. The voice alarm system shall be capable of broadcasting prerecorded emergency alarm messages and live speech in the event of fire detection system activating. 1.6 Evacuate signal relates to a general evacuation message and alert message corresponds to standby instructions. 1.7 In addition a FIRE DRILL and an ALL CLEAR message shall be incorporated into the operation. 1.8 A fire alarm broadcast signal shall cancel any public address operation and shall override it. 1.9 A fireman's microphone shall be fitted to the Audio Control Units. These shall allow direct voice instructions to be transmitted to a single zone, selected zones or all zones. 1.10 When a fireman's microphone is operated, this shall override any automatic voice alarm signal being transmitted to the zone selected. The Alert and Evacuate prerecorded messages shall be maintained in other zones while live voice fire announcements are being broadcast to selected loud speaker zones. 1.11 The system for this project shall be provided with a dedicated voice alarm system and integrated public address (PAVA) facility. The PAVA system shall be properly integrated with the fire alarm system for the whole building. 1.12 The Audio Control Unit (ACU) shall be designed to complement the fire alarm control panel, providing manual access to the voice alarm section of the system. Controls on the ACU shall be available for up to 64 broadcast zones of the voice alarm. Standard configurations shall allow for recorded Alert and Evacuate messages as well as an emergency microphone to be operated in each area. In addition up to four other recorded messages shall be stored in the ACU. 1.13 The distributed amplifier units (DAU's) shall house 8 x 50 watt amplifiers or as is required, as per the load of the speakers. The speaker zoning circuits shall be wired as shown in the schematics. The DAU's shall be mounted close to the broadcast zone they are to serve so that the loudspeaker wiring is minimized. Each DAU shall house the power supply, battery backup and full monitoring facilities. The DAU units shall be modular in construction allowing for a high degree of flexibility so that the performance can be closely matched to requirements. The DAU shall meet the meet the Voice Alarm Standards of BS 7443.

End of Section



T05-20/11/2013



SECTION 15800

AIR CONDITIONING & VENTILATION SYSTEM



T05-20/11/2013



Section 15800 AIR CONDITIONING & VENTILATION 15800.1 SCOPE OF WORK The Contractor shall furnish all labour, materials, equipment, tools, appurtenances, services and temporary work to provide and complete the air conditioning and ventilating installations all in perfect working order. This work shall include but not be limited to the following: −

Air cooled roof top packaged units, number, size and capacity as indicated on drawings.

−

Individual air cooled ducted type split system air conditioners where indoor units are installed above toilets and outdoor units are installed on the roof. Capacities as indicated on drawings.

−

Air cooled screw Chillers complete in accordance with the requirements of the Contract Documents.

−

Installation of ductwork, pipework, insulation, air outlets, controls and comfort instruments.

−

Electrical connection from isolators to outdoors units and control wiring between outdoor units and indoor units and thermostat wiring and installation.

−

Condensate pipework from units to nearest drain point.

−

Installation of mini split type air conditioner units and drain connection. Capacities indicated on drawings.

−

Ventilation system for toilets, kitchens, pantries services areas and fresh air supply including installation of fans, ductwork, air outlets, electrical connection etc.

−

Builder’s work as required including concreting the pipes with box out details.

−

Testing of all piping system, equipment, controls and other devices to demonstrate that each and the entire installation is in perfect working order.

All equipment and materials shall be brand new bearing stamped ratings as required and must be approved by the Engineer prior their use. The foregoing sub-paragraphs are not intended to itemize all works required by this section of the specifications and are only for the purpose of outlining the extent of work. Work materials, equipment or services not specifically mentioned above but mentioned or implied in other clauses of this section or indicated on the drawings must be furnished and installed by the Contractor. 15800.2 ELECTRICAL WORK All electrical equipment shall be designed for continuous and satisfaction on all electrical supply as specified under Electrical Installations Section. All electrical wiring, conduits, etc. shall conform to the requirements of the Electrical Specifications Sections. 15800.3 Shop Drawings The Contractor shall, as possible after signing the Contract, submit to the Engineer for approval detailed shop drawings and operating data for the several systems of the mechanical installations including all D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



equipment, materials and control of whatever nature which he proposes to incorporate in the works. Shop drawings shall include the following: *

Large scale drawings of equipment, piping and ductwork complete with insulation and accessories, in plan and sections, showing clearances between units and the relation of the equipment.

*

Sizes, location and method of insulation of all parts supplied, including marking of components for site erection.

*

Weights, fixings, anchoring details, supports, concrete bases and anchor bolt locations of all equipment, piping and accessories.

*

Manufacturer’s scale drawings and catalogues, including descriptive literature and complete characteristics of each item of equipment, showing major dimensions, capacity, pressure drop, code requirements, motor drive and testing.

*

Wiring diagrams of starters and controllers.

*

Manufacturer’s name of insulation and others not covered by shop details.

*

The Contractor shall supply three sets of manufacturer’s installation, commissioning, operation, servicing and maintenance manuals, technical catalogues and detail spare parts manuals for all items for the guidance of the Employer operators in operations, servicing and maintenance of the plant. One set shall be supplied to the Engineer for scrutiny and approval well before shipment of the items by the manufacturer/supplier and the balance four sets simultaneously with or before the arrival of the items at site. Shop drawings scale shall be minimum 1:50 or as approved by the Engineer.

*

After completion of the installation work, the Contractor is to provide tracing on linen base and 3 copies of as built drawings showing runs and locations of all the plant, equipment, controls, piping, ducting, electric wiring etc. giving all necessary details of the works as actually installed.

15800.4 Equipment Drive Guards All equipment driven by open shafts, belts, chains, or gears shall be provided with approved all-metal guards enclosing the drive mechanism adequately protect all personnel working on or in the vicinity of equipment. Guards shall be constructed of galvanized sheet steel of galvanized 1” mesh screen (woven wire or expanded metal) set in a frame of galvanized steel members. Guards shall be secured in position by steel braces or straps which will permit easy removal for servicing the equipment. Where safety codes or regulations are applicable, the guards shall conform thereto in all respects. The “live” parts of electrical equipment shall be protected in such a way as to adequately safeguard from injury all personnel working on or in the vicinity of equipment. Wherever possible, all protective guards should be supplied by the equipment manufacturer. 15800.5 Name-Plates Each unit of equipment shall be identified by a permanently attached name plate made of brass or other corrosion resistant metal. Plates shall be engraved with the information pertaining to the unit as follows: * *

System and unit designation. Manufacturer’s name and address.



T05-20/11/2013



* Serial and model numbers. * Rated capacity. * Electrical or other power characteristics. * Temperature, pressure or other limitations. 15800.6 Painting Surfaces requiring prime painting shall be cleaned thoroughly of all rust, loose scale, oil, grease and dirt. Use wire brushes and solution for this purpose. No painting shall be some on damp surfaces. Shop coated surfaces shall be cleaned thoroughly and retouched where necessary. The paint shall be evenly spread and well brushed out so that there shall be no drops, runs or sagging. Care shall be taken not to paint controls, label plates and name-plates. All items that have rusted or corroded in storage or in place shall be reclined or repainted upon the request of the Engineer. Finishing coats shall be made in accordance with a colour code, based on ASHRAE recommendations after being submitted to and approved by the Engineer. All steelwork in connection with supports for equipments exposed to the elements shall be painted with two coats of an approved rust preventive paint. All insulation surfaces exposed to view shall be painted with two coats of enamel paints of an approved colour. Internal surfaces of grilles, diffusers, etc. and connections visible to occupants of rooms, shall be painted with two coats of dull black paint or other colour, as directed by the Engineer. 15800.7 Lubricants During testing and prior to acceptance, the Contractor shall furnish all lubricants necessary for the proper lubrication of all equipment furnished under this Contract. 15800.8

COORDINATION, ACCESSIBILITY & PERMITS

All cutting and patching of walls, partitions, ceilings and floors shall be performed by the Contractor. The Contractor shall be responsible for dimensions and locations of sleeves, forms, inserts and access doors. The Contractor shall confer with other contractors and furnish them information, so that all other contractors will be able to install their work satisfactorily and with least possible interference or delay. Additional work required, due to interference with other contractors, shall be performed at no additional cost to the Employer. All work shall be so installed as to be readily accessible for operation, maintenance and repair. The Contractor shall obtain and pay for all necessary permits, inspections and tests, for the proper installation of his works as may be required by the various administrative authorities having jurisdiction. Certificates of inspections, tests, etc. shall be secured by the Contractor and these documents shall be delivered to the Engineer before the work in question will be accepted. 15800.9 TESTING The Contractor shall supply skilled staff and all necessary instruments and carry out any test of any kind on a piece of equipment, apparatus, part of system or on a complete system if the Engineer requests such a test for determining specified or guaranteed data, as given in the specifications or in the schedule of Equipment, and where furnished by the Contractor.



T05-20/11/2013



Any damage resulting from the tests shall be repaired and/or damaged material replaced, all to the satisfaction of the Engineer. In the event of any repair or any adjustment having to be made, other than normal running adjustment, the tests shall be void and shall be recommenced after the adjustment or repairs have been completed. The test shall not be made void due to circumstances beyond the Contractor’s control. All testing, balancing and final adjustment shall be in accordance with the provision of the applicable ASHRAE Standards. 15800.10 EQUIPMENT All ventilating equipment air dampers, ductwork and air outlets shall be adjusted and balanced to deliver the specified air quantities indicated, at each inlet and outlet in the drawings. Where the equipment or system depend upon controls for proper operation, functioning and performance, the latter shall be operated simultaneously with the equipment or system during tests. If air quantities cannot be delivered without exceeding the speed range of the sheaves of the available horsepower, the Engineer shall be notified before proceeding with the balancing or air distribution system. Other tests as specified under the specific equipment headings ate to be completed to the satisfaction of the Engineer. 15800.11 PIPING SYSTEM Pressure tests shall be applied to piping only before connection of equipment and appliances. In no case shall piping, equipment or appliances be subjected to pressure exceeding their rating. If necessary piping shall be taken down and reassembled as no makeshift method of temporarily repairing leaks, etc. will be permitted. Tests shall be completed and approved before any insulation is applied or pipes, valves and fittings have been concealed. Tests shall be performed in the presence of and to the satisfaction of the Engineer. Any leak or defects uncovered by the tests shall be repaired and the system resettled as above, all at the Contractor’s own expenses. All refrigerant system shall be tested and proven tight under nitrogen pressure of at least 150% of maximum working pressure which shall be maintained for four (4) hours. Before completely charging refrigerant the whole system shall have a holding charge and be tested for leaks by means of a leak decorator. 15800.12 NOISE TEST Noise levels inside all rooms shall not exceed NC 35. Nose levels inside kitchen/cafeteria shall not exceed NC 45. 15800.13 VIBRATION TEST All equipment provided shall be inspected to ensure that it is free from excessive vibration. Any minor vibration which may occur shall not be transmitted from equipment into or through the supporting or enclosing structure. Should the Engineer consider that excessive vibration is present, such as to warrant the need for specialist testing apparatus and personnel, then the Contractor shall engage and employ such specialist services at no additional cost to the Employer. 15800.14 ELECTRICAL EQUIPMENT All electrical equipment shall cleaned and adjusted on Site before application of power. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The following tests shall be carried out: − Wire and cable continuity tests. − Insulation resistance tests, phase to phase and phase to earth, on all circuits and equipment, using a 500 volt megger. The megger reading shall be not less than one megohm. − Phase out and phase rotation tests. − Operating tests on all protective relays to prove their correct operation before energizing the main equipment. − Operating tests on all starters, circuit breakers, etc. 15800.15 TESTS ON COMPLETION After finishing the above tests and adjustments, the Contractor shall be responsible for running a performance test for the whole installations for a period of two months. Such test shall take place during the appropriate season when design conditions are met or approximated or at any reasonable time subject to the approval of the Engineer. During the performance tests, tests shall be conducted on the air conditioning equipment and ventilating equipment. Air balancing test shall be conducted and the result shall be submitted to the Engineer for approval. The test data shall not deviate by more than three percent from the guaranteed capacity data. Should any part of the apparatus of system fail to meet with Contract requirements, it shall be adjusted, repaired or replaced to the satisfaction of the Engineer. No plant can be considered as finally accepted until it has passed the above tests to the satisfaction of the Engineer. 15800.16 MAINTENANCE The Contractor shall be responsible without additional charge to the Employer for maintenance and servicing of the complete plant for a period of one year after the issue of the certificate of completion by the Engineer. The Contractor shall service the complete plant regularly according to the schedule of servicing and maintenance as approved or amended by the Engineer but not less than a month during the operational season. The servicing and maintenance shall be carried out by skilled labour under competent supervision. 15800.17 AIR CONDITIONING EQUIPMENT Design Conditions: - Location - Summer Ambient Conditions - Indoor Design Conditions - Daily Temp. Range - Summer Hottest Months Design Conditions for Chiller -

: Dubai, Sharjah, Ajman (UAE) : 46 deg.C DB/32% RH : 22 deg.C plus minus 0.5 deg.C & 50% RH plus/minus 5%. : 25 deg.C. : May, June, July & August.

Supply and install where shown in the drawings packaged type air cooled screw water chillers with at least two refrigerant circuits note each compressor must have its own circuit, having capacities as shown in the drawings



T05-20/11/2013



-

Air cooled rotary screw chillers with R134A or other approved ozone friendly working during the peak load.

refrigerant all

-

Each machine to be capable of providing the specified cooling when the outside ambient is at 46.1oC and the supply temperature of 6.67°C and a delta T of5.6°C.

-

The cooling of hermetic motor windings and other auxiliary equipment shall not be considered as part of the unit output performance.

-

Units to be capable of operating in the U.A.E. outdoor environment having ambient ranging from (- 1°C,to 55° ) ambient dry bulb temperature .

-

Chillers shall be completely factory assembled, piped, wired, and shipped with refrigerant charge in bottles, and oil charge. The only required field connections shall be the system water piping and the electrical power supply. They shall be provided with lifting lugs.

-

Units shall include condenser, condenser fans and motors, evaporator, semi hermetic screw compressor, compressor motor, control module, and starters for all motors.

-

All components shall be mounted on a continuous structural steel base resting on vibration isolators. Isolators shall be proportioned for the loads at all points under unit.

-

The system shall be designed and supplied for R-134a refrigerant operation.

-

The chiller shall operate from a 380V, 3 phase and neutral power supply connected into the control panel.

-

The power supply cables and protective devices shall be rated as recommended by the manufacturer.

-

Chillers shall have 1 year comprehensive warranty and 5 year warranty on compressors.

-

The unit shall be able to start up with an evaporator entering fluid temperature up to 45°C

-

Chillers must be rated to Eurovent class ‘A” at nominal conditions which means best energy efficiency in its class even for high ambient series chillers.

-

Compressors shall be semi-hermetic twin screw type

-

Compressor speed shall not exceed 3000 RPM

-

Compressors shall be equipped with a capacity control slide valve capable to adjust the chiller capacity from 100%to 15% load.

-

Compressors shall start at minimum load

-

Compressor capacity shall be microprocessor controlled to maintain the required chilled water temperature, and protect the motor against overload or the refrigeration circuit against high pressure cut out.

-

Low vibration & sound level subject to engineer’s approval.

-

The heat exchanger will consist of multiple transversal V shaped coils to provide self protection. Each V will have an angle superior to 50° to ensure optimum air distribution



T05-20/11/2013



-

Coil shall be easily cleanable using a high pressure cleaner.

-

Fan Speed shall not exceed 950 rpm

-

The three-phase electric motors shall have class F insulation, IP 55 protection with a minimum efficiency of 80%. They shall have individual overload protection via a circuit breaker.

-

Chiller shall have independent circuit for each compressor to provide maximum redundancy

15800.18 Electric Power Supply The electric power supply shall be as stated in the Electrical Drawings, single phase supply to be used only for lights, control circuits and for fractional horsepower motors. The permissible electric supply voltage variation would be plus minus 10% of the supply voltage and all electrical equipment shall be of design to operate satisfactorily with this voltage variation. 15800.19 AIR CONDITIONING EQUIPMENT GENERALLY All air conditioning equipment shall be of the capacities indicated on the drawings. Packaged units shall be factory assembled and all safety and operating controls shall be adjusted, set tested at the factory. 15800.19.1 MINI-SPLIT UNITS Air Cooled Condensing Units Air cooled condensing units for mini split A/C systems shall be completely factory assembled and shall include hermetic compressor, condenser coil, condenser fan, motor and prewired control panel mounted in corrosion resistant all weather cabinet. Units shall be shipped from factory with a full charge of oil and holding charge or Refrigerant-22. Condensing units shall be suitable for outside mounting. Cabinet shall be thermally and acoustically installed on all exposed interior surface. Compressor shall be fitted with suction and discharge service valves, crankcase heater, internal thermal protection to protect motor under all start and run conditions and continuous compressor. Fan Coil units Fan coil units for mini split A/C systems shall be of the horizontal ceiling mounted type or wall mounted type as shown of the drawings. Casing: Minimum 18 gauge galvanized steel enclosure, braced to prevent vibration. Panels removable for access. All air passages internally lined with minimum 25mm fibre glass(or any insulation as per engineer approval). Complete with mounting brackets, suitable for either wall hanging or ceiling mounting. Coil: Copper tubes, aluminium fins mechanically bonded to the tubes seamless copper of 85% red brass headers with air vents and drains the coil should be with minimum 4 rows for chilled water System. .



T05-20/11/2013



Drain Pan: To extend completely under cooling coil and the control and shut-off valves. Minimum 16 gauge galvanized steel, joints brazed water-tight, all coated with waterproof sealing compound and insulated to prevent condensation. Pitch to a minimum 3/4” drain coupling brazed to the pan. Fan Assembly: Forwardly curved aluminium fan wheels statically and dynamically balanced in scrolls of bonderized steel or aluminium mounted on common shaft with the motor. Mount the fan and motor assembly on an acoustically treated reinforced galvanized steel panel board removable as a unit. Motors: Fan motor of the shaded pole type, three speeds. Provide rubber isolators and thermal overload protective devices. Fan Control: Local control three-speed on and off fan switch with inter-connecting wiring to electrical control box. The three-speed control shall be wall mounted. Filter: 25mm thick aluminium cleanable type, spring clip fastened. 15800.19.2 DUCTED SPLIT SYSTEM A/C UNITS Air-cooled Condensing Unit Air-cooled condensing shall be in accordance with the performance schedule shown on the drawing and the installation shall be in accordance with the manufacturer’s recommendations and all applicable international and local codes. Air-cooled condensing units shall be UL (CSA) approved. Completely assembled for non-piece shipment and rigging leak, pressure and functionally tested at the factory to assure a trouble-free start-up after installation. Covered by a 5-years compressor warranty and a 1-year warranty on the complete unit. (Only unit upto 15 tons). In current production with published literature available to check their performance, limitations, specifications, power requirements, dimensions, operation and appearance. Each unit enclosure shall have a steel angle frame to provide the rigid support required for shipping, rigging and years of dependable operation. Exterior panels of 18-gauge, zinc coated steel that have been bonderized and finished with baked enamel to provide a quality, long lasting appearance. Removable panels to provide easy to the internal components. The dimensions of each unit shall not exceed those specified on the plans. Each compressor shall be mounted on spring isolators and shall be enclosed in a separate compartment to minimize the transmission of sound and vibration. The condensers shall be drawn-thru, shall consist of copper tubes arranged in staggered rows and mechanically expanded into aluminium fins, and shall have a separate circuit for sub-cooling the liquid refrigerant approximately 19 def.F at design conditions. The condenser fan motors shall be directly connected to the condenser fans and shall have permanently lubricated ball bearing and inherent overload protection. Single phase motors shall be permanent split-capacitor. The propeller type condenser fans shall be arranged for vertical discharge of the condenser air. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The wiring for each unit shall include: A crankcase heater (One per compressor). 1 24-Volt temperature control unit. High and low pressure cut-outs. Solid state compressor motor protection on units 10 ton and above. Low ambient controls to regulate condenser fan operation and condenser capacity to permit year round operation. The refrigerant piping for each system shall include a strainer-drier, a moisture indicating sight glass and service access valves. The strainer-drier and moisture indicating sight glass may be shipped loose in the unit for field installation. Evaporator Blowers The evaporator blowers shall be covered by a 1-year warranty, in current production with published literature available to check performance, limitations, specifications, power requirements, dimensions, operation and appearance and equipped with a drive package that is rated at least 25% above the required. HP, and will permit the blower ORM to be adjusted to meet the exact CFM requirement of the system. Each unit enclosure have a steel angle frame to provide the rigid support required for shipping, rigging and year of dependable operation, exterior panels of 18 gauge steel that have been bonderized and finished with baked enamel to provide a quality long lasting appearance. Removable panels to provide easy access to the internal components for maintenance and service, and a rack to accommodate 1” filters. The dimensions of each unit shall not exceed those specified on the plans. The blower motor shall be mounted within the isolated cabinet to minimize the transmission of sound to the surrounding space, and have a service factor of at least 1.15. The direct expansion coil shall consists of copper tubes arranged in staggered rows, mechanically expanded into aluminium fins, be draw-thru, and include factory mounted expansion valve(s). The face velocity across the evaporator coil shall not exceed feet per minute. The blower wheels shall be dynamically balanced to minimize the levels of sound and vibration generated by the unit. Acoustic insulation mats to be provided to minimize the sound level below each Fan Coil Unit.

MATERIAL ABOVE 3000 CFM SYSTEM DESCRIPTION Indoor, double skin packaged air-handling unit for use in commercial split systems. Unit shall have a multi position design and shall be capable of horizontal or vertical installation on a floor or in a ceiling, with or without ductwork. (Only vertical units are to be applied without ductwork.) QUALITY ASSURANCE a) Coils shall be designed & tested in accordance with ASHRAE 15 Safety Code for Mechanical Refrigeration (U.S.A.), latest edition. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



b) Unit shall be constructed in accordance with ETL (U.S.A.) and ETL, Canada, standards and shall carry the ETL and ETL, Canada, labels. c) Unit insulation and adhesive shall comply with N EPA-90A (U.S.A.) requirements for flame spread and smoke generation. d) Unit shall be manufactured in a facility registered to the ISO 9002 manufacturing quality standard. e) Chilled water coils shall be burst and leak tested at 435 psi (2999 kPa).

EQUIPMENT Double skin Indoor mounted, draw-thru, packaged air-handling unit 40RMS that can be used in a suspended horizontal configuration or a vertical configuration. Unit shall consist of forward-curved belt-driven centrifugal fan(s), motor & drive assembly, prewired fan motor contactor, cooling coil, 1-in. (25.4-mm) washable air filters, and condensate drain pans for vertical or horizontal configurations. Base Unit (Painted): a) Cabinet shall be constructed of zinc coated steel and polyester powder painted to protect them from corrosion. b) Cabinet panels shall be double skin fully insulated with 1/2 in. (12.7-mm) fire-retardant material. c) Unit shall contain PVC condensate drain pans for both vertical and horizontal applications. Drain pans shall have connections on right and left sides of unit to facilitate field connection. Drain pans shall have the ability to be sloped toward the right or left side of the unit to prevent standing water from accumulating in pans. d) Unit shall have factory-supplied 1-in. (25.4 mm) washable-type filters installed upstream from the cooling coil. Filter access shall be from the front of the unit. Coils: Coils shall consist of 4 rows minimum of copper tubes with sine-wave aluminium fins bonded to the tubes by mechanical expansion. Chilled water coils shall be rated for an operating pressure of not less than 300 psig (2069 kPa). Operating Characteristics: A one coil unit installed in a 2 pipe system shall be capable of providing cooling as determined by the operating mode of the central water supply system. Motor: a) Units shall be suitable for use with 400V-3Ph-50Hz electrical supply. b) Fan motor of the size and electrical characteristics specified on the equipment schedule shall be factory supplied and installed. c) Motors rated at (0.97 through 2.76 kW) shall have internal thermal overload protection. Motors rated at (3.73, 5.60, and 7.46 kW) shall be protected by a circuit breaker

15800-19.3 AIR COOLED CHILLER Refrigeration Units . GENERAL Each unit shall -

Supply and install where shown in the B.O.Q packaged type air cooled screw water chillers with at least two refrigerant circuits note each compressor must have its own circuit, having capacities as shown in the B.O.Q. Packaged chillers shall be completely factory assembled on a continuous structure steel base and shall be individually performance tested in the factory, as a complete assembly, at the job design condition. Test certificates shall be submitted for consultant’s approval. Chillers shall be Eurovent class A certified for high efficiency and shall comply with EC requirements for machinery, electromagnetic and pressure equipment directives.



T05-20/11/2013


-


Chillers shall be especially designed for operation on HFC-134a. Refrigerants containing CFC’s or refrigerant blends shall not be acceptable. Chillers sound pressure levels must not exceed 70 dBa at a radial distance of 10M from the sound source under free field conditions.

Equipment: -

Factory assembled single piece air-cooled liquid chiller, Includes two or more independent refrigeration circuits, power and control system. Each circuit equipped with a fully accessible twin screw compressors, an electronic expansion valve and a charge of ozone friendly R134a refrigerant.

Quality insurance -

The chiller shall be designed, manufactured and tested in a facility with a quality assurance system certified ISO 9001 and an environment management system certified ISO 14001. Thermodynamic performances shall be measured according to EN14511 and sound according to ISO 9614 standards and according to Eurovent Standard. All units shall undergo a complete run test in the factory before shipment. The chiller shall be CE marked and shall comply with the requirements of the following European directives: Machinery directive 2006/42/EC modified, Low-voltage directive 2006/95/EEC modified, Electromagnetic compatibility directive 2004/108/EEC modified and with the applicable recommendations of European standards European Pressure Equipment Directive 97/23/EC. Machine safety, electrical equipment in machines, general regulations: EN 60204-1, Radiated electromagnetic emissions: EN50081-1 Conducted electromagnetic emissions: EN 50081-2, Electromagnetic immunity: EN 50082

Performance -

The unit shall be able to start up with an evaporator entering fluid temperature up to 45°C The unit shall be able to operate as standard with an outside air temperatures from -10°C to 55°C and an evaporator leaving fluid set point between 3.3°C and 15°C Chillers must be rated to Eurovent class ‘A” at nominal conditions which means best energy efficiency in its class even for high ambient series chillers.

Compressors & motors Compressors shall be semi-hermetic twin screw type. All main components shall be fully accessible. Compressors shall be mounted on sliding rail and equipped with discharge gas shut-off valve for ease of service Compressor speed shall not exceed 3000 RPM Electric motor - Two pole motor cooled by suction gas with full stream 120 micron efficiency suction gas filter. - The motor shall be protected by an electronic board capable to prevent the following defaults: - Motor overheat by means of internal temperature sensors - Motor overload according to the current drawn - Loss of phase - Phase reversal D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



- Voltage dips Lubrication - External oil separator for each compressor with no moving parts , designed for 2100 kPa working pressure, - Oil separator shall include a temperature actuated heater and an oil level safety switch - Refrigerant system differential pressure shall provide oil return through 5 micron replaceable oil filter external to the compressor. Oil filter shall be equipped with service shut off valve for easy replacement Capacity control - Compressors shall be equipped with a capacity control slide valve capable to adjust the chiller capacity from 100 to 15% load. - Compressors shall start at minimum load. - Compressor capacity shall be microprocessor controlled to maintain the required chilled water temperature, and protect the motor against overload or the refrigeration circuit against high pressure cut out. - Low vibration & sound level - Compressor rails shall be mounted on rubber in shear anti-vibration blocks. - Compressor shall have a discharge gas muffler to dampen gas pulsation. - Compressor and oil separator shall have an acoustic enclosure with large access doors easily removable with 1/4 turn screws. Evaporator -

The unit shall be equipped with shell-and-tube flooded type evaporator. Independent refrigerant circuits shall be provided per compressor. The maximum refrigerant-side operating pressure shall be 2000 kPa and the maximum water side pressure shall be 1000 kPa. The evaporator shall be tested with pressurised dry. Water or oil pressure is not acceptable. The weld-free copper tubes shall be internally finned and expanded into the tube sheets. The evaporator shall be mounted on support feet with thermal bridge rupture Shell shall be integrally insulated with 19-mm thick polyurethane foam mechanically protected by factory fitted Aluminium cladding for external aggression (Mechanical & UV protection). The chiller shall have only one inlet/outlet water connections of VICTAULIC type connections to ensure mechanical decoupling between the unit and the hydronic installation. The evaporator shall be equipped with a water drain and a purge plug.

Air cooled condenser The heat exchanger will consist of multiple transversal V shaped coils to provide self protection. Each V will have an angle superior to 50° to ensure optimum air distribution. Each module shall have 2 coils and max two fans. Coils with integrated sub cooling will be entirely made of aluminium to limit galvanic corrosion and will offer a resistance to corrosion compatible with coastal or urban environments. Coil shall be mounted in a painted frame to reduce corrosion risk and shall be isolated from the Chiller frame by rubber insulating mount. The coil shall pressure test at 4400 kPa. Coils should have a thickness of 1 inch to generate low air pressure drop and offer reduced sensitivity to clogging. The fins shall be 0.1mm thickness and shall in rows protected by the coil rows from top and bottom. Fins shall be brazed to the coil from top and bottom in an automatic process in an oven to create sturdy coil/fins body. Manual brazing is not accepted. Coil shall be guaranteed for a period of three years. Condenser coil shall be easily cleanable using a high pressure cleaner up to 60 bar pressure rating. The condenser coils shall be leak-tested by helium gas detection. Fans -

The low-noise direct-drive fans shall be equipped with an impeller with 9 aerodynamic blades and a rotating shroud to ensure optimal leak-tightness between the blades and the fan mouth. The impeller shall



T05-20/11/2013


-


be a one-piece type and made of a corrosion-resistant composite material, and statically and dynamically balanced. The air shall be discharged vertically upwards. The fans shall be protected by polyethylene-coated steel wire grilles. Fan Speed shall not exceed 950 rpm The three-phase electric motors shall have class F insulation, IP 55 protection with a minimum efficiency of 80%. They shall have individual overload protection via a circuit breaker.

Refrigerant circuit component - Chiller shall have independent circuit for each compressor to provide maximum redundancy - Each refrigerant circuit shall include: discharge gas shut-off valve, liquid shut off valve, electronic expansion valve controlled by a stepper motor, liquid sight glass, filter drier with removable cartridge, refrigerant economizer controlled by an auxiliary electronic expansion valve and complete charge of both refrigerant and oil shall be filled in the factory. - Instrumentation and safety devices shall include : high-pressure safety switch, low pressure safety relief valve, low and high pressure transducers accessible without draining the refrigerant charge - The refrigerant circuit shall be factory leak tested with pressurized air and helium gas detection at 2500 kPa Unit frame: - Frame shall be made of U steel beam with hot dip galvanization or electrophoresis treatment completed with paint - Panels and electrical box shall be made of galvanised sheet steel with oven-baked polyester powder paint finish in light grey colour (RAL 7035) and be capable of withstanding a 500-hour salt spray test in accordance with the ISO 9227. Power and electrical components - Power requirement - The unit shall operate at 400 volts, 3 phases, 50 hertz (400 V ± 10%) without neutral. - Chillers with two compressors shall have single power connection and for chillers having more than two compressors shall have dual power connection to have electrical redundancy, ease of maintenance & small cable size. - Main disconnect switch with lockable handle for each compressor shall be provided at point of incoming.

-

-

Power and control cabinets Powder painted steel cabinet with hinged and gasket sealed doors. Power box doors shall be interlocked with main disconnect switch handle so that doors opening may not be possible without disconnecting power, but a special opening system should be provided to troubleshoot while power is on. Power cabinet includes: compressor short circuit and overload protection, fan and control circuit breakers Separate control cabinet for safe and easy access to control display. Each circuit must be protected with fuse. Each circuit must have control transformer. Each transformer must be protected with breaker at input and fuse at output. Compressor starter Motor starter shall be Wye –Delta type for minimum inrush current, Wye-Delta transition shall be managed electronically without electromechanical relays. Compressor motor winding should have two sensors one on line and one spare. The temperature of the refrigerant cooling motor winding should be managed by the microprocessor a sensor installed in the suction housing. Control transformer



T05-20/11/2013


-


The control circuit voltage should be 24 V maximum, supplied by a factory-installed transformer as well as 115volts for Y D contactors.

Unit control General - The chiller shall be equipped with microprocessor control, regulating all unit operating and safety parameters in order to optimise energy efficiency and minimise the risk of the refrigerant circuit shutting down due to a fault. Main control features: - Entering or leaving water temperature control by PID loop with equalisation of the compressor operating times and number of compressor start-ups, run hours of each compressor and machine as well. - Protection against excessive compressor cycling by auto adaptive control algorithm acting on the leaving water set point deadband. - Optimisation of the condensing pressure with a floating set point based on the outside temperature and the thermal load in order to limit power consumption. The Dynamic control provided by the processor through EXV, should control the suction super heat, discharge superheat, MOP (maximum operating pressure), cooler approach ( leaving water temperature – saturated suction temperature) , also in off cycle protecting the compressors against migration of liquid refrigerant in to cooler. - Control of one or two water pumps (standby pump) with run time equalisation and automatic changeover to the standby pump in case a fault occurs. - Periodic water pumps start-up when the unit is shut down in order to prolong the operating life of the mechanical pump seal. - Automatic compressor unloading when an abnormally high condensing pressure is detected to prevent the shutdown of the refrigerant circuit due to a high-pressure fault. - Master/slave control of two chillers operating in series or in parallel with run time equalisation. Display & key pad - 320 x 24 pixels touch screen display for easy access to all operating parameters. Icon driven menu for self intuitive navigation and display of full test message in English or other language Display data: Water entering/leaving temperatures, outside air temperature, compressor suction/discharge pressures and temperatures, chilled water set point, compressor operating times and the number of start-ups. Fan operating time, percent loading, compressor current, Quick test function to verify correct operation of compressor, fan , electronic expansion valve, probes and sensors for easy & fast commissioning Chiller diagnostics with last 50 alarm history for quick trouble shooting and 5 alarms current will be displayed. Chiller should have built in Black box and can store 6 alarms with selective readings 75 scan before trip and 5 after trip and processor stored 80 scanned data in the black box. Automatic operation - The chiller shall be equipped with a programming clock, permitting: On/off control Changeover to the second set point (unoccupied mode) Capacity or current drawn limitation - The control shall ensure the following operating modes: On/off mode based on the outside temperature Set point reset based on the outside air temperature or the return water temperature Remote control - The chiller shall include dry contacts permitting: On/off control D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013


-

-


Capacity or current drawn limitation (one stage) Changeover to the second set point (unoccupied mode) Integration of customer safety device The chiller shall include output contacts permitting: Signalling that the unit is ready to start Signalling the occurrence of a minor incident (alert relay ) Signalling the occurrence of a major incident (alarm relay) Water pump on/off control (single or dual pump with automatic changeover) The chiller shall be equipped with an RS485 serial port for remote control via a communication bus.

Chiller-visor System Manager - CSM (Controls) -

A factory-furnished, programmed, microprocessor-based controller shall be provided to supervise and optimize the operation of the individual Product Integrated Controllers (PIC) for each chiller. All application software actually performing the required control functions shall be factory-supplied with the controller and shall be pre-tested and pre-configured.

-

The networked chiller Product Integrated Controllers (PICs) shall interface with a Chiller System Manager (CSM) installed on the network. The CSM shall include software that allows dynamic interaction between the CSM and the chiller PIC(s) to create a complete chilled water plant system as described within this specification.

-

The CSM shall include inherent input and output capability. The input/output capability shall include as a minimum a combination of standard HVAC sensor inputs (5k, 10k, 4-20mA and discrete) an output to drive an alarm annunciator and/or alarm light, and two analog outputs for differential pressure control. Each analog input channel shall include an operator-adjustable sensor trim (adjustable to 1/10°F) and programmable low and high alarm/alerts, as applicable.

-

The CSM shall not interfere with the PIC’s stand-alone operating or safety algorithms but shall enhance the operation by providing the following inherent capabilities as a minimum: • Control of up to eight chillers (staged or rotary) of equal or unequal sizes • Enable/disable the chiller plant based on its internal time schedules, remote contact closure, analog temperature override, network command, or time schedule override • Chiller fault logic and automatic starting of lag chiller(s) • Automatic alarming and switching to backup sensors if any primary sensor fails • Diverse operator selectable chiller sequences including a sequence with a designated chiller to perform “feathering” functions • Algorithms that properly match the chillers with the load • Chiller inhibit timers • Bypass valve control • kW balancing and ramp loading • Demand limiting • Chilled water reset • Power fail restart.

-

The CSM shall contain factory-programmed software for the following types of mechanical systems: • Two to eight chillers with dedicated chilled water pumps and no secondary piping. • Two to eight chillers with chilled water pumps in a parallel arrangement and no secondary piping • Two chillers piped in series with a single chilled water pump and no secondary piping. • Two to eight chillers with dedicated primary (production loop) pumps and secondary (distribution loop) pumps piped in a parallel arrangement. • Two to eight parallel chillers, common primary pumps, constant flow (common constant speed secondary pumps), variable flow (two-way valves) with a differential pressure valve and bypass line • Two to eight parallel chillers, common primary pumps, variable flow (two-way valves), with a



T05-20/11/2013



differential pressure valve and bypass line. CSM Attributes -

The controller shall be powered from standard, off-the-shelf, Class II, 24-volt transformers. The controller shall be listed under UL916 PAZX (Energy Management), UL 864 UDTZ (General Utility Signaling), VDE, and CSA. Products shall be manufactured in a facility having a Quality System that is registered to either ISO 9002 or ISO 9001 Quality Assurance Standard. The controller shall be designed to be easily mounted in a standard NEMA 1 type enclosure without special rails or mounting hardware and as local and national code dictates.

-

The controller shall include a 365-day real time clock and watchdog timer diagnostic indicator provided by an LED. The watchdog timer shall reset upon power on and be resettable by software thereafter. Should the watchdog timer not be resettable during the timing period, it shall time out and set all outputs to their non-powered state. The LED shall illuminate solidly to indicate this failure. All configuration data will be stored in nonvolatile memory. The controller shall provide a minimum of two days data retention for the time clock.

-

The controller shall include the capability to provide a local interface for all operating values, alarms, etc., via a panel mounted, Local Interface Device. The controller shall also be capable of interfacing to a portable PC for configuring or altering the configuration, setting the address, performing uploads/downloads, etc., through a separate, additional RJ14 plug.

-

The CSM shall utilize common chilled water supply and return water temperature sensors wired to the CSM as its primary control sensors. An optional load return sensor shall be supplied if the I/O summary requires such or the sequence of operation requires the starting and stopping of equally sized chillers as a function of how much water is being bypassed.

-

The CSM shall monitor the status of each chiller’s present local/auto selector position, through network communications. Whenever the position is indexed to local, the PIC shall perform its stand-alone control functions. When the PIC is indexed to the local mode the CSM shall determine that the chiller is not available for chiller plant control and shall be bypassed by the CSM. When the mode is indexed to the remote position the chiller PIC shall have the following programs superseded by the CSM: • Lead/lag • Chilled water reset • Remote contact start • Demand limiting.

CSM Control Requirements -

Program Enable/Disable: The CSM shall have the ability to manually enable or disable its program by the operator through a point available on the points list screen. This point shall also automatically disable itself if an erroneous entry was made in the configuration. An alarm shall be generated whenever the program disables itself.

-

Lead/Lag Determination: The chiller start sequence shall be operator-selectable from the first chiller through the last chiller. The CSM shall allow the operator to select any of the following Lead/Lag sequences: • Fixed Sequence — The starting and stopping sequence is predetermined and fixed. • Diverse Sequence — Smaller chiller(s) are assigned to the beginning of the chiller starting order but as load increases the smaller chillers shall be stopped (after starting next stage of cooling capacity) and are automatically moved to the end of the starting order. • Diverse Sequence with Feathering — Chillers are assigned to a fixed sequence. One smaller chiller



T05-20/11/2013


•


shall be designated to be used as a feathering chiller in the start/stop sequence. The operator shall have the ability to have the CSM automatically select any of the above sequences based on outside air temperature, calendar date or both.

CSM System Requirements -

-

The CSM shall include the ability to rotate the chiller sequence while chillers are running. If the chiller sequence changes while the chiller(s) are running, the CSM shall start all required chillers before the unneeded chillers are stopped to prevent any interruption in the supply of chilled water to the facility. The CSM shall include the capability to automatically change the rotation based on runtimes and a rotation day and time entered by the operator. Occupancy: The occupancy status shall determine when to operate the chilled water plant. When occupied, the chiller plant shall be enabled and when unoccupied, disabled. Occupancy status shall be automatically indexed by any of the following factors: • System Force — A networked force (option module, custom programming in a field-installed controller, etc.) shall override the occupancy until it is autoed or forced to a different value by the operator. • Operator Override — The operator shall have the ability to override the unoccupied mode by entering an override value (0-1-2-3-4 hours) through any of the interface devices. If the timed override option is initiated during an occupied period, the time schedule shall remain occupied for the duration of the time entered. If the operator initiates an override during the unoccupied period, the time schedule shall be indexed to occupied for the duration of the value entered. • Occupancy Override — The CSM shall include the ability of monitoring a remote on/off discrete input wired to it. Whenever the switch is indexed to on, the CSM shall index itself to the occupied mode. Refer to the Input/Output Summary and/or the Sequence of Operation to determine if this input is required. • Water System Manager (WSM) — A WSM shall send an enable signal through the network to index the system to the occupied mode to satisfy the needs of the loads (i.e. Air Handler adaptive optimal start, terminal occupancy timed override). • Temperature Override — The CSM shall be capable of monitoring an analog input override sensor (thermistor, or 4-20mA) and shall disable the chilled water plant whenever the system has been indexed to the occupied mode and the override sensor is below its configured setpoint value.

-

Time Schedule Occupied: When the CSM time of day reaches the operator adjustable occupancy time the CSM shall be occupied. When the time of day reaches the unoccupied time the CSM shall be unoccupied unless one of the above overrides are initiated or a network command has initiated an override.

-

Pull-down Timer: This delay time shall allow the lead chiller a chance to cool down the building chilled water loop before starting the lag chillers during system start-up.

-

Chiller Faulting: A chiller shall be considered faulted if a fault status is reported to the CSM by the chiller PIC. Chillers having a communication failure (after the operator adjustable start time value has expired) shall be left in their last commanded state. Chillers faulted for any other reason shall be commanded off. All faulted chillers shall be automatically replaced, if applicable, to maintain on-line capacity.

-

Power Fail Restart: If the CSM loses power, it shall be capable of selecting one of two different recovery control schemes based on how long the power was off and whether the operator adjustable threshold time has been exceeded. If the power was lost for less than the threshold time, it shall start the chillers at one-minute intervals until the on-line capacity before the power failure is restored.If power was lost for more than



T05-20/11/2013



the threshold time, the configured pulldown timer shall be skipped and the chillers shall be started at the lag start delay time interval until the load has been satisfied. Chiller Inhibit Timers: Additional chillers shall not be started if the length of time remaining before the next unoccupied period is less then the input value entered by the operator to avoid starting additional chillers that will be turned off shortly. -

Start/Stop Delay Timers: The CSM shall include operator adjustable time delay values to prevent chillers from cycling due to short duration conditions.

-

Additional Cooling Required Algorithm (ACR): The starting of additional chillers beyond the lead shall be enabled if the following criteria are met: • When supply water temperature is used as the control criteria and the ACR temperature sensor is above the current chilled water supply setpoint, plus an adjustable delta temperature value. • When return water temperature is used as the control criteria and the ACR temperature sensor is greater then the current chilled water return setpoint plus an adjustable delta temperature value. • The pulldown rate is less than 0.5°F/minute for the running chillers. • Load Indicator Timer has timed out. (This operator-adjustable value is used by the CSM to determine how long the ACR load indicators must be true before an additional chiller is started). • New chiller inhibit timer is not active. (This operator-adjustable value is used by the CSM to determine how many hours before the start of the unoccupied cycle to stop performing the ACR load indicator tests). This shall help prevent the starting of a chiller that will have to be stopped shortly thereafter when the CSM becomes unoccupied). • The chiller(s) are not faulted, ramping, or in a power fail restart condition. • Resequencing is not occurring. The percent demand limit being sent to all running chillers is above a calculated value.

-

If the sequence of operation or the I/O summary requires a chilled water load return algorithm, the CSM shall determine the percentage of bypassed water based on an algorithm that calculates the mixing ratio of the supply, return, and mixed temperatures. The CSM shall compare this calculated value to a factory pre-configured % bypass value and turn on a chiller if the bypassed value is less than this pre-configured value and the effective capacity is the same for all chillers. -

An alarm shall be generated if the algorithm determines that an additional chiller is required to maintain setpoint and no chillers are available.

-

Reduced Cooling Required Algorithm (RCR): The CSM shall include a load target equation to determine when a lag chiller shall be stopped. The load target program shall calculate a RCR kW setpoint based on present chiller plant tonnage, capacity of the lag chiller to be stopped, operator-adjustable deadband to prevent short cycling and an operator-entered correction factor to compensate for non-linearities in the relationship between %kW and cooling capacity under low load conditions. If the average %kW for all running chillers is below the corrected RCR kW setpoint, plus the control temperature sensor’s value is below the setpoint including an adjustable delta temperature value, and the stop requirements for the delay timers are clear, the next lag chiller shall be stopped.

-

Chilled Water Reset: The operator shall have the ability to enable or disable chilled water reset. The operator shall have the ability to adjust the following as a minimum: • Reset sensor location and name • Reset start and stop temperatures • Reset ratio



T05-20/11/2013


•


Maximum reset amount.

-

The algorithm shall be capable of using the following sensors as the reset sensor: • Outside air temperature • Optional reset sensor • External reset input. • Upon loss of communications with the reset sensor, the CSM shall generate an alarm and shall utilize its configured control setpoint value.

-

If the WSM is active, this algorithm shall be automatically disabled and the WSM shall compute the amount of reset, if any, based on system cooling load it is also presently monitoring.

-

The chiller plant manager shall consist of web server operator interface. A web server shall gather data from chiller plant system and generate web pages accessible through a conventional web browser on each PC connected to the network. Operators shall be able to perform all normal operator functions through the web browser interface. Operators with sufficient access level shall have an ability to make changes to all system and equipment graphics in the web server in addition to having full chiller plant system access to make configuration changes to the control system. Any tools required for making graphic changes shall be provided with web server.

-

The Webserver shall have the ability to view and configure the trends, reports and alarms of chiller plant manager.

-

The Chiller plant manager shall be supplied by the chiller manufacturer.

-

The chiller plant manager has to control and monitor the chillers and associated chilled water pumps and cooling towers(Applicable in water cooled chiller application)

-

The chiller plant data shall interface with the BMS (Building Management Control System) via open standard BACnet/IP protocol for monitoring.

INSTALLATION Supply the services of a factory trained representative to supervise the installation, field testing, dehydration, charging and initial start up of each chiller. Adjust chiller in alignment on concrete foundations, sole plates and sub-bases. Level grout and bolt in place. Arrange piping for easy dismantling to permit tube cleaning. Provide suitable vibration isolation as recommended by manufacturer, in accordance with section 15100 and guaranteed to prevent transmission of vibration to building structure. Arrange for all power wiring to electrical equipment panel by Division 16. Provide all control wiring from unit to all remote control devices. Arrange for wiring between building management system and chillers. Supply initial charge of refrigerant and oil.



T05-20/11/2013



COMMISSIONING Notify Engineer two weeks in advance of commissioning date. Ensure that all chilled water systems are connected and that all pumps run and control valves open to provide maximum cooling load. Start up each chiller individually and check refrigerant pressures, chilled water pull down, oil pressure, condenser for operation and cycling. Check electric power, current draw at start up, running amps, voltage for each phase and power draw at 20%, 40%, 60%, 80% and 100% loads. Document all test results and have them certified by the Engineer. Test demand limit control. Noise level test and measurement. Test all UCM functions locally and at BMS. TRAINING PROGRAM Allow for two week training program of Employers staff on site. This program to provide the following: Understanding of the equipment supplied. Importance of daily checks and logging procedures. Operating Parameters. Preventive maintenance. Refrigeration circuitry. Water side circuits. Adjustments. Oil circuit. Changing oil. Charging Machine. Leak tests. Electric power distribution Controls and wiring. Safeties. Annunciator panel. Troubles shooting.



T05-20/11/2013



Re-commissioning/start-up procedures. TOOLS Sub-contractor to provide two sets of tools as provided and/or recommended by manufacturer and necessary to perform maintenance and service work including but not limited to: a. Wrenches, all sizes and types required to carry out preventive maintenance. b. Infra red refrigerant leak tester. c. Regulators for refrigerant and nitrogen. One set each complete with gas charging set and 10 metres hose. d. Pressure gauges, one No. of each type.

15800.20 CONTROLS AND INSTRUMENTS The Contractor shall supply and install all the control equipments, viz. duct mounted sensors, room thermostats for package unit, air conditioning units, split units, etc. The Contractor shall also provide wall mounted thermostat for modulating type VAVs as required in specification clause 11.15. 15800.21 Control Devices

Temperature Sensors Duct temperature sensors shall have their sensing elements immersed inside the duct and the wiring enclosure mounting on the outer surface of the duct and shall be of the averaging duct type with linear output and suitable for ambient limits -4 to 120 deg.C. Sensor shall be complete with a steel wiring enclosure with 1/2” conduit knockout (top and bottom) and a 1500mm long sensing element. Sensors shall be of corrosion proof construction. Sensing elements for water pipe mounting shall be of the rod and tube type with linear output and shall be furnished complete with separable stainless steel bulb wells filled with heat conductive compound. Sensor shall be factory calibrated and tamperproof. If easily adjustable sensors are provided, they shall be located inside metal enclosures with cylinder lock and key to prevent unauthorized setting. Room Thermostats Room thermostat shall have metal locking covers and shall be provided with concealed adjustment means. Each room thermostat shall be supplied with metal auxiliary mounting bases and metal sub-bases for surface mounting application, plus a plastic guard. Thermostat shall be of the low voltage self contained type with 1 1000 ohm sensing element and an amplifier. Thermostat shall have a control dial range 13-29 deg.C. and a throttling range of 1 deg.C. for a 3 Vdc output change. Automatic Controls Installation Central chiller plant control shall be provided for the sole purpose of electrical power economisation and humidity control of building. This shall be a programmed, microprocessor based controller to optimise the D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



operation of individual controller on each chiller and create a complete “Chiller Water Plant System”. This will be designed as chiller management system, to be supplied by chiller manufacturer. The features of the controller shall include the following: Control multiple chillers based on system load with control on each capacity step. The capacity control algorithm shall take into consideration the inherent part load efficiency of air cooled screw chillers with multiple compressors and provide chilled water at set temperature from the plant utilising least energy. The chiller plant control shall also be capable of carrying out a chilled water temperature reset on the main header temperature (i.e., lower header temp 5oC for average enthalpy over 31 BTU/Lb of dry air and a modulating reset to 8oC for enthalpy lower than 28 BTU/Lb of dry air). However, once the ambient temperature drops below 37oC, an overriding signal shall be provided to the controller to maintain the header chilled water supply temperature in the following manner: Four enthalpy sensors are to be installed in critical areas in the building and an output signal of 4-20mA shall be provided to the chiller plant controller on the basis of which the chilled water temperature is to be provided by the plant. Control the on/off operation of chilledwater pumps with periodic cycling facility. Enable chiller operation based on a timeclock that interacts with the chillers own time clock. In case of failure of any chiller, automatically switch another available chiller “on”. Allow chiller sequencing in any of the following modes: i) Fixed operator selected ii) Weekly rotating sequence iii) Runtime equalisation Demand limit the entire chiller plant to pre-configured level on receipt of external signal by contact closure. Reset chiller plant temperature based on external signal. This feature shall be based on enthalpy signal. Activate common alarm on receipt of alarm from any of the connected chillers. Chilled Water Pumps The chilled water pump control panel shall be complete with status and selector switches to enable selection of duty pump, as well as hand/off/auto facilities for each pump, run and trip lamps, all requisite relays, overload fuses, etc.. Periodic cycling and autochange over in case of pump failure shall be provided. Chilled Water Pressurisation Unit The panel shall be complete with starters, selector switches, run and trip lamps, fault indications for this unit, together with all necessary relays, overloads, fuses, etc. Chilled Water Treatment Plant The automatic chemical dosing plant shall be complete with its integral control panel with sensors, changeover and all necessary relays, volt free contacts etc. General Unless otherwise instructed by the Engineer the complete Automatic Controls Installation covered by this section shall conform to the requirements of: (i) Electrical Specification, Part 2, for this Project. (ii) The current edition of the Regulations for Electrical Installations with the latest amendments, issued by the Institution of Electrical Engineers.



T05-20/11/2013



(iii) The Electrical Regulations and requirements of ADWEA, Abu Dhabi. In case of any contradiction the more stringent shall be applicable. The Contractor shall be responsible for providing automatic control systems to meet the material, standards, and performance requirements of this specification. The tender drawings are in outline only. In certain instances and depending on the equipment selected, and their versatility or limitations, it may prove necessary to employ several items to fulfil the purpose of one item described in the specification. The Contractor shall be deemed to have included for all such items in his tender. The number, cabling requirement and size of all control equipment is not shown on the tender drawings to allow for variations between control manufacturers products selected for works. Any wiring to items of plant shown on the tender drawings is based on the equipment that was used in the formation of the tender scheme. In all instances where, due to the nature of the equipment and its associated system elements selected, the electrical rating is affected the Contractor shall be deemed to have included for all necessary variations in cable sizes, numbers of cores, etc. to meet the requirements of this specification. All control systems shall be of a type designed to maintain the specified conditions within the specified permissible tolerances. The response time of control systems shall be arranged to suit the response times of the systems They serve to avoid undue dynamic overshoot and ‘hunting’. All modulating valves, dampers and the like shall be selected to provide appropriate ‘authorities’. The Contractor shall include for all tests and the provision of all test equipment deemed necessary to meet the above requirements. The Automatic Controls Specialist shall be a Sub-Contractor to the Contractor. He shall design, supply and install the complete automatic controls installation except those elements specifically excluded in the following clauses. The Contractor shall remain responsible for the design specification, detailed development, inspection, testing and commissioning of the complete installation, notwithstanding that part of the work carried out by others. The automatic controls installation shall comprise all electric and electronic controls, actuators and sensing devices; all motor starter equipment and control panels; all medium and low voltage wiring, conduit and cable trays, together with ancillary items of equipment required to serve all the Mechanical Services installations specified, unless specifically stated otherwise hereafter. The Automatic Controls Specialist shall be responsible for the supply of all electric and electronic duct mounted or pipeline mounted control or sensing equipment to the Contractor for installation. The power supplies to the control panels shall be provided and connected to the appropriate terminals on the control panels and to the Automatic Controls Specialist’s detailed requirements. Automatic Control Equipment shall be solid state type with plug-in modular electronic controllers with proportional, integral and derivative action with individual adjustment of each controllers output forming the control sequence. The control equipment shall be fully protected against interference from high voltage or normal voltage electrical cable induction and against radio transmission interference or alternatively shall be inherently non-susceptible to any such interference. All control equipment shall require no preventive maintenance and shall be non-susceptible to drift. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Temperature, humidity and differential pressure controllers shall be compatible for providing voltfree contacts through alarm units to allow connections to be taken for indication/alarm functions. The automatic controls installation shall be a stand-alone system able to fully provide operational and environmental control of the installations. Testing and Commissioning Testing and commissioning shall be as detailed in the relevant clauses of electrical specification and shall be carried out in accordance with British Standards, CIBSE Commissioning Codes and the relevant section of this document in the presence of the Engineer, or his representative, on site and where requested at the place of manufacture. Throughout testing and commissioning the Contractor shall use properly calibrated and certified instruments and apparatus supplied by the Contractor. Where test parameters are not given results obtained equal to or better than the minimum standards set out in the British Standard shall be deemed satisfactory. The Contractor shall carry out final testing and commissioning on the completion of the whole installation. The Contractor shall forward to the Engineer certified copies of results obtained upon satisfactory completion of each test. A final test shall be carried out at the end of the Maintenance and Defects Liability Period to demonstrate satisfactorily to the Engineer that the installation is operating efficiently and that all components are functioning correctly. Control Panels and Control Panel Components General Control panels shall incorporate all the necessary equipment and shall be delivered to site complete with internal wiring, with all connections arranged within the panel in a neat, symmetrical and logical manner. The controls shall be arranged such that work may be carried out on any circuit in complete safety with all other circuits live and in service. All components shall be readily accessible for maintenance with the panel doors open and any component must be capable of being removed without the necessity of removing the panel doors. Construction Control panels shall be manufactured from best quality pickled and oiled mild steel plate to a minimum thickness of 1.65mm in a folded and welded construction. Back plates within panels, for fitting internally mounted equipment, shall be mild steel to a minimum thickness of 1.65mm, bolted to angle iron frame. Equipment shall be fitted using fixings such that back nuts are not required, however the use of selftapping screws shall not be permitted. Back plates shall be suitable for supporting all equipment within any section without visible distortion. Panel doors shall be flush fitting mild steel with folded edges and welded corners suitable for eliminating distortion and whip, to a minimum thickness of 1.65mm, and shall have concealed, non-ferrous, lift-off hinges. Panels shall be dust and damp proof enclosures generally to BS 5420 with suitable gaskets provided around doors and any removable covers. Gaskets shall be a foamed plastic, dust protective strip or neoprene tube sealing gasket.



T05-20/11/2013



Where panels require to be manufactured in more than one section, for ease of handling, etc. then each section shall be supplied with fully numbered interconnecting terminals and the price shall include for bolting up and wiring between sections on site after they have been positioned. Where the panel is to be delivered in sections and the load in any section exceeds 200A then the power connection shall be by means of copper bus bars. The bus bars shall be to BS 159, and their short circuit rating shall be compatible with the associated isolating switches and fuse switches. If the load is below 200A cable connections shall be acceptable. Bus bars shall be located in a separate enclosed compartment within the panel, and shall be PVC insulated. All joints in bus bars shall be accessible for inspection and tightening when the panel is in its final position on site. Panel construction shall be such that adequate provision is made for ventilation for internal heat dissipation and in no circumstances shall the internal temperature rise above 40oC. Painting and Finishing All surfaces of control panels shall be smooth and free from burrs, weld marks and sharp edges. After fabrication the panel sections shall be degreased and chromate etched before being sprayed with two coats of rustproof primer, then two undercoats followed by a final finish of two coats of epoxy resin paint, the final coat drying to form a hard semi-gloss finish. External panels shall be supplied painted internally with a matt white finish. Finishing colours shall be to the Engineer’s approval. Labelling Generally, labels, both internal and external, shall be in traffolyte material engraved to give black letters on white background. All labels shall be fixed with bright finish instrument head screws or rivets of the same colour as the label. In those cases where any item of equipment or section of panel is not deenergised when normal isolation procedures are followed, such items or sections must bear clearly visible warning labels engraved to give red letters on white background. Actual engraving details shall be subject to Engineer’s approval. Cable Entries Entry to the panel terminals shall be via bottom or top entry, removable, undrilled, non-ferrous gland plates. All plates shall be sealed against the ingress of dirt, dust and moisture. Plates shall be readily detachable for drilling purposes. All entries for cables shall be easily accessible and marked to correspond with the panel wiring diagram and diagram for external connections. Internal Wiring The main current carrying conductors of each main circuit from the incoming terminals shall be capable of carrying for one second without distress, the through fault current equivalent to the 3 phase short circuit of the system specified. The removal of insulation shall be carried out by the hot wire stripping method. Power Wiring (220 Volts and Above) All power wiring cables shall be PVC insulated cables and shall be coloured in accordance with the IEE Regulations to indicate different phases. All power wiring shall be kept physically segregated from all other wiring and the working voltage shall be indicated on the fixed portion of the associated terminal boards. Small Wiring (Control, Indication or Alarm Circuit)



T05-20/11/2013



The insulation of small wiring shall be PVC. All small wiring shall be black, except where cables are on differing voltages, where coloured bands shall be used in addition to the working voltage of the cables being indicated where specified. All small power wiring shall be physically separate from all other small wiring and the working voltage shall be indicated on the fixed portion of the associated terminal boards. Neutral Bar or Link A neutral bar shall be incorporated within the panel and shall be of sufficient size to allow each separate circuit neutral conductor to be connected by a separate terminal. Arrangement and Installation of Wiring All wiring shall, as far as possible, be grouped according to the circuits involved. It shall be run in insulated cleats of the limited compression type, flexible tubing, rigid steel conduit or plastic trunking and shall be taken to terminal boards mounted not less than 230mm from the top of the panel, as required. Sharp, tight bends shall be avoided. If it is necessary to bunch wiring, no bunch shall contain more than 12 wires. Back of panel wiring shall be arranged so that access to the connecting stems of relays, instruments and other apparatus is not impeded. Wires shall be cleated so that they can be easily checked against diagrams without removing cleats. All internal wiring shall be identified in the same manner as the internal wiring diagrams. The system of marking of cables shall be in accordance with BS 158. Cable Terminations and Terminals Each wire shall be separately terminated with an approved crimped terminal to suit the terminal used. All wires shall have numbered ferrules or sleeves at both ends. The ferrules or sleeves shall be of insulating material which, except where otherwise specified, shall be white and shall have a glossy finish. The ferrules or sleeves shall be unaffected by oil or damp. Characters shall be indelibly marked in black. Where internal wires connected to the outgoing terminals terminate their other end on apparatus with terminal identification different to the wire number, this identification shall be shown on a ferrule or sleeve of a different colour to the one indicating the wire number. Both ferrules and sleeves are to be clearly visible when wire is installed, and the wire number marking is to be fixed nearest to the terminal. This secondary cable identification must be shown on the wiring diagram. Wires shall not be jointed or teed between terminal points. Bus wiring shall be fully insulated and run separately. Terminals and Terminal Boards and Connections All terminals and terminal boards for small wiring shall have crimped type terminals, and for ease of maintenance shall be the snap-on type. For power wiring, terminal boards shall preferably be of the stud type, the studs for which shall be positively locked in position without the use of locknuts. Pinch screw terminal boards shall not be permitted. All connections shall be made on the front of terminal boards. Current shall not be carried through the board by the stud. Terminal boards shall have separate terminals for incoming and outgoing wires, and not more than two wires shall be connected to any one terminal. Twenty per cent spare terminals shall be provided within each section of the terminal assembly. Insulated barriers shall be fixed between adjacent terminals. The height of the barriers and the spacing between terminals shall be such as to give adequate protection whilst allowing easy access to terminals.



T05-20/11/2013



Terminals must be provided for the incoming main cable so that the cable does not have to be terminated straight on to the lugs of the main isolator. All terminals must be located so that they are accessible to straight screw drivers and no terminals may be located behind fixed panel work. No live metal shall be exposed at the back of the terminal boards. Terminals shall be provided for all spare cores of outgoing multi-cables. All terminal boards shall be shown on diagrams as they are fixed in service. Any terminal which may be alive when the panel is isolated from the supply shall be clearly identified. All terminal boards associated with circuits shall be provided with covers of transparent insulating material. Such covers shall be sectionalised so that groups of associated terminals may be exposed without uncovering the whole board. Circuit identification shall be fitted to the fixed portion of terminal boards and not to the loose covers only. Outgoing terminals connected to equipment with terminal markings different from the internal wires shall be indicated by a double sleeve or ferrule on the internal wires showing both numbers and in a distinctive colour. These shall be shown on all diagrams. An allowance shall be made on the length of each wire at all connections in order to permit the cutting off and remaking of unsatisfactory connections. Contactor Contactors shall be of the air-break type and shall comply with BS 775 and BS 587. They shall be of uninterrupted rating and of mechanical duty Class III and of Category A4 for a.c. contactors and D4 for d.c. contactors. All except smaller contactors shall be fitted with arc shields and magnetic blow outs. Contacts shall be of the self-cleaning type and easily renewable and the design shall be such as to prevent welding in. All operating coils of contactors shall be designed to operate on the control system voltage of the control panel, preferably at low voltage. All motor starting contactors shall be of the direct-on-line for motors up to and including 5 kW. For motors greater than 5 kW the starters shall be automatic star-delta type. All 3 phase motor starting contactors shall be fitted with phase failure relay to ensure that the motor is tripped out of circuit in the event of loss of any one of the supply phases. The phase failure relay shall be operative at and above 55% of the motor full load current. All motor starting contactors shall be fitted with either an overload relay, having adjustable trip settings with the maximum trip setting of 110%, or with a thermistor relay to operate in conjunction with thermistors built into motors. On DOL starters if the starting current is in excess of six times full load, a suitable means shall be provided to over-ride the overload devices during the start period. Both the phase failure and overload relays shall interrupt the main contactor coil circuit and shall be of the manual reset type. Contactor equipment in a control panel shall be so screened from adjacent units and current carrying parts that it is possible to carry out, in complete safety, work on its outgoing cable whilst other equipment in the panel remains live on load. Means of isolation shall be provided to isolate all primary supplies and secondary circuits to contactors, but means shall be provided to temporarily reinstate interlock or other circuits interconnected with equipment which is required in service whilst the contactor is isolated. Contactors used in motor control centres shall be of the withdrawable type to provide isolation of individual units. Withdrawable contactors shall move easily and smoothly and provision shall be made for rigidly locating the contactor in the service, isolated and test positions. Isolators for contactors shall be capable of breaking the stalled motor current of the motor controlled by the contactor, or in the case of a circuit other than a motor, the rated continuous current of the contactor at a power factor of 0.0-0.3. Other main current carrying parts of contactor circuits, excluding contactor isolating devices, shall be capable of carrying without distress a through fault current equivalent to the short circuit MVA specified, but limited in magnitude and duration by the cut-off characteristics of the larger size HRC fuse-link, which may be fitted in the equipment. Power Factor Correction Capacitors



T05-20/11/2013



All capacitors shall be supplied in accordance with BS 1650. The capacitors shall be of the totally enclosed, dry type or shall contain a non-flammable coolant such as chlorinated biphenyl or equivalent. Components shall be of welded sheet steel construction. Cable Entries A blank gland plate, shall be provided for cable entry. Compression type cable lugs shall be provided suitable for terminating the incoming cable.

Name Plates Each capacitor shall have a name plate clearly stating the rating, its serial number and the serial number of the motor with which it is to be used. The name plate shall state the period after switch-off before the voltage falls below 50 volts which shall be no longer than one minute. Unit Power Factor Correction for Individual Motors Electric motors rated at 1HP and above shall have capacitors to maintain a power factor of 0.9 lagging throughout the normal working range. The power factor correction capacitors shall be supplied and installed adjacent to each motor, being connected directly to the motor terminals. If the distance between motor and capacitor exceeds three metres, the motor shall be complete with a two section terminal box. One section shall contain the motor terminals, and the other section shall contain HRC fuses of the appropriate rating. If the separate distance is less than three metres, the HRC fuses can be mounted on the capacitor. The interconnecting cables shall have high temperature insulation. It should be noted that in no instances shall the capacitor rating in kVA exceed 85% of the no load kVA rating of the motor being connected. Relays All electric relays used within the control panels shall be interchangeable and, of the plug-in type with equal number of normally open and normally closed contacts, of ratings adequate for their operating duties. All relay operating coils shall be rated for continuous duty and protected by a common control circuit fuse. Control Circuits Control circuits may be 24 volt a.c. or d.c. or 240 volt a.c. single phase. Where control circuits are taken outside the panel 24 volt operation is preferred. Where the control system supply is used as low voltage a.c., a transformer shall be supplied of rating suitable for the control system load of the panel plus 20% spare capacity. The transformer shall be in compliance with BS 3535, Section D and shall be provided with an external label of approved type and size lettering. The primary voltage shall be either 415 or 240 as detailed with tappings giving 410-420/430-440 or 220, 230, 240, 250 respectively, and the secondary voltage (the control system voltage) at full load with rated primary voltage and load power factor of the system. The voltage regulation atthis power factor shall not exceed 10%. A continuous metallic screen shall be interposed between the primary and secondary winding. The screen, together with all non-current carrying parts, shall be bonded together and brought out to an external earth terminal together with either one pole of the secondary winding or the midpoint of the secondary wiring, depending on the system voltage. Where the control system is specified as d.c., the d.c. supply equipment is identified separately, or where the Contractor decides to use d.c., the Contractor shall supply the d.c. supply equipment and shall submit full details with his Tender. Indicator Lights and Alarms



T05-20/11/2013



Each motor starter in the control panel shall be provided with three associated indicator lights on the front of the panel, one green light to identify the running condition, one red light to identify stop and yellow light for trip conditioner any condition which causes the starter contacts to open other than a deliberate witching off of the starter. A blue “PANEL LIVE” lamp shall be provided. A neon control circuit fuse failed lamp shall be provided for each control circuit fuse. Orange coloured indicator lights shall be provided to indicate whenever a live feed out of the panel not controlled by a starter is on. Operation of any safety circuit shall be indicated by a red lamp. Indicator lights shall be of the 12 volt, low wattage, filament type. Glasses of not less than 20mm diameter shall be fitted. The indicator lamps shall be of enhanced bright with 240/12 v built-in transformer. Where indicator lamps are not immediately adjacent to their associated switches they shall be clearly labelled. Lamp test pushbutton shall be provided on each panel. Time Switches Time switches shall be the programmable, 7-day, 24 hour, digital type with 30 minutes intervals. The time switches shall have 100 hours reserve time. Selector Switches All selector switches shall be of the spring actuated type and it shall not be possible for the operator to leave them or hold them in mid-contact position. Where standby equipment is called for, a rotary selector switch with two “OFF” positions shall be provided. All motor control units shall be provided with a selector switch for “Hand/Off/Auto”. In the “Hand” position each starter must be capable of independent operation by the push-button on its own cover. The “Hand/Off/Auto” switch must make inoperative any alarm conditions associated with the circuit and must also switch off any existing alarm indications when put into the “Off” position, but all alarm conditions must remain operative in the “Hand” position as well as the “Auto” position. Where duty selector or sequence selection switches are required for other than standby these shall be detailed in the description of operational function. Interlocks Where external apparatus such as flow switches, pressure gauges, etc., are used in interlock circuits, the normal “Hand/Off/Auto” hand switch shall isolate these in the “Off” position and the circuit shall be arranged so that the operation of any one of these interlock circuits causes a shutdown of the plant in the same manner as switching the “Hand/Off/Auto” switch to the “Off”position. Isolators Each control panel shall be fitted with an isolator of rating such that it will be capable of carrying for three seconds without distress, a through fault current equivalent to the 3 phase short circuit MVA of the system specified. The utilisation factor of these isolators shall be AC 22 or AC 23. Should any current carrying metalwork not be isolated by the main isolator, it shall be permanently labelled “LIVE TERMINALS” and the voltage stated. Fuse Protection All fuses inside the panel shall be of the HRC type ASTA certified to BS 88. Control circuit fuses shall comply to BS 1362.



T05-20/11/2013



Fuse links shall be arranged in banks which shall be easily removable to facilitate wiring and connection and shall, where possible, be mounted on non-ferrous busbars of adequate cross sectional area and using back connection stems. Every fuse shall be clearly labelled detailing the circuit numbers and coloured in accordance with BS 5472. Each fuse and line link shall be fully shrouded. Below each bank of fuses shall be its relative neutral bar and connections to the neutral bar shall be made in the same order as the connections to the fuse-ways. Mounted in suitable trays within the control panel, the manufacturer shall supply and fit 10%, or a minimum of two, spare fuses of each size fitted in the panel. Miniature Circuit Breakers All miniature circuit breakers shall be rated to withstand the fault currents of the circuits they protect without causing any interference in any other protective device associated with the distribution system, at the same time, the design of the circuit breaker shall be such that it will protect the circuit for which it is intended and not cause or allow other protective devices to operate when fault conditions apply. Circuit breakers shall be in accordance with BS 3871 and as specified elsewhere. The fault rating for these MCB’s shall not be less than 6 KA. Earthing An earth bar shall be provided throughout the length of the panel and provision shall be made for connecting to this busbar from within the panel or outside the panel. Facilities shall be allowed on the earthing bar for connection of earth continuity conductors to remote equipment. Moving contacts such as hinges shall not be used for earth continuity within the panel and these must have a bonded loop fitted parallel with them. These earthing positions shall be marked with the International Earth Symbol. Drawings The control panel manufacturer must provide within the panel, a waterproof plastic container fixed to the inside of one of the access doors. Immediately after commissioning the Contractor shall place in this plastic container a complete set of panel internal wiring diagrams, external wiring diagrams, fuse charts, spare parts list, maintenance and operating instructions. These shall be related to the control panel and are additional to any record drawings called for elsewhere. Ease of Maintenance The equipment shall be constructed to facilitate maintenance. All parts subjected to heavy wear and which may need replacement in the course of normal maintenance shall be capable of replacement without major dismantling of other parts of the equipment. All specially fitted parts such as doors shall be clearly marked in relation to their housings to ensure that they cannot be inadvertently interchanged with other similar parts in the equipment. Component Labelling All components shall be labelled or otherwise designed to permit them to be readily identified on the circuit diagram. In the case of any small components which may be replaced as a unit in the course of maintenance, the labelling shall be on the equipment adjacent to the component. Indicating Instruments Instruments shall be “Industrial” grade complying with BS 89 and of approved manufacture. The instruments shall be of robust construction and enclosed in dust-tight metal cases arranged for flush mounting and securely fixed by an approved method. The instruments shall have 240o movement and the D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



maximum possible length of scale with a minimum dial size of 100mm. The scales shall be white, clearly divided and indelibly marked in black. The pointer shall have clear outline and the markings of the dial shall be to the approval of the Engineer. Ammeters indicating motor current shall be of the compressed scale type. All ammeters shall have the normal full load current of their associated circuits marked by means of a red line. A/C. instruments shall be of the moving iron type and d.c. instruments shall be moving coils supplied complete with associated shunts. Directly connected ammeters shall be limited to circuits of below 40A full load. Ammeters shall be capable of carrying rated current continuously without overheating, be suitable for operation without damage in association with the DOL starting of motors and shall withstand the passage of fault currents until operation of the main protective device. Ammeter scaling shall be such that normal full load current gives approximately three-quarters full scale deflection. All instruments shall be back connected and all metal cases shall be earthed. Approved means shall be provided for zero adjustments of the instruments without dismantling. All remote ammeters for AC circuits shall be current transformer operated. The method of securing current transformers in position shall be such that no undue pressure is executed on the windings. For each electric motor of 7.5 kW and above an ammeter shall be provided on the panel. Current Transformers Current transformers for the combined duty of over current protection, efficiency tests and for the operation of current measuring equipment shall comply with the requirements of BS 3938. Current transformers for the operation of the apparatus with which they will be associated shall, where appropriate, comply with the requirements of BS 3938. Current transformers shall be constructed so as to withstand the mechanical and thermal stresses set up by a short circuit equal to the full short circuit rating of the associated switchgear. The secondary windings of each set of current transformers shall be earthed at one point only. Each such connection to the earth bar shall be made through a removable link placed in an approved position. Current transformers shall be capable of withstanding for one minute without damage the effects of an accidental open circuit in the secondary circuit with full load in the primary. Temperature and Humidity Controllers Controllers shall be of the solid-state, electronic type suitable for operation on a 24v, 50 Hz. electrical supply. These shall be panel mounted with a plug-in construction suitable for flush or back plate mounting. Proportional, Integral and Derivative actions shall be selected for each application with individual adjustment of each controller’s output and dead bands forming the control sequence. Indication lamps on the face of the controller shall indicate the condition of the individual output signals and shall glow in intensity in proportion to the signal to the controllers shall also be available to be passed to modules shall have circuiting of the same accuracy class as the controller. Controllers together with the ancillary alarm and indication modules shall be selected to suit the control accuracy of the system under control. Where a manufacturer fails to meet the requirements of the specification they shall offer a voluntary alternative which shall be listed separately. The system components shall comply with all relevant DIN standards and the system including all components shall be in accordance to VDE. Cabinet mounting equipment shall be of the plug-in construction suitable for mounting on standard racks with locking screw to fix when mounted in place. Controllers shall have internal switches for selection of direct and reverse acting, direct and reverse re-adjustment and P, P + I, or P + I + D action as required. Controllers shall have single output 0-10v or 0-20v d.c. with current limiting at 20mA. Temperature and Humidity Sensors



T05-20/11/2013



Temperature sensors shall be of the resistance thermometer pattern or thermistor type. The sensor range shall be selected for each application to provide a large resistance and to allow veryaccurate temperature measurement with fast detection of temperature changes. Sensors shall be room, duct or pipeline mounted as indicated. The measuring range of all temperatures shall be as specified and shall provide a measuring accuracy compatible to that of the controllers. Humidity sensors shall be of the thin film capacitor or plastic strip type suitable for duct or room mounting as required. The measuring range shall be sufficient to cover the conditions required in service and shall provide a measuring accuracy compatible to that of the controllers. Sensor pockets shall be of the same material as the pipework into which they are fitted and shall be available in lengths ranging from 100mm to 400mm in length. Automatic Control Valves Modulating control valves shall be two way or three-way as specified on drawings for mixing or diverting applications. Valves shall be constructed from the various materials listed and shall be complete with flanged connections in accordance with BS 4504 and screwed connections in accordance with BS 21. A manual over-ride shall be incorporated in each valve to permit water balancing and temporary heating/cooling without the need to energise the controllers. Valve sizes below 65mm shall be screw type. The control valves shall be capable of providing the necessary turn-down ratio required for the specific control duty required in each application. A spring return shall be provided so that the valve shall fail safe to the closed position in less than five seconds on loss of power. Pressure compensation shall be provided within the valve so that difference in pressure between the valve parts shall not cause fluctuations in the valve position. All moving parts within the valve and actuator shall operate with minimum friction. The valves shall be materially suitable for operating with the fluid temperatures and fluid compositions in the pipelines on which they are placed. All automatic control valves shall be protected before all inlet ports by a common pipeline strainer, or by one for each port if necessary. Automatic Damper Actuators Dampers motors shall be of the direct drive type and shall respond to intermittent or continuous control signals. The stroke of the damper motor shall automatically be adjusted to accommodate the terminal of the damper blades. Maximum stroke time shall be no longer than two minutes unless specifically requested. Where indicated, switches shall be incorporated within the damper motor to provide interlocks to stop/start other items of equipment. On power shut down or release of control signal controllers shall automatically recycle. Differential Pressure Control Differential pressure switches shall be of the spring-loaded, diaphragm type with positive and negative sides of the diaphragm connected to either side of the element being measured. A difference in pressure on the diaphragm shall activate the contact of the sharp element. A voltfree, changeover contact shall provide an interlocking indication requirement. The differential pressure switches shall be suitable for operating in the pressure ranges encountered in service. Step and Proportional Power Controllers Step controllers shall be of the plug-in construction and shall consist of a baseplate and plug-in control unit containing all electronic components as well as time delay switches. The switching state of all step controllers shall be indicated by lamps on the front plate of the controller. The step controller shall convert the signals from the controllers previously described into independently adjustable, volt-free, two position, changeover outputs. As well as an adjustable starting point each relay shall be adjustable for differential and time delay. The action of each output shall also be selective so that the switching function is actuated by an increasing or decreasing input signal.



T05-20/11/2013



Proportional power controllers shall be used on electric heater batteries. On low loads up to a maximum of 20 kW controllers shall be of the mercury switch pattern with a rangeability of 150:1. On high loads controllers shall be of the thyristor type these controllers shall be used on low loads where greater accuracy is required. Flow Switches Air flow switches shall have a steel drip-proof enclosure with integral mounting plate and a stainless steel paddle and shall be capable of being mounted on top, side or bottom of duct, and the control point of the flow switch shall be adjustable. Liquid flow switches shall be suitable for use in water systems and can be used on liquids with temperatures as low as -30oC and as high as +130oC. The paddles shall be either stainless steel or phosphor bronze and shall vary in length between 25mm and 150mm. The flow rate control point shall be adjustable. Flow switches shall be VDE and SEV approved and both enclosures shall be to IP66 (DIN 40050 and IEC 144). Great care must be taken by the Contractor in selecting flow switches to suit the flow pattern in the duct or pipe and the flow rate in relation to the sensitivity of the flow switch; alternatively a pressure differential switch could be employed. It shall be the Contractor’s responsibility to ensure that flow switches will operate at the flow rates in the relevant pipeline and, if not, to provide an alternative method of flow detection such as Pressure Differential Switches. Tenderers must allow for this possibility in their Tenders. Time Clocks Time clocks of the digital pattern shall either be plug-in modular type or the DIN rail mounted type. The time clocks shall be distinguished by 12 freely programmable switching commands as well as day and week programmes. The operation of the time clocks shall be micro-processor supported and the shortest switching and programming time shall be one minute. The supply voltage shall either be 240v a.c. or 24v AC. The time clocks shall be compatible with the controllers previously described. Control Panel Wiring All wiring within the panel shall be in accordance with IEE Regulations for Electrical Installations. All cables shall be PVC insulated with 105oC insulation rating. Control Switches and Interlocks For the control of electrical equipment which operates independently an “ON/OFF” rotary snap switch shall be fitted on the front of the panel for each item of plant. Where plant operates dependently, e.g. an extract fan which should not run unless the supply fan is running, an “ON/OFF” switch shall be fitted for the master item and a “HAND/OFF/AUTO” switch shall be fitted for each item of dependant plant. The switch positions shall be clearly labelled to show which item of plant it controls. With a “HAND/OFF/AUTO” switch in the “AUTO” position the dependant item of plant shall start automatically when the master item is switched “ON” and shall operate automatically under the dictates of any controlling device. The operation of the switch to the “HAND” position shall over-ride any controlling devices except those which are necessary for the safe operation of the plant. Similarly the operation of a master switch to “OFF” with dependent plant at “AUTO” shall cause all plant to stop, in sequence where necessary. Emergency Stop and Isolation Facilities All items of rotating machinery, such as pumps and fans, shall have a mushroom type emergency stop button immediately adjacent and a separate or combined local isolating switch which shall be within reach of personnel working at that plant.



T05-20/11/2013



15800.22 VENTILATION FANS a) Construct all apparatus of materials suitable for the conditions encountered during operation. b) Where corrosion can occur, appropriate corrosion-resistant materials and assembly methods must be used including isolation of dissimilar metal against galvanic interaction. c) Where in contact with the air stream, isolation against erosion of flaking by a factory applied plastic or mat facing. d) Locate and arrange motors, filters, and other components and accessories so that they are accessible for repair maintenance and replacement. e) Locate and arrange motors, filters, and other components and accessories so that they are accessible for repair maintenance and replacement. f) Mount grease fittings directly on bearings unless the latter are not readily accessible. Where equipment bearing are not visible or are inaccessible, provide easily accessible extensions to bearing lubrication fittings. g) Thoroughly clean the entire system before installing fitters or iterating the fans. h) On systems containing filters, install filters and permanently seal the filter frames air-tight before operating the fans. The Contractor, at his own expense, shall replace all dirty filters before turning over the system to the Employer.

15800.22.1 Small Extract Fans The Contractor shall supply and install all fans as indicated on the drawings. Unless otherwise specified these shall be of the cabinet, centrifugal type and shall be selected with particular attention to low noise levels. Electrical connections shall be via plug in type connector and a short length of heat resisting flexible cable connected to an adjacent flex outlet plate supplied and installed by others. All such fans shall be supplied with automatic non return dampers. Alternatively approved duct mounted dampers may be installed providing adequate access to the dampers is provided. 15800.22.2 Axial Flow Fans The Contractor shall supply and install all fans as indicated on the drawings and detailed in the schedules. Axial flow fans shall have long type casing with facilities for external lubrication and shall be direct driven with the motor in the air stream except where indicated. All fans shall be of the airfoil type which shall be statically and dynamically balanced prior to dispatch from the works. All axial fans shall run at a maximum speed of 1400 R.P.M. and be resiliently mounted. All final pressure drop calculations shall be submitted with the full fan details at the approval stage and before ordering. Motors shall be single speed and suitable for ambient temperatures of 50 deg.C with class F. 15800.22.3 Dual Fan Roof Extractor Supply and install Dual fan roof extractor as shown on the drawings to suit the duties given on the equipment schedules. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Unit shall be curb mounted on the roof with a base intake spigot. Continuous operation shall be ensured by an automatic control panel which provides change-over to the standby fan due to any event of failure of duty fan. The panels shall be incorporated into central unit to be located in the roof plant room and casing shall be constructed from heavy gauge aluminium. Each cased centrifugal fan shall be powered by a ball bearing motor and V-belt drive. The approximate static pressure will be 0.4 inch of water, however exact static pressure shall be proposed by the Contractor when exact routing of duct installation are finalized. Generally all roof units exhaust system shall be supplied complete with the following optional equipment: • • • • •

Run and standby motors suitable for automatic changeover. Automatic shutters. Protection guards. Isolating switch. Motors with class ‘F’ insulation. Where motors cannot be supplied with class ‘F’ insulation, the Contractor shall submit for approval a comparable standard of isolation.

15800.22.4 Wall Mount Fan Ring frame in steel sheet. AC/A with shaped cone only on inlet side; AC/B with shaped co neon inlet and outlet side. Protected against the atmospheric agents by epoxy paint. Axial impeller with aerofoil profile blades in glass reinforce polyamide and die-cast aluminum hub, balanced according ISO 1940. Variable pitch angle in still position with setting means. Execution 4 (impeller directly coupled to motor shaft). Air flow from motor to impeller. Inlet protection guard in steel rod directly welded on the ring frame, according to UNI12499norm. Asynchronous three-phase or single-phase motors according to international standards IEC 60034, IEC 60072, EMC 2004/108/CE,LVD 2006/95/CE, CE marked, IP 55, class F. Service S1 (continuous working to constant load) Maximum pole for motor should be 6/8 Pole and sound pressure level in Db(A) shall not exceed above 48.0 at 3mtr distance. Efficiency of fan shall be minimum 60%.

15800.22.5 FILTER Filter - 2” Cleanable a. Filter media shall be aluminium wire mesh enclosed in a galvanized or painted steel enclosing channel with drain holes for drainage during cleaning. b. Efficiency of the filter shall be 78% at 2m/s, pressure drop across the filter shall be 25 pa W.G. when clean at 2.8 m/s air flow. c. Provision shall be made for easy removal of filters for cleaning.



T05-20/11/2013



15800.23 DUCTWORK • • • • • • • • • • • •

Duct bracing and supports indicated are the minimum acceptable. Install additional bracing or supports to eliminate any distortion or vibration when the systems are operating or under tests. Where hanger rods for ducts, piping or equipment must pierce ducts, provide closure plates fitted around the rod and riveted or welded to the duct used I conjunction with duct sealing compound to make an airtight seal. Make all connections between ductwork, including flexible connections, fittings and equipment with gradually tapered transition fittings. Provide access doors in ducts at all fire dampers. Construct ductwork and casing joints square with all sharp edges removed. Support and brace sheet metal rigidly to prevent vibration. Install duct, casing and hangers straight, plumb and level. Route ductwork directly with a minimum of directional changes and abrupt transitions Provide adequate space around ducts to assure proper support and to allow the installation of the insulation specified. Install diverting vanes at branches connected into the main duct without a neck. Provide fairing where pipes or structures must penetrate ducts. When fairing is longer than 60cm maintain the original velocity. When fairing is shorter than 60cm the velocity may be increased by not more than 10 percent. Furnish test wells made-up of a brass nipple welded into the duct or casing and a cap on the downstream side of each coil and fan. Provide turning vanes in elbows whose centre line radius is less than 150 percent of the duct width or where indicated on the drawings. 15800.23.1 Protection & Cleaning • During construction cover all upon ends of ductwork with one layer of canvas. • Remove all foreign materials and clean the duct inside and outside. • Clean ducts before operating fans and filters. Never operate fans unless filters are installed. After tests, wash cleanable filters and replace renewable media. 15800.23.2 Dissimilar Metals • • •

Separate connections between dissimilar metals by dielectric insulation. Make joints between dissimilar metal duct sections with companion flanges separated by a compressed asbestos gasket. Construct all nuts, bolts, screws and other hardware used in the sheet metal construction of materials identical or similar to the duct material to prevent galvanic corrosion.

15800.23.3 Welding Of Ducts • • • •

Make all welds free grease, rust, oil or other foreign substance. Use welding electrode in accordance with the specifications for corrosion-resisting chromium or chromium nickel steel covered welding electrodes ASTM 298-55T, or approved equal. For ductwork lighter than 18 gauge use filler rods in accordance with specifications for brazing filler metals ASTM B260-AWS 5.8, or approved equal. Do not through the ductwork. For galvanized ducts, after welds are completed and tested, apply one coat of Socony 13F-2330 Zicote Grey Primer. After properly preparing the surface supply one coat of Socony 11-A-19 structural aluminium paint or approved equal to each joint.

15800.23.4 Flexible Connections



T05-20/11/2013


a. b. c.


Install airtight flexible connections where ductwork connect fans. Fasten connections securely with bolted clamps. Make the unclamped portion of the connection not less than 15cm long, crimped for flexibility. For fans to 1250 pa w.g. Static Pressure : 570 grams chemically impregnated fire retardant canvas. Use the flexible connection to break direct sheet metal contact and to correct small misalignments. Do not use flexible run outs in place of elbows and/or fittings. Changes in direction shall not be more than 90 degrees made with gradual sweep. Limit the flexible connection length to 120cm maximum.

15800.23.5 Ductwork a. b. c. d.

e. f. g.

h.

Supply and install as shown on the drawings galvanized sheet steel ductwork complete with all necessary bracings and supports, all in accordance with NFPA 90A. Galvanized sheet shall be of G90 coating designation within ASTM A525-75 standard specification for “steel zinc coated by hot dip process”. The minimum weight of coating on both sides of duct shall be 275 g/m2. Gauge, joints and bracings for sheet metal ductwork shall comply with ASHRAE and SMACNA standards. Duct gauges shall be in general as follows: upto 200mm : Gauge 24 225 600mm : Gauge 22 625 1200mm : Gauge 20 1225 1800mm : Gauge 18 Un-insulated ducts larger than 450mm shall be cross broken. Duct section of 120cm may be used with bracing angles omitted, instead of 240cm lengths with joints indicated. Changes in section of ductwork shall be effected by tapering the ducts with as long a taper as possible. All branches shall be taken off at not more than 45 deg. angle from the axis of the main duct unless otherwise approved by the Consultant. Connections between suction and discharge ductworks and air-conditioning units or fans shall be made with best quality heavy canvas having an overall length of 15cm Furthermore, heavy canvas connection shall connect ducts across structural expansion joints. All ducts shall be sealed in accordance with ASHRAE standard 90 and SMACNA low pressure duct construction standards.

15800.24 FIRE DAMPERS a) Supply and install fusible link fire dampers wherever required. Dampers shall be of steel plate, mounted to turn freely in steel plate frame inserted in the duct. Dampers shall be proportioned and weighted to close at once if released from a link with spring catches and shall stay closed until manually reset. Standard fusible links normally holding them open, but releasing upon contact with fire shall be provided. Dampers and frames shall have suitable peep holes. b) Single blade dampers upto 450mm in any direction shall be no. sixteen (16) gauge. From 475mm to 900mm in any direction they shall be no. twelve (12) gauge. Above 900mm in any direction they shall be no. seven (7) gauge. c) Blades shall be outside air stream. 15800.25 HANGERS FOR DUCTS



T05-20/11/2013



Supply and install steel work necessary for the support of the ductwork. Hangers shall be adjustable and spaced not more than 2.1 meter apart, and at all changes of direction. Two types of hangers shall be used. − U bar hangers shall be used on ducts with greatest dimension below 500mm. − Two threaded bars and bottom support angle for ducts greatest dimension − 500 or above. 15800.26 AIR OUTLETS Seal all outlets around the edges to prevent air leakage. a. b. c.

Diffuse supply air with no air velocities in excess of 0.25 m/s 1.8 or less above the floor line. Mix room air with the primary air by induction to effect subsequent equalization of the room temperature without stratification. Where supply or return outlets are installed in continuous line, omit intermediate frames and margins, Provide guides for each element to keep adjoining length aligned and butted without breaks. At corners, niter and align the adjoining lengths. Outlets shall be finished with a color approved by the Engineer.

15800.27 AIR DIFFUSSERS - GENERAL Diffusers shall be of the diffusion and air mixing type. Diffusion shall be effected without objectionable air motion at a point within 1.8m above the floor line. The specified discharge volume shall be diffused at a noise level of not more than 40 decibels. Room air shall be mixed with the primary air to effect subsequent equalization of the room temperature and prevent air pockets. Each diffuser shall be provided with a throat damper and arranged to balance air quantities. In addition equalizing deflectors shall be installed on all air diffusers with concealed stay rods. Diffuser shall not project appreciably below ceiling or duct. All air outlets are to be powder coated to a finish as approved by the Engineer. Supply and exhaust diffusers, registers and grilles shall have opposed blade damper. 15800.28 CELING MOUNTED SUPPLY/RETURN LINEAR DIFFUSERS The Contractor shall supply and install, in the locations shown on the drawings, supply and return linear diffusers. The slot diffusers shall be suitable for horizontal discharge by the adjustment of the blades. The diffusers shall be the constructed of extruded aluminium with the front face etched and clear lacquer finished, the rear section matt black finished The supply diffusers shall be supplied with galvanized mild steel plenum boxes shall be 81x 300 x 900 or 1500mm long. Supply diffusers shall have opposed blade damper. Ceiling diffusers supplying precooled outside air to those rooms which are also provided with fan coil units shall of the jet and diffusing type of air outlet. The direction of the three-way valve as desired, i.e. jet, diffusion and shut. The diffusers shall be fabricated fro thermosetting which is non-flammable, directionally stable and has a high resistance to cracking and blemishing. A metal back plate shall be provided for each diffuser. The inlet spigot sizes shall be as shown on the drawings. The diffusers shall be provided with a hit and miss volume control, grid pattern air straightener and air deflection blades. The plenum boxes shall be internally isolated with 13mm thick acoustic material for noise control. The internal lining of the units shall not relive the Contractor from his obligation to place external thermal isolation in accordance with this specification.



T05-20/11/2013



The diffusers shall be connected to the ductwork system by flexible ducting sized to suit the diameters of the entry spigots. The selection shown on the drawings is for quotation purposes only and the Contractor shall check the air performance of the diffusers prior to placing any orders. The selection shall be based on the ceiling heights shown on the drawings and an air temperature differential (room to air supply) of 10 degrees C. The noise rating in NR for a horizontal projection supply linear diffuser of 2 slots and 1700mm long shall not exceed 29 NR when supplying 100 litters per second per active meter. The pressure drop with the damper in the 100 percent open position shall not exceed 40 Pa for the supply air. 15800.29 CEILING DIFFUSER a) Diffuser shall be square, for way air patterns, anodized aluminium, with flange for surface mounting on ceilings or exposed ductwork. It shall have multiple flared discharge members and circular inlet neck, providing an even discharge air pattern, combining draftees air diffusion, 25% aspiration and secondary air motion, supply diffusers shall have opposed blade damper. The inner assembly of the diffusers shall be attached to the other assembly by means of a spring lock permitting assembly and disassembly without the use of tools. The diffuser shall provided with equalizing deflector and volume dampers or the splitter of louver type. b) The diffuser shall be capable of delivering air for cooling at 11 degree C. below room temperature without objectionable conditions with the spaces served. 15800.30 REGISTERS a) Register shall be constructed of extruded anodized aluminium, and shall be of the double deflection type with individually adjustable horizontal face bars and vertical rear bars. b) Register shall be equipped with a vertical opposed blade, key operated damper assembly. 15800.31 FRESH AIR EXHAUST DISCHARGE LOUVERS a) Contractor shall supply and install where shown drawings and whenever necessary louvers for fresh air intake, and for exhaust. They shall be anodized aluminium. b) Louvers shall be waterproof, with fixed blades set at 30 and shall have free area of 85%. c) Louvers shall be furnished with 1/2” (13mm) mesh-bird screen secured in removable extruded aluminium frames. d) Fresh air louvers shall be with opposed blade dampers and cleanable sand trap. 15800.32 DOOR GRILLES a) Contractor shall supply and deliver door louvers to the door manufacturer for installation. They shall be sized so that face velocity does not exceed 250 fpm (113m/s). Louvers shall be extruded aluminium completely light proof V-section with double frame. 15800.33 NOISE ATTENUATION The Contractor shall supply and fix acoustic insulation and noise attenuator units where necessary to reduce the air borne noise transmission through the distribution duct system, so the specified noise criteria levels are satisfied. a) Attenuator Units D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The attenuator units shall be inserted in the ducts where they pass through the mechanical room wall, the gap between the wall and attenuator being packed with felt to form an air tight seal. However where this is not possible, the attenuator shall be fitted in the duct between the fan and the mechanical room wall with the duct between the silencer and the wall acoustically lagged to prevent noise re-entry. Attenuators shall consist of attenuator splitters which are assembled in one attenuator casing. Splitter case shall be made from galvanized sheet steel absorption material moisture repellent and abrasion proof up to approx. 18 m/s air velocity, control plates on surface of splitters is made from galvanized steel sheet. Sound attenuator casing shall be made from galvanized sheet steel, with pre-drilled angle flanges. Attenuators or splitters of large cross section or length can be manufactured in modular section as required for ease of site handling. b) Internal Acoustic Lining Of Ducts Furnish and install internal lining wherever shown on drawings, 3.0m from mouth of all A/C unit minimum. Where it is possible to achieve the required attenuation by lining the interior of duct runs, this may be accomplished by applying one inch thick lining to the inside of the ducts. Lining rectangular ducts shall be semi-rigid fibrous glass and blanket with special surface treatment and for apparatus casings, large pickups, and masonry air shafts shall be rigid coated fibrous glass board. Acoustic insulation shall be suited to the atmosphere in which it is to operate, and shall be incombustible or self-extinguishing non-flame spread grade, vermin proof and adequately fixed to ducting or mechanical room walls. Linear density shall be 24 Kg/m3 and shall comply with NFPA requirements. Acoustic insulation shall be suited to the atmosphere in which it is to operate, and shall be incombustible or self-extinguishing non-flame spread grade, vermin proof and adequately fixed to ducting or mechanical room walls. Linear density shall be 24 Kg/m3 and shall comply with NFPA requirements. Surface to be lined shall be covered 100% with a fire retardant adhesive. Mechanical fasteners on 150mm centres on all duct surfaces shall used. 15800.34 CONDENSATE PIPES All condensate piping and fittings shall be insulated UPVC to BS 5414 with solvent weld joints, and shall be insulated as specified with cellular neoprene throughout including chased in walls. Condensate piping on roof, in service rooms and anywhere subject to mechanized damage shall be galvanized steel, heavy duty and insulated with 1/2” foam rubber insulation, 60Z canvas cloth and aluminium cladding. 15800.35 INSULATION AND LAGGING Insulation and vapour seal shall be provided on all cold surfaces to ensure that condensation does not occur. The thermal conductivity of the insulating material shall not exceed 0.034 W/m degrees Celsius at a cold surfaces temperature of 10 degrees Celsius. Insulation over access doors and test holes etc. shall be easily removable. Insulation shall be continued through walls and roofs etc. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Surfaces to which adhesives are applied shall be cleaned prior to application and any materials losing their adhesion shall be completely removed and replaced. The insulation shall be carried out in manner approved by the Engineer and the Contractor shall take adequate steps to protect all adjacent surfaces and equipment from damage or soiling. All superfluous materials and refuse shall be removed from the site, both during the progress of the works and after completion. This insulation shall be carefully cut to fit all bends, flanges etc. with the minimum number of joints shall be sealed with an approved filler. The Contractor shall cut open the insulation, if so instructed by the Engineer for inspection and approval, and make good as necessary after inspection has been completed. The complete installation shall present a uniform and symmetrical appearance to first class trade standards. All recommendations of the manufacturers in relation to use of materials, vapour seals adhesives etc. shall be complied with in full. The Engineer will reject any materials or workmanship which do not, in his opinion, fulfill the requirements of this specification. 15800.35.1 Ductwork Exposed To Outside Air Conditions & Within Plant Rooms All conditioned supply and return air ducts shall be thermally insulated with 50 mm thick mineral or glass fibre rigid slabs, with a minimum density of 64 Kg. per cubic meter. The material shall be properly secured using adhesive and mechanical fittings, to prevent deflection under its own eight. The corners of the insulation shall be reinforced with 50mm by 50mm by 0.6mm thick aluminium angle, pinned to the slabs. The whole of the insulation shall then be vapour sealed by two brushed coats of foster on canvas cloth to provide a maximum composite water vapour performance of 1.0 per m. 15800.35.1 Ductwork Exposed To Outside Air Conditions & Within Plant Rooms The supply and return air ductwork system inside the plant rooms and the exposed areas of roofing shall also be provided with 0.5mm thick covering of aluminium sheeting. 15800.35.2 Inside Air Conditioned Spaces Insulation against damage and sealed with approved sealant. The material shall be properly secured using adhesive and mechanical fittings, to prevent deflection under its own eight. The corners of the insulation shall be reinforced with 50mm by 50mm by 0.6mm thick aluminium angle, pinned to the slabs. The whole of the insulation shall then be vapour sealed by two brushed coats of foster on canvas cloth to provide a maximum composite water vapour performance of 1.0 per m. Air supply, return, exhaust and fresh ductwork inside the ceiling voids and service shafts, including the external surfaces of plenum boxes, grilles and diffusers, shall be insulated with 25mm thick insulation with a minimum density of 48 Kg/m3 and vapour sealed as in specified in clause 11.17.a above without the aluminum or galvanized sheeting. 15800.35.3 Piping Insulation Condensate and all the refrigerant suction pipes with fittings and valves shall be insulated with flexible formed closed cell elastomeric tubular type, moulded in cylindrical form to fit snugly. One piece construction with a maximum K-factor of 0.043 W/m deg. C at a mean temperature 24 deg. C. Condensate and all the refrigerant suction pipes with fittings and valves shall be insulated with flexible formed closed cell elastomeric tubular type, moulded in cylindrical form to fit snugly. One piece construction with a maximum K-factor of 0.043 W/m deg. C at a mean temperature 24 deg. C. Refrigerant pipes 25mm thick Condensate pipes 20mm thick D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013


Chilled Water Pipes


i. ii.

Indoor 25mm Outdoor unit 50mm

Insulation shall then be wrapped with canvas cloth and 2 coats of approved foster thus making a vapour barrier. PPipes passing through floors, wall or ceilings etc. shall be fully insulated and pipe sleeves and duct frames shall be sufficient size to accommodate the insulation. Any external insulation, exposed, shall be weather-proofed and shall be protected by aluminium cladding at least 0.5mm thick. 15800.36 SERVICE PANEL Demountable service panel in either wall or false ceiling shall be provided at all locations requiring any maintenance work A/C, electrical or plumbing items. The locations shall be as fixed by the Engineer. The finish of the panel shall be the same as the adjacent wall or ceiling. 15800.37 AIR HANDLING UNITS: Manufacturers of air handling units shall have the following certifications as a proof of quality assurance: - Manufactured in facility registered to ISO 9001:2000 / EN ISO 9001:2000 / ANSI/ASQC Q9001:2000 - Air handling units with below mentioned minimum Eurovent certification is acceptable: - Mechanical Strength Class D1 - Casing Air Leakage Class L3 - Filter By-Pass Leakage Class F7 - Thermal Transmittance Class T3 - Thermal Bridging Class TB2 - Eurovent certification shall be provided/checked on the website as confirmation that such certification is applicable on the date of submission. - Non Eurovent certified units or Eurovent rated units are not acceptable - Airtight seal material meets NFPA 90A requirements for flame spread and smoke generation - Casing sheet metal to withstand 1000-hours salt spray exceeding ASTM B117 - Air filters performance according to ASHRAE Standard 52-76 or EUROVENT Standard 5/6 - Electric Heater Heating Elements manufactured accordance to NEC and UL Space Heating Standard No 1996 - Fan performance tested and certified to DIN and AMCA Standard - Standard EFF2 fan motor manufactured to confirm IEC Standard (optional EFF1 motors with UL listed). - Product of manufacturer regularly engaged in production of Air handling units and supplied in UAE for more than 10 years. 15800.37.1 GENERAL REQUIREMENTS: Air Handling Units casing construction should be fabricated from highest grade galvanized steel G90. Construction of panel and frames are folded to form sturdy Side/Top/Bottom panels within a rigid structure “Penta-Post” profile frames. The construction should serve thermal protection, reducing machine noise, absorbing vibration and avoiding air leakage. Modular sizes of panel and penta-post should be easily assemble and reassemble. 15800.37.2 Air Handling Unit must include: 1. 2. 3. 4.

Supply Fan sections with centrifugal, airfoil Backward inclined fans DWDI design, as specified. Motor shall be suitable for Variable frequency drive operation (NEMA MG-1) where applicable. V-belt drive and door guard. Cooling coil section with SS304 condensate pan.



T05-20/11/2013



5. Bag filters section with filters. 6. Flat filters section with filters. 7. Access doors into fan section, coil section and mixed air sections. 15800.37.2.1 Following items are required to be added if specified in design equipment schedule: 1. Extract/Return air Fan sections 2. Heat recovery section 3. Horse Shoe Heat Pipe pre-cool and reheat 4. Mixing box section with low leakage dampers. 5. Empty Section with access door after Heat recovery Section. 6. UV-C Emitters Section The space available for the units shall be confirmed with civil and architectural proposals of the main contract and size of units shall be selected to fit into the space available. 15800.38 CASING AND FRAME STRUCTURE CONSTRUCTION: 1. Each assembly shall be of compact construction and shall consist of a rigid metal framework with insulated double skin sheet metal panels. All sections shall comprise a heavy duty framework formed from hollow rectangular sections mild steel tube of preformed pressed steel Penta-post. Cross members and Carrier rails should be of the same section to provide the maximum rigidity and strength. 2. Double skin construction and sandwiched with superior polyurethane insulation between the panel interior and exterior skins to furnish compressive strength up to 30 psi shall be Tested for a strength at ± 2500 Pascal with deflection < 2 mm/m and without permanent deflection, confirmed to EN 1886 Class D1(=2A). 3. The frame shall hold a 50-mm double skin casing wall with panels, doors, inspection hatches and removable centre posts. 4. Panel exterior skin shall be made from highest-grade hot-dip galvanized steel, minimal spangle grade G90, painted with highly durable heat hardened polyester based powder paint RAL 7035 with 50 microns film thickness. Panel interior skin shall be made from primed or pre-coat, hot-dip galvanized steel for excellent insulations adhesion and extra corrosion protection, the both skin should be with minimum 0.8 mm thickness for interior unit and 1.5 mm for exterior AHU. 5. The AHU manufacturer shall guarantee that no condensation shall take place on the exterior of panels. In the event that any condensation problems appear after installation, the Contractor shall undertake all remedial measures to rectify and to the satisfaction the Consultant. Any stacked or double height coils shall have separate drain pans to reduce carry over; such pans will be piped to the main drain, not into the lower pan. 6. Weather proof canopy shall be provided for units exposed to sunlight. 7. The paint shall conform to ASTM D-2201 and ASTM D-2092 for gloss, adhesion, impact resistance, withstand up to 1000 hours salt spray resistance test, exceeding 500 hours ASTM B117. 8. Thermal Transmittance, U-value shall be 1.37 W/m2K & shall be conformed to Eurovent EN 1886 Class T3



T05-20/11/2013


9.


Thermal Bridging Factor kb 0.61 shall be conformed to Eurovent EN 1886 Class TB2

10. Fasteners shall be zinc coated comply with 400 hours salt spray resistance test ASTM B117. 11. Panels and frames shall be assembled with a closed cell self-adhesive neoprene foam gasket layer installed in between them to prevent air leakage, reduce vibration noise, minimized thermal losses. 12. A closed cell self-adhesive neoprene foam gasket layer shall be provided to avoid external water from penetrate inside the unit and shall block heat infiltration and avoid external contamination into the conditioned space area inside the unit. 13. The construction of panels to the penta-post frames shall provide minimum air leakage Class L3. Casing leakage tested and shall be conformed to Eurovent Standard EN 1886. 14. Door and access panels shall be hinge type with handle and lock - access door panel equipped with hard nylon hinges, nylon handle and metal lock. EPDM rubber sealed at door perimeter. This access door type shall be at the Fan Section and the Mixing Box Section. 15. Quick Released Compressed Door and totally removable - access door shall be at Filter Section with side rail mounting. Safety Access Panels – hinged access door type accessible internally and externally. 16. Removable Access Panels - the fixing of panel to the penta-post frames shall be with bolts to provide additional access to ease mobility for major service work on large and heavy component such as coil, fan and motor. 17. The acoustic performance of the panels shall be certified and acoustic casing insulation for sound index reduction in accordance with Eurovent must be achieved as per table below: Acoustic casing insulation (dB) Attenuation (dB)

125 Hz

250 Hz

500 Hz

1 kHz

2 kHz

4 kHz

8 kHz

9.4

11.4

12.4

11.8

16.4

31.1

32.5

18. The Fan section and empty section shall be supplied with double plastic glass inspection window sealed with rubber from the inside and outside panel skin.

15800.39 FAN SECTION AND DRIVE ARRANGEMENT: 1. Fans shall be double inlet double width, backward curved centrifugal type with airfoil blades. Plug fans are not acceptable. 2. Backward and airfoil fans blades shall be treated with epoxy paint. Wheel shall be statically and dynamically balance within fan operating speed in compliance to DIN ISO Standard 1940. Standard fan bearings are “eccentric clamp bearing” type, single row ball bearing, mounted in pressed steel housing, pre-lubricated and sealed for life.



T05-20/11/2013



3. All fans shall be tested in accordance with AMCA 300 & 301 standard and all components shall be factory approved by AMCA or other competent authority and shall be currently catalogued product Fan shall be tested AMCA 300-85. 4. The fan shall be reinforced with suitable bolted angle flanges or by any other approved means to safeguard full rigidity of the unit. The fan shall be belt driven with adjustable motor sheaf. Belts shall be of the oil resistant V-type to suit horse power transmitted. 5. Door guard shall be factory supplied and installed. 6. The fan shall meet the safety requirement of the CE. Back curved fan should be coated with 60 micron 25-micron epoxy painting of high quality. 7. Fan shall not exceed a maximum outlet velocity of 12 m/sec. 8. Fan drive shall be rated at 120 % of the maximum motor power of the units and shall be fitted with adjustable belt tension arrangement. 9. The fan motor make should be brook and Crompton, Europe and shall be suitable for operating 380-415V, 3Ph, 50Hz electrical power supply. Motors shall be totally encased, foot mounted, fan cooled, IP 54 with Class ‘F’ insulation. 10. The fan motor shall be equipped with three thermistors as standard (PTC element) and shall be wired to the safety isolation switch or connection box. 11. The fan motor and belt drive shall be mounted using mounting method (B3) on a robust beam frame effectively separated from the unit casing by internal spring type anti-vibration mountings, so that the vibration and noise from the units shall not be transmitted to the building structure. Vibration isolation frame on four heavy duty spring isolators providing 95% isolation efficiency. 12. The static resistance of the various systems have bean calculated by the Engineer and the SubContractor shall be required to check and recalculate the resistance in the system taking into consideration the resistance through the equipment that is finally approved and satisfy himself that the resistance figures for the fan is adequate. If necessary the total fan resistance shall be adjusted and agreed with the Engineer. No claim shall be allowed by the Engineer if the SubContractor falls to fully acquaint himself with the capabilities of the various systems. The fan shall have provision for connecting variable frequency device. 13. All motors rated for use with variable frequency drive (VFD) shall compatible with the drive to which it is connected. Use of motor with a VFD shall not adversely affect the operation, useful life, or warranty of the motor.

15800.40 COIL SECTION 1. Coils shall be fully enclosed within the section and shall have double wall galvanized floor construction consistent with the unit casing construction. 2. Coils shall be tested at 300-psig submerged under water; designed to operate up to 230 psig (16 Bar) at 200°F (93°C). Extended header connections out side the coil section shall be protected with metal shield to avoid any damage during transportation. 3. Piping connections shall extend to the outside through rubber grommets



T05-20/11/2013



4. Coil(s) shall include galvanized steel blank off sheets to hold coil(s) rigid and prevent air from bypassing the coil(s). 5. Removable 50 mm thick access panels shall be provided on both sides to remove coils through casing, wall normal to the direction of airflow, without disturbing other coil sections. 6. Coils shall be housed in factory fabricated frame independent of unit casing and shall be individually removable. Multiple coils shall be mounted on independent support structure. Directly stacking coils using coil casing as structural support for other creep is not acceptable. 7. Drain pans shall have a double slope for positive drainage, constructed of SS304 and continuously welded. 8. The primary surface of all coils shall be round seamless copper tubes. The secondary surface shall consist of aluminum fins for higher capacity and structural strength. Fins shall have full drawn collars to provide a continuous cover over the entire tube surface for maximum heat transfer. The tubes shall be mechanically expanded into the fins to provide a continuous primary to secondary compression bond aver the entire fin length. Aluminium fin spacing, protective factory applied coating heresite for corrosion protection. Field applied coating will not be acceptable. 9. Coil construction materials shall be of Seamless copper tube with aluminum fins. 10. Headers shall be heavy section seamless copper tubing with threaded screw outlet. The coil shall be provided with manual air vent and threaded drain point. Fittings shall include plugged vent and drain taps for each section. 11. The coil shall be designed to operate at 16 bar NP and tested at 21 bar. 12. The manufacturer shall guarantee that each coil can meet the specified duty. 13. Coils shall be pitched and installed as required in the manufacturer’s installation instructions 14. Where coils are stacked, provide condensate pan for each coil. Pipe upper pan drain to lower condensate pan. 15800.41 MOISTURE ELIMINATOR 15. Non metal (Mineral Reinforced PVC) eliminator profile, highly efficient to trap moisture molecules at much higher velocity. 16. Eliminator shall be installed at down stream of the coil when ever face velocity approaching 2.5 m/s (2.3 m/s for fresh air coil at highly humid condition). 15800.42 FILTERS 1. 2. 3. 4. 5. 6.

The pre-tilter section shall contain 50mm G4 thick throw-away heavy duty filters, with 75%(EU4) arrestance efficiency. Preliminary filter shall be made from synthetics media. Synthetics filter media shall be in flat form or pleated form. Preliminary air filters (synthetics) shall be with hard cupboard or galvanized steel frames.



T05-20/11/2013


7. 8. 9.


Pleated synthetics V-filter, pleated depth shall be up to 50-mm, 90% Gravimetric Efficiency (Average Weight Arrestance, Am at 90%) equivalent to EU4. The bag filters F8 shall be high capacity filters with dust spot efficiency of 90%. They shall comprise of a corrosion resistant frame housing the filter media, which shall be supported by a 3mm-dia. wire assembly, designed to keep the media cartridge in a fully open position. The media cartridge shall be preformed and shall consist of glass fibers. Filter shall be capable to operate under high humidity conditions. The bag length shall not be less than 500mm. Filter efficiencies shall be according to EURO VENT 4/5.

10. 11. Filters shall be flame retardant to BS 5588.Pt 9:1969. 12. 13. Pressure tapping together with inclined manometers for visual indication of filters pressure drop shall be provided before and after each filter. See Control section for any additional tappings, if required. 14. 15. Static pressure tips, shut off valves and tubing with adjustable signal flag suitably marked to indicate need to change filter shall be provided and installed by the AHU manufacturer 15800.42.1 FILTER MOUNTING FRAME: 16. Mounting frame is made from galvanized steel and filter can be accessed on to the mounting frame from “front” (front or rear access or existing frame mounting) or “slide” (side mounting) type. 17. Frame mounting frame or rails should be sealed for a minimal air leak Class F7 according to EN 1886. 18. Aluminum frame for media frame and mounting frame available as an option. 15800.42.2 FILTER ACCESS DOOR 19. Filter sections access door for “Front Filter Mounting” shall be equipped with hard nylon hinges and metal lock, accessible internally and externally for safety release. 20. Filter sections access door for “Slide Rail Filter Mounting”; shall be a “quick release and totally removable access door” type.

15800.43.1 AIR MIXING SECTION (IF APPLICABLE) 21. Dampers construction are made from heavy gauge galvanized steel for sturdy and rigid structure. 22. Nylon or bronze bushing, metal side linkages enable damper blades to operate within low torque. 15800.43.2 DAMPER CONSTRUCTION (IF APPLICABLE) 23. Damper blades shall be with a single skin laminar type, made from galvanized steel, operate in parallel or oppose blades position. 24. Class IV air leakage, 0.5% leakage rate at 100 Pascal ΔP per square meter damper area, according to UL555S. 25. Shafts are with 12 mm diameter; seated on non-corrosive bronzed or nylon bushing for less resistance, free maintenance and lowest torque. 26. Extended shaft length is provided for provision to electrical motor actuator to regulate dampers blades opening and closing. 27. Frames are made from galvanized steel, reinforced at very 1200-mm and flanged at both ends to facilitate external ductwork or sand trap louvers connection. 28. Metal linkage made from steel pushrods is installed for dampers with top-rear position to allow damper to inter connected at open and closed position. 29. 30. Damper blades quadrant shall be assembled to guide blades opening and closing position. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



31. Hinged type access door is assemble at Mixing Box 15800.43.3 ELECTRIC HEATER (if applicable) 32. Electric heater shall be of the cartridge type. 33. Heaters shall be framed with a slide in-out track so that the complete assembly is removable. 34. Electric Heater Closed Tubular Finned Type 35. Electric heater shall be from Closed Tubular Finned Type, composition 80% Ni and 20% Cr. 36. Heating component is according to AISI 321 and AISI 430. 37. Assembly of the heating element is secured inside the stainless steel spherical sheathed fins copper tube (except for heater for 460 volt heater – without spherical fins). 38. Heater assembly, the basic components shall be airflow switch, power terminal board, grounding lug and primary & secondary over load temperature sensor. 39. Components are assembled inside terminal box integrated with heating elements frame assembly. 6.02.06 Frames shall be from a heavy gauge (G16) galvanized steel frame.

15800.43.4 RECOVERY HEAT WHEEL (if applicable) 40. The ECW or enthalpy wheel shall be constructed of corrugated synthetic fibrous media, with a desiccant intimately bound and uniformly and permanently dispersed throughout the matrix structure of the media. 41. Rotors with desiccants coated, bonded, or synthesized onto the media are not acceptable due to de-lamination or erosion of the desiccant material. 42. Media shall be synthetic to provide corrosion resistance and resistance against attack from laboratory chemicals present in pharmaceutical, hospital, etc. environments as well as attack from external outdoor air conditions. 43. Coated aluminum is not acceptable. 44. Face flatness of the wheel shall be maximized in order to minimize wear on inner seal surfaces and to minimize cross leakage. 45. Rotor shall be constructed of alternating layers of flat and corrugated media. Wheel layers should be uniform in construction forming uniform aperture sizes for air flow. 46. Wheel construction shall be fluted or formed honeycomb geometry so as to eliminate internal wheel bypass. 47. Wheel layers that can be separated or spread apart by air flow are unacceptable due to the possibility of channeling and performance degradation. 48. The minimum acceptable performance shall be as specified in the drawings/submittal. 49. Aluminum wheel coated with desiccant as not acceptable. 50. The desiccant material shall be a molecular sieve, and specifically a 4A or smaller molecular sieve to minimize cross contamination. 51. 52. The wheel frames shall consist of evenly spaced steel spokes, galvanized steel outer band and rigid center hub. The wheel construction should allow for post fabrication wheel alignment. 53. The wheel seals shall be full contact nylon brush seals or equivalent. Seals should be easily adjustable. 54. Cassettes shall be fabricated of heavy duty reinforced galvanized steel or welded structural box tubing. Cassettes shall have a built in adjustable purge section minimizing cross contamination of supply air. Bearings shall be inboard, zero maintenance, permanently sealed roller bearings, or alternatively, external flanged or pillow block bearings. Drive systems shall consist of fractional horsepower A.C. drive motors with multilink drive belts. 55. The wheel shall be ARI certified and must bear the ARI certification stamp. Private independent testing performed "in accordance with" various standards is not a substitute for ARI certification and shall not be accepted. The wheel shall be listed or recognized by UL or equivalent.



T05-20/11/2013



15800.43.5 PLATE HEAT EXCHANGER RECOVERY (if applicable) 56. 57. 58. 59. 60. 61. 62.

Static Aluminum plates, recover sensible energy. Standard cross flow energy transfer efficiency performance up to 75%. Exhaust and Supply flow are separated by special seal of flat plate with swirl control. Superb seal minimize cross contamination from Exhaust Air into Supply Air. Extremely low leak 0.2% of nominal airflow at 200 Pascal ΔP. Anti corrosion and non-inflammability construction made of Aluminum material. Potential latent energy recovery and condensation occurrence whenever Fresh Air temperatures lower than Exhaust Air dew point.

15800.43.6 HEAT PIPES FOR ENERGY RECOVERY (if applicable) Energy recovery heat pipes shall be included within the AHU or within the supply and extract ductwork. The heat pipe shall be a single section and will straddle the airways in the supply and extract decks of the AHU or the supply and extract ductwork. The heat pipe shall be suitable for either side by side mounting between the two adjacent ducts (horizontal heat pipe) or top and bottom mounting with the warmer air flowing through the bottom section (vertical heat pipe). The length of the heat pipes in the supply and extract section shall be selected so as to match the respective air volumes. The external fins shall be of vinyl coated aluminium with a minimum thickness of 0.15mm. Fins shall be of the continuous plate type to optimize the airside heat transfer. Tubes shall be of refrigeration standard seamless copper C106 for heat exchanger use. Tube diameter shall be 12mm with a grooved inner surface to enhance the internal surface area and minimum root thickness of the tube shall be 0.35mm. Casings shall be from galvanized sheet steel with a minimum thickness of 1.6mm. The casing shall incorporate tube plates, continuous side plates and a centre dividing plate to prevent crosscontamination between the two airstreams. The working fluid shall be refrigerant type classified as ASHRAE safety group A1. The refrigerant shall be either R22 or R134a. There shall be a multitude of loops in the height/width of the heat pipe and each loop shall be individually charged. Heat pipes with header assemblies containing a single circuit are not suitable as a single leak will render the entire heat pipe inoperative. Heat pipe performance shall be independently type tested and certified in line with the requirements of British Standards BS 5141 pt1 / European Standards EN 305 & 306 / American Standards ARI 410 for testing and rating of heat exchangers. The heat pipe should have a third party independent test report conducted by a certified laboratory from CETIAT (FRANCE) / BSRIA (UK). The heat pipe manufacturer shall have minimum 10 years experience in manufacturing of heat pipes and must have heat pipes commissioned for a minimum period of 5 years in the Middle East market. 15800.43.7 HORSE SHOE HEAT PIPES FOR ENHANCED DEHUMIDIFICATION. (if applicable) Heat pipes shall be included within the AHU and wrapped around the main cooling coil. The external fins shall be of aluminium with a minimum thickness of 0.15mm. Fins shall be of the continuous plate type. Tubes shall be of refrigeration standard seamless copper C106 for heat exchanger use. Tube diameter shall be 12mm with a grooved inner surface and minimum root thickness of the tube shall be 0.35mm,of tow rows minimum . Casings shall be from galvanized sheet steel with a minimum thickness of 1.6mm. The casing shall incorporate tube plates and top and bottom plates around both the precool and reheat heat pipe blocks. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



The working fluid shall be refrigerant type classified as ASHRAE safety group A1. The refrigerant shall be either R22 or R134A. The heat pipe circuits shall be factory charged and hermetically sealed with the calculated weight of refrigerant. There shall be a multitude of loops in the height of the heat pipe and each loop shall be individually charged. Heat pipes with header assemblies containing a single circuit are not suitable as a single leak will render the entire heat pipe inoperative. Heat pipe performance shall be independently type tested and certified in line with the requirements of British Standards BS 5141 pt1 / European Standards EN 305 & 306 / American Standards ARI 410 for testing and rating of heat exchangers. All software used to predict the performance of heat pipes shall be based upon the results of these independent tests. The heat pipe should have a third party independent test report conducted by a certified laboratory from CETIAT (FRANCE) / BSRIA (UK). The heat pipe manufacturer shall have minimum 10 years experience in manufacturing of heat pipes and must have heat pipes commissioned for a minimum period of 5 years in the Middle East market.

15800.43.8 UVC EMITTER ULTRAVIOLET DISINFECTION (IF APPLICABLE) 15800.43.8-1 PART 1 GENERAL 1.02

RELATED WORK SPECIFIED IN OTHER SECTIONS: UVC Emitters . 1.03 QUALITY ASSURANCE: a. UL Compliance: Comply with UL Standard 1995 as applicable to usage of UVC Emitters in HVAC Equipment. b. ISO Certification: Fixtures must be manufactured in a ISO 9001:2000 registered facility 1.04 DELIVERY, STORAGE AND HANDLING: c. Store UVC Emitters in a clean dry place and protect from weather and construction traffic. Handle UVC Emitters carefully to avoid damage to components, enclosures and finish. Leave factory-shipping covers in place until installation and only when called for in the installation instructions. Do not install damaged components; replace and return damaged components to equipment manufacturer. d. Comply with manufacturer’s installation instructions placement, wiring and testing. 15800.43.8.2 PART 2 – PRODUCTS 2.01 A.

UVC EMITTERS

GENERAL Acceptable Manufacturers: Steril-Aire, Inc. Model DE, SEN or SE Series as shown on Schedule or Drawings. Substitutions: (10) day prior approval is required and is to include documentation by a recognized Industry Independent Testing Lab on UVC Emitter performances. Performance results must meet or exceed the performance for Emitters in an HVAC environment as detailed in Paragraphs A, 2.b, Paragraph B, Item 2, and Paragraph C, Items 3, 4 and 5. 2. Quality Assurance: g. Qualifications: Each component and product is to be inbound and outbound tested before shipment in accordance with ISO 9001:2000 test procedures. 1. e. f.

b. 3.

Output Verification: Independent testing shall indicate total output per one inch arc length shall not be less than 9 μW/cm2, at one meter, in a 500 fpm airstream of 50° F. Warranty:



T05-20/11/2013


A. B. B.

C.

D. C. E. F. G. H.

I.


Fixture and Emitter shall be 100% warranted to be free from defects for a period of one year. An additional prorated 4 years are warranteed for the power supply. DESIGN REQUIREMENTS Irradiation - Emitters and fixtures are to be installed in sufficient quantity and in such an arrangement so as to provide an equal distribution of UVC energy on the coil and in the drain pan. To maintain energy efficiency, the UVC energy produced shall be of the lowest possible reflected and shadowed losses. Intensity-Shall be measured by a Solid State Photodiode UV Sensor at the coil. Calibration wavelength is 254 nm. Accuracy is to be ± 10% and be NIST traceable. Operating range shall be 35º F- 158º F. Read by a Display module with a 3.5 digit LCD screen/panel. Irradiance range shall be 0-1999 (x10) µW/cm2 with a resolution of 10 µW/cm². Installation - Emitters and fixtures shall be installed downstream of the cooling coil at right angles to the coil fins, such that UVC energy bathes all surfaces of the coil and drain pan. EQUIPMENT Units shall be high output, HVAC-type, germicidal UVC light sources, factory assembled and tested. Components shall include a housing, reflector, high efficiency electronic power source, Emitter sockets and Emitter tube, all constructed to withstand HVAC environments. DE, SEN and SE Unit housings shall be made of 304 stainless steel, with DE Units having electrical connectors on both ends to simplify gang wiring and wiring to power. They shall include mounting holes to assist in securing the fixtures. DE reflectors shall be constructed of high spectral finished aluminum alloy with a minimum 85% reflectance of 254 nm UVC energy. High efficiency electronic power sources shall be 115 or 208/230 V, 50/60 Hz. They shall be UL listed to comply with UL Standard 1995 and capable of igniting each Emitter at temperatures from 35º - 158° F in airflow velocities common to HVAC systems. They shall be equipped with RF and line noise suppression. Emitter tube shall be of the high output, hot cathode, T5 (15mm) diameter, and medium bi-pin type. They shall produce 95% of their energy at 254 nm and be capable of producing the specified output at airflow velocities common to HVAC systems and at temperatures of 35º 158° F. UVC Emitters shall produce no ozone or other secondary contamination.

PART 3 – INSTALLATION 3.1 INSTALLATION OF UVC EMITTERS J. Coordinate with installation of HVAC equipment and install Emitters as indicated after such equipment is properly installed. K. Provide an interlock switch on the access to the UVC Emitters to turn the lights off when the access is opened. L. If specified to include a Steril-Aire stationary radiometer, install the radiometer and adjust and set in accordance with manufacturer recommendations. M. Install provided Caution Labels on all accesses to the Emitters.

15800.44 FIRESTOPPING 15800.44 .1 PART 1 - GENERAL 1.01

RELATED DOCUMENTS A.

1.02

Drawings and general provisions of Contract, including General and Supplementary Conditions and Division-1 Specification Section, apply to work specified in this section.

DEFINITIONS



T05-20/11/2013


A.

1.03


Firestopping: Material or combination of materials used to retain integrity of fire-rated construction by maintaining an effective barrier against the spread of flame, smoke, and hot gases through penetrations in/ joints between fire rated wall and floor assemblies.

GENERAL DESCRIPTION OF THE WORK OF THIS SECTION Only tested firestop systems shall be used in specific locations as follows:

1.04

A.

Penetrations for the passage of duct, cable, cable tray, conduit, piping, electrical busways and raceways through fire-rated vertical barriers (walls and partitions), horizontal barriers (floor/ceiling assemblies), and vertical service shaft walls and partitions.

B.

Safing slot gaps between edge of floor slabs and curtain walls.

C.

Openings between structurally separate sections of wall or floors.

D.

Gaps between the top of walls and ceilings or roof assemblies.

E.

Expansion joints in walls and floors.

F.

Openings and penetrations in fire-rated partitions or walls containing fire doors.

G.

Openings around structural members which penetrate floors or walls.

RELATED WORK OF OTHER SECTIONS A. Coordinate work of this section with work of other sections as required to properly execute the work and as necessary to maintain satisfactory progress of the work of other sections, including: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

1.05

Cast-In-Place Concrete Joint Sealers Masonry Work Lath and Plaster Gypsum Drywall Systems Sound, Vibration and Seismic Control Fire Suppression and Supervisory Systems Basic Mechanical Materials and Methods Mechanical Insulation Fire Protection Plumbing Basic Electrical Materials and Methods

REFERENCES A. B.

Test Requirements: ASTM E-814-02, "Standard Method of Fire Tests of Through Penetration Fire Stops" Underwriters Laboratories (UL) of Northbrook, IL runs ASTM E-814 under their designation of UL 1479 and publishes the results in their "FIRE RESISTANCE DIRECTORY" that is updated annually. 1.

UL Fire Resistance Directory: a. b.

Firestop Devices (XHJI) Fire Resistance Ratings (BXUV)



T05-20/11/2013


c. d. e.

2.

1.06


Through-Penetration Firestop Systems (XHEZ) Fill, Voids, or Cavity Material (XHHW) Forming Materials (XHKU)

Alternate “Omega Point Laboratories Directory” (updated annually).

C.

Test Requirements: UL 2079, “Tests for Fire Resistance of Building Joint Systems” (July 1998.)

D.

Test Requirements: ASTM E 1966-01, “Standard test method for Fire Resistive Joint Systems”

E.

Inspection Requirements: ASTM E 2174 – 01, “Standard Practice for On-site Inspection of Installed Fire Stops.”

F.

International Firestop Council Guidelines for Evaluating Firestop Systems Engineering Judgments

G.

ASTM E-84-01, Standard Test Method for Surface Burning Characteristics of Building Materials.

H.

All major building codes: ICBO, SBCCI, BOCA, and IBC.

I.

NFPA 101 - Life Safety Code

J.

NFPA 70 - National Electric Code

K.

BS 476, “ Fire Tests on Building Materials

L.

DafStb guidelines for the protection and repair of concrete building components, Part 4, Section 2.4.5.6, with subsequent fire testing to ensure long term functionality.

QUALITY ASSURANCE A.

A manufacturer's direct representative (not distributor or agent) to be on-site during initial installation of firestop systems to train appropriate contractor personnel in proper selection and installation procedures. This will be done per manufacturer's written recommendations published in their literature and drawing details.

B.

Firestop System installation must meet requirements of ASTM E-814, UL 1479 or UL 2079 tested assemblies that provide a fire rating equal to that of construction being penetrated.

C.

Proposed firestop materials and methods shall conform to applicable governing codes having local jurisdiction.

D.

Firestop Systems do not reestablish the structural integrity of load bearing partitions/assemblies, or support live loads and traffic. Installer shall consult the structural engineer prior to penetrating any load bearing assembly.

E.

For those firestop applications that exist for which no UL tested system is available through a manufacturer, an engineering judgment derived from similar UL system designs or other tests will be submitted to local authorities having jurisdiction for their review and approval prior to installation. Engineering judgment drawings must follow requirements set forth by the International Firestop Council (September 7, 1994, as may be amended from time to time).



T05-20/11/2013


1.07

SUBMITTALS A. B. C. D. E.

F.

1.08

B.

Special Warranty: Written warranty, signed by Contractor agreeing to repair or replace fire stopping system that do not comply with performance and other requirements specified in this Section within specified warranty period. Warranty Period: Five years from date of Substantial Completion. Age Testing Certificate: Provide Firestop Systems which have been tested and rated to withstand aging in normal service life between 25 and 30 years in accordance with DafStb Guidelines for the repair and protection of building components part 4, Section 2.4.5.6 with subsequent fire testing to ensure long term functionality. Age Testing Certificate for each product to be submitted.

DELIVERY, STORAGE, AND HANDLING A. B. C. D. E.

1.11

Engage an experienced Installer who is certified, licensed, or otherwise qualified by the firestopping manufacturer as having been provided the necessary training to install manufacturer’s products per specified requirements. A supplier’s willingness to sell its firestopping products to the Contractor or to an Installer engaged by the Contractor does not in itself confer qualification on the buyer.

WARRANTY A.

1.10

Submit Product Data: Manufacturer's specifications and technical data for each material including the composition and limitations, documentation of UL firestop systems to be used and manufacturer's installation instructions to comply with Section 1300. Manufacturer's engineering judgment identification number and drawing details when no UL system is available for an application. Engineering judgment must include both project name and contractor’s name who will install firestop system as described in drawing. Submit material safety data sheets provided with product delivered to job-site. Sound Insulation Test Reports: Provide Test Certificates from qualified independent laboratories showing clearly a minimum of 54 dB sound reduction for Firestop Systems is achieved. Ageing Test Report showing Firestop Systems which have been tested and rated to withstand aging in normal service life between 25 and 30 years in accordance with DafStb Guidelines for the repair and protection of building components part 4, Section 2.4.5.6 with subsequent fire testing to ensure long term functionality. Submit certificate by firestopping manufacturer that products supplied comply with LEED requirements for indoor environmental quality credit .

INSTALLER QUALIFICATIONS A.

1.09


Deliver materials undamaged in manufacturer's clearly labeled, unopened containers, identified with brand, type, and UL label where applicable. Coordinate delivery of materials with scheduled installation date to allow minimum storage time at job-site. Store materials under cover and protect from weather and damage in compliance with manufacturer's requirements, including temperature restrictions. Comply with recommended procedures, precautions or remedies described in material safety data sheets as applicable. Do not use damaged or expired materials.

PROJECT CONDITIONS



T05-20/11/2013



A.

Do not use materials that contain flammable solvents.

B.

Schedule installation of firestopping after completion of penetrating item installation but prior to covering or concealing of openings.

C.

Verify existing conditions and substrates before starting work. conditions before proceeding.

D.

Weather conditions: Do not proceed with installation of firestop materials when temperatures exceed the manufacturer's recommended limitations for installation printed on product label and product data sheet.

E.

During installation, provide masking and drop cloths to prevent firestopping materials from contaminating any adjacent surfaces.

Correct unsatisfactory

15800.44.2 PART 2 - PRODUCTS 2.01

2.02

FIRESTOPPING, GENERAL A.

Provide firestopping composed of components that are compatible with each other, the substrates forming openings, and the items, if any, penetrating the firestopping under conditions of service and application, as demonstrated by the firestopping manufacturer based on testing and field experience.

B.

Provide components for each firestopping system that are needed to install fill material. Use only components specified by the firestopping manufacturer and approved by the qualified testing agency for the designated fire-resistance-rated systems.

C.

Firestopping Materials are either “cast-in-place” (integral with concrete placement) or “post installed.” Provide cast-in-place firestop devices prior to concrete placement.

ACCEPTABLE MANUFACTURERS A.

2.03

Subject to compliance with through penetration firestop systems and joint systems listed in Volume 2 of the UL Fire Resistance Directory; provide products of the following manufacturers as identified below: 1.

Hilti – Emirates L.L.C PO Box : 11051 ,Dubai, U.A.E. TEL: 800-44584, 048854445, FAX: 048854405 Web site: www.hilti.ae

2.

Provide products from the above acceptable manufacturer.

MATERIALS A.

Use only firestop products that have been UL 1479, ASTM E-814, or UL 2079 tested for specific fire-rated construction conditions conforming to construction assembly type, penetrating item type, annular space requirements, and fire-rating involved for each separate instance.



T05-20/11/2013


B.

Cast-in place firestop devices for use with non-combustible and combustible plastic pipe (closed and open piping systems) penetrating concrete floors, the following products are acceptable: 1.

C.

Cast-In Place Firestop Device with Intumescent Wrap Strips Pipe Closing Devices: Material: Solvent free Intumescent Pipe wrap strips, unaffected by water, frost or ultraviolet light. The wrap is to exert an expansion pressure of 2 bars

Sealants, intumescent material or foams for use with non-combustible items including steel pipe, copper pipe, rigid steel conduit and electrical metallic tubing (EMT), the following products are acceptable: 1.

2. 3.

4. 5.

D.


GRAPHITE BASED FIRESTOP SEALANT ,ONE PART HIGH PRESSURE EXERTING INTUMESCENT PASTE UNAFFECTED BY WATER OR MOISTURE WHEN CURED CONTAINING NO SOLVENTS, INORGANIC FIBERS, OR SILICONE COMPOUNDS, WITH MINIMUM EXERTING PRESSURE OF 5 BARS Self-leveling Firestop Sealant INTUMESCENT FIRESTOP FOAM, EXPANDING MATERIAL FIRE SEAL FOAMING AGENT (CFC) AND SOLVENT- FREE,GASTIGHT, PERMANENT SEAL WITH REINSTALLATION POSSIBILITY TO PROVIDE UP TO 2 HOURS INTEGRITY AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10% FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% top Sealant

Sealants and intumescent materials for use with sheet metal ducts, the following products are acceptable: 1. 2. 3.

E.

FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10% GRAPHITE BASED FIRESTOP SEALANT , ONE PART HIGH PRESSURE EXERTING INTUMESCENT PASTE UNAFFECTED BY WATER OR MOISTURE WHEN CURED CONTAINING NO SOLVENTS, INORGANIC FIBERS, OR SILICONE COMPOUNDS, WITH MINIMUM EXERTING PRESSURE OF 5 BARS Sealants and spray materials for use with fire-rated construction joints, soffit joints (top of the wall joints) and other gaps, the following products are acceptable:



T05-20/11/2013


1.

SPRAYABLE


LATEX

BASED

DISPERSION

WITH

50%

MOVEMENT

CAPABILITY 2. 3. F.

SUITABLE FOR CONSTRUCTION FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10%

Sealants and Spray materials used for Curtain wall Joints (openings between Slab and Curtain Wall), the following products are acceptable: 1. SPRAYABLE LATEX BASED DISPERSION WITH 50% MOVEMENT CAPABILITY SUITABLE FOR CONSTRUCTION 2. FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% 3. AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10% 4. Self-Leveling Firestop Sealant

G. Intumescent sealants for use with combustible items (penetrants consumed by high heat and flame) including insulated metal pipe, PVC jacketed, flexible cable or cable bundles and plastic pipe, the following products are acceptable: 1.

H.

Foams, intumescent sealants, caulking or putty materials for use with flexible cable or cable bundles, the following products are acceptable: 1.

2.

3. 4. I.

GRAPHITE BASED FIRESTOP SEALANT , ONE PART HIGH PRESSURE EXERTING INTUMESCENT PASTE UNAFFECTED BY WATER OR MOISTURE WHEN CURED CONTAINING NO SOLVENTS, INORGANIC FIBERS, OR SILICONE COMPOUNDS, WITH MINIMUM EXERTING PRESSURE OF 5 BARS

GRAPHITE BASED FIRESTOP SEALANT , ONE PART HIGH PRESSURE EXERTING INTUMESCENT PASTE UNAFFECTED BY WATER OR MOISTURE WHEN CURED CONTAINING NO SOLVENTS, INORGANIC FIBERS, OR SILICONE COMPOUNDS, WITH MINIMUM EXERTING PRESSURE OF 5 BARS INTUMESCENT FIRESTOP FOAM, EXPANDING MATERIAL FIRE SEAL FOAMING AGENT (CFC) AND SOLVENT- FREE,GASTIGHT, PERMANENT SEAL WITH REINSTALLATION POSSIBILITY TO PROVIDE UP TO 2 HOURS INTEGRITY FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10%

Non curing, re-penetrable intumescent sealants, caulking or putty materials for use with flexible cable or cable bundles, the following products are acceptable: 1. 2.

Intumescent Firestop Putty Stick Intumescent Plugs: pressure exerting graphite based intumescent fire prevention Plugs with an expansion ratio of 1:5 providing dust, fiber, asbestos, halogen and



T05-20/11/2013



solvent free installation of gas and air tight, with a temperature resistance f -50 to +60 C. K.

Wall opening protective materials for use with U.L. listed metallic and specified nonmetallic outlet boxes, the following products are acceptable:

1. K.

Firestop collar or wrap devices attached to assembly around combustible plastic pipe (closed and open piping systems), the following products are acceptable: 1. 2.

L.

Intumescent Firestop Putty Pad

Firestop Steel Jackets: Material: Prefabricated steel jacket with a graphite based intumescent to all flammable plastic pipes, the jacket to exert an expansion pressure of 2 bar to provide 4 hours integrity Intumescent Wrap Strips Pipe Closing Devices: Material: Solvent free Intumescent Pipe wrap strips, unaffected by water, frost or ultraviolet light. The wrap is to exert an expansion pressure of 2 bars

Materials used for complex penetrations made to accommodate cable trays, multiple steel and copper pipes, electrical busways in raceways, the following products are acceptable: 1.

2.

3.

Firestop Mortars Usage/Material: Pre-packaged, dry mixes of Firestop Mortar, consisting of a blend of inorganic binders, hydraulic cement, fillers and lightweight aggregate formulated for mixing with water at project site to form a non shrinking, homogenous mortar, fire and impact resistant, load bearing where required, for use in large openings, in static, non moving, penetrations such as cable trays, electrical and communication bundles, conduit and combustible sleeves and pipes. Intumescent Bricks: pressure exerting graphite based intumescent fire prevention blocks with an expansion ratio of 1:5 providing dust, fiber, asbestos, halogen and solvent free installation of gas and air tight, with a temperature resistance f -50 to +60 C. INTUMESCENT FIRESTOP FOAM, EXPANDING MATERIAL FIRE SEAL FOAMING AGENT (CFC) AND SOLVENT- FREE,GASTIGHT, PERMANENT SEAL WITH REINSTALLATION POSSIBILITY TO PROVIDE UP TO 2 HOURS

INTEGRITY M.

Non curing, re-penetrable materials used for large size/complex penetrations made to accommodate cable trays, multiple steel and copper pipes in raceways, the following products are acceptable: 1.

2.

Intumescent Bricks: pressure exerting graphite based intumescent fire prevention blocks with an expansion ratio of 1:5 providing dust, fiber, asbestos, halogen and solvent free installation of gas and air tight, with a temperature resistance f -50 to +60 C. Coated Board System: Material: Firestop Coated Board System comprising high density mineral fiber board, minimum density 160 kg/m3, pre coated with chemical Intumescent or ablative coating to form a non shrinking seal, fire resistant, for use in large openings, in static, non moving, penetrations and have to smoke , gas tightened and to provide sound insulation.



T05-20/11/2013


N.


Sealants and Spray materials used for openings between structurally separate sections (Expansion Joints) of walls and floors, the following products are acceptable: 1. SPRAYABLE LATEX BASED DISPERSION WITH 50% MOVEMENT CAPABILITY SUITABLE FOR CONSTRUCTION 2. FIRESTOP SILICONE SEALANT ONE PART, LOW MODULUS, MOISTURE ACTIVATED CAPABLE OF WITHSTANDING HIGH MOVEMENT IN COMPRESSION AND EXTENSION, SEALANT TO PROVIDE +/- 25% 3. AN ACRYLIC BASED FIRESTOP MASTIC THAT OFFERS MOVEMENT CAPABILITIES UP TO +/- 10% 4 Self-Leveling Firestop Sealant

O.

For blank openings made in fire-rated wall or floor assemblies, where future penetration of pipes, conduits, or cables is expected, the following products are acceptable: 1.

2.

Intumescent Bricks: pressure exerting graphite based intumescent fire prevention blocks with an expansion ratio of 1:5 providing dust, fiber, asbestos, halogen and solvent free installation of gas and air tight, with a temperature resistance f -50 to +60 C. Intumescent Plugs: pressure exerting graphite based intumescent fire prevention Plugs with an expansion ratio of 1:5 providing dust, fiber, asbestos, halogen and solvent free installation of gas and air tight, with a temperature resistance f -50 to +60 C.

P.

For curtain wall firestopping use Sprayable fire-rated flexible joint mastic with 50% movement capability, and to have acoustic characteristics of STC (sound transmission min. 55) and to be tested to resist seismic type cycling movement, to ensure fire resistance not less than that specified for compartment walls and floors, including insulation and integrity when subject to the test conditions of BS 476: Pt 20/prEN 1366, after age testing to DafStb guidelines . All installations to be in full accordance with manufacturer’s application instructions.

Q.

Provide a firestop system with a "F" Rating as determined by UL 1479 or ASTM E814 which is equal to the time rating of construction being penetrated.

R.

Provide a firestop system with an Assembly Rating as determined by UL 2079 which is equal to the time rating of construction being penetrated.

15800.44.3 PART 3 - EXECUTION 3.01

PREPARATION A.

Verification of Conditions: Examine areas and conditions under which work is to be performed and identify conditions detrimental to proper or timely completion. 1.

Verify penetrations are properly sized and in suitable condition for application of materials.



T05-20/11/2013


3.02

3.03

3.04

3.05


2.

Surfaces to which firestop materials will be applied shall be free of dirt, grease, oil, rust, laitance, release agents, water repellents, and any other substances that may affect proper adhesion.

3.

Provide masking and temporary covering to prevent soiling of adjacent surfaces by firestopping materials.

4.

Comply with manufacturer's recommendations for temperature and humidity conditions before, during and after installation of firestopping.

5.

Do not proceed until unsatisfactory conditions have been corrected.

COORDINATION A.

Coordinate location and proper selection of cast-in-place Firestop Devices with trade responsible for the work. Ensure device is installed before placement of concrete.

B.

Responsible trades to provide adequate spacing of field run pipes to allow for installation of cast-in-place firestop devices without interferences.

INSTALLATION A.

Regulatory Requirements: Install firestop materials in accordance with UL Fire Resistance Directory or Omega Point Laboratories Directory.

B.

Manufacturer's Instructions: Comply with manufacturer's instructions for installation of through-penetration and construction joint materials. 1.

Seal all holes or voids made by penetrations to ensure an air and water resistant seal.

2.

Consult with mechanical engineer, project manager, and damper manufacturer prior to installation of UL firestop systems that might hamper the performance of fire dampers as it pertains to duct work.

3.

Protect materials from damage on surfaces subjected to traffic.

FIELD QUALITY CONTROL A.

Examine sealed penetration areas to ensure proper installation before concealing or enclosing areas.

B.

Keep areas of work accessible until inspection by applicable code authorities.

C.

Inspection of through-penetration firestopping shall be performed in accordance with ASTM E 2174, “Standard Practice for On-Site Inspection of Installed Fire Stops” or other recognized standard.

D.

Perform under this section patching and repairing of firestopping caused by cutting or penetrating of existing firestop systems already installed by other trades.

ADJUSTING AND CLEANING A.

Remove equipment, materials and debris, leaving area in undamaged, clean condition.



T05-20/11/2013



B. Clean all surfaces adjacent to sealed holes and joints to be free of excess firestop materials and soiling as work progresses.

End of Section



T05-20/11/2013



SECTION 16000 ELECTRICAL SYSTEM



T05-20/11/2013



Section 16000 ELECTRICAL 16000.1

GENERAL

16000.1.1 Scope These specifications cover the following systems that are intended to be used for the project in accordance with the Drawings, Specifications and as directed and approved by the Engineer. -

Electric Power System Lighting System Telephone System Interphone System T. V. Antenna & Satellite System Servant Call Bell System Earthing System Other Misc. System

16000.1.2 General Requirements The Contractor shall supply all labour, materials and plant necessary and shall install, complete and ready for use the abovementioned systems including the installation and wiring of miscellaneous equipment and devices, as indicated on the Drawings and as herein specified. The Contractor shall carry out the whole of the Electrical Work in a workman like and substantial manner and in strict conformance with the codes listed in the following clauses, or approved equal. The Contractor’s attention is directed to the requirements of the GENERAL CONDITIONS OF CONTRACT and Section - 1 GENERAL of the Specifications as applicable for the Electrical Work. If actual ratings of equipment supplied under other sections are different that the values indicated on the Drawings, Contractor shall bring the matter to the attention of the Engineer. Contractor shall implement all necessary modifications at no extra cost, to the approval of the Engineer. 16000.1.3 Interference and Erroneous Locations The Contractor shall verify on site all data and final locations of Work done under other Sections of the Specifications, required for the placing of the Electrical Work. In case of interference with other work or erroneous locations with respect to equipment or structures, the Contractor shall supply all labour and materials necessary to complete the work in an acceptable manner. Where runs of piping, ducts, cable ways etc., are shown, they do not necessarily indicate exact locations within the confines of the building area concerned The final locations of all such services, one with another and each with the building, shall be determined by the Contractor in the preparation of his Installation Drawings. Allowance shall be made in the preparation of Tenders to cover such deviations between Contract and Installation Drawings D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



16000.1.4 Protection of Electrical Equipment Electrical equipment shall be protected from the weather, especially from water dripping or splashing upon it, at all times during shipment, storage, and construction. Equipment shall not be stored outdoors. Where equipment is installed or stored in moist areas, such as unheated buildings, etc., it shall be provided with an acceptable means to prevent moisture damage. Should any equipment or material be subjected to possible damage by water, it shall be dried out thoroughly and put through a special dielectric test as directed, at the expense of the Contractor, or shall be replaced by the Contractor without additional charge. 16000.1.5 Codes and Standards The Contractor shall carry out all Electrical Work in accordance with the latest issue of the “Regulations for Electrical Installations” published by the Institution of Electrical Engineers and where not in contradiction with the Local Power Authority Requirements. If any redesign or modification of the works is necessitated by the adoption of another approved code or due to Local Electrical Authorities or Safety instructions requirements, the extra cost incurred (if any) both for design and material shall be done by the Contractor. Except where modified by this Specification, equipment and materials shall be in accordance with IEC (International Electro-technical Commission), ISO (International Organization for Standardization) and BSS (British Standards Specification) recommendations. When IEC or ISO or BSS recommendations, or national standards are referred to the Edition shall be that current at the date of Tender, together with any amendments issued to that date Otherwise they shall comply with the latest relevant BS Specifications or approved equal. 16000.1.6 Acceptance Tests Any work which is not in accordance with the Specifications or to the satisfaction of the Engineer and/or Local Power Authorities shall be removed and replaced or repaired at the Contractor’s own expense. All materials supplied must be factory finished and/or painted to the approval of the Engineer. 16000.1.7 Electrical Service The electrical power system will operate on 220/380 volt, 3-phase, 4-wire, 50 Hz System. The low current systems shall operate on the voltages specified or as recommended by the manufacturer, to the approval of the Engineer. 16000.1.8 Climatic Conditions All electrical equipments shall have finishes and materials of construction suitable for following ambient conditions. -

Maximum shade temperature Direct sum temperature Relative humidity maximum (Approx) Relative humidity average ( Approx )

- 50 deg. C - 85 deg. C - 100% - 60 -70%

16000.1.9 Equipment Supplied and Installed by Others



T05-20/11/2013



Certain items of control and other equipment are indicated on the Electrical Drawings for connection, but are specified in other sections pertaining to plumbing, air conditioning, etc. such items are not supplied as part of the Electrical work. All connections to such equipment shall be done under this section. 16000.1.10 Equipment Not In Contract (NIC) Equipment so indicated or noted will not be in contract. Connections to such equipments shall not be carried out by the Contractor, unless otherwise indicated or noted. 16000.1.11 Local Electrical Authorities Requirements The Contractor shall attend on and afford all facilities to the Local Electrical Authorities and shall provide oil drainage pits, terminal cable pits, terminal boxes for cables, as well as underground ducts to facilitate all main feeder work and shall be responsible for satisfying the requirements of the above mentioned authorities, and shall follow the Engineer’s instruction on site. The Contractor shall be responsible for preparing shop drawings concerning feed in routings, and shall consult the local power supply authorities in accordance with the Engineer’s instructions, to seek approval of these authorities. The Contractor shall also be responsible for follow up of the application for Electrical Connection. The application form will be filled in by the Engineer unless otherwise requested by the Contractor who shall carry out the same without extra charges. 16000.1.12 Abbreviations In addition to abbreviations described in SECTION 1 - GENERAL of the Specifications, abbreviations used in this Section stand for the following: BS IEE IEC

British Standards The Institution of Electrical Engineer International Electro-technical Commission

Abbreviations for words and/or expressions used only on the Drawings are as shown on the Drawings. 16000.1.13 Terminology Terminology is used in the sense defined in the issue of BS 4727. 16000.1.14 Engineer’s Drawings The Engineer’s Drawings issued with these Specifications are complimentary to these specifications. These Drawings indicate the approximate location of all electrical devices and equipment. The Contractor shall be responsible for locating exact position of the equipment upon approval of the Engineer on site. The Contractor shall check Architectural, Structural, Air Conditioning and Plumbing Drawings to avert possible installation conflicts. Should drastic changes from the original plans be necessary to resolve such to resolve such conflicts, the Contractor shall secure the Engineer’s approval of such changes before any installation work is started.



T05-20/11/2013



All accessories and appurtenances which the Engineer deems functionally necessary for a complete installation shall be supplied and installed whether or not explicitly indicated or described. Discrepancies shown on different Drawings or between Drawings and actual Site conditions, or between Drawings and Specifications shall be brought to the attention of the Engineer for a decision. 16000.1.15 Shop/Construction Drawings The Contractor shall submit shop drawings as called for in the Specifications, or as required without extra cost. Drawing scale shall be min. 1:50. No equipment or system for which shop drawings are required shall be ordered or installed unless all such drawings are duly reviewed and approved by the Engineer. The Contractor shall upon the request of the Engineer provide plain paper copies of the standard extracts to which references are made in the specifications. Two copies of the brochures shall be originals as published by the manufacturer. Other copies may be clear paper copies. The Contractor shall upon the requested of the Engineer, submit copies of extracts of standards to which references are made. 16000.1.16 As-Built Drawings As-Built Drawings shall be submitted as called for in Section 1 of the Specification. 16000.1.17

Instructions Manual

The Contractor shall provide the Employer with 3 complete sets of instructions manuals covering operation, maintenance and ordering of spare parts for all of the electrical equipment and as directed by the Engineer. 16000.1.18

Nameplates

Nameplates in arabic and English shall be installed on all devices or pieces of equipment for which the use or identification may not be readily apparent, such as, but not limited to starters, relay, contactors, controls, push-button indicating lights, switches. Nameplates shall be made of laminated sheet plastic, 2.5 mm thick, or of anodized aluminium, approximately 1.5 mm thick engraved to provide white letters on a black background, and fastened in place with corrosion resistant screws. Nameplates shall also be provided on all manufactured assemblies to identify the assembly as well as feeders, circuits, compartment, switches, internal components, etc. Nameplates shall be located in a position to be easily readable after completion of the installation of equipment. Nameplates for equipment weighing more than 15 kgs. shall be marked giving the approximate weight to the nearest + or - 5%. 16000.1.19

Modifications



T05-20/11/2013



If during the work, the Contractor wishes to make changes or modifications, then these modifications shall be submitted to the Engineer’s for approval. If these changes result in extra expenses in design and/or material these expenses shall be borne by the Contractor. 16000.2

MAIN AND SUB-MAIN DISTRIBUTION BOARD

16000.2.1 Main L.V. Distribution Panel Boards The Contractor shall supply, install, test connect and commission in the approximate locations indicated on the drawings. Main low voltage distribution panel board, designated MDB, comprising components all in accordance with the requirements of these specifications and as detailed in the distribution schematic drawings. All major components and enclosure to be from same manufacturer. 16000.2.2 General The main L.V. distribution board shall be 600V/1000V insulation grade and shall be designed and constructed to comply with the requirements of I.E.C.439. The MDB shall be factory built in the original manufacturer works. Local assembly will not be accepted. All incoming and outgoing apparatus shall be housed in individual separate compartments which are completely withdrawable without disconnection any busbars or cables. All busbar sections of the boards shall be designed and certified to withstand a short circuit of 50KA (rms) for 1 second. The boards shall be of modular cubicle patter, Form 2, floor mounted, front access, air insulated busbar totally enclosed, fully interlocked. The boards shall be of sealed version to comply with degree of Protection IP 54 as defined by I.E.C. 529. The boards shall be made of corrosion resistant sheet steel coated with an alloy of Aluminium, Zink and silicon (ALLUZINK) in a proportion of 55% Aluminium, 43.4% zinc and 1.6% silicon. The housing should be constructed so that they will be suitable for future extensions at either end and will allow for interchange ability of switchgear. Provision shall made for top, or bottom entries for cables as appropriate. All necessary cable boxes, glands and clamps appropriate to the cable sizes shall be provided. The boards shall be of suitable design to facilitate ease of cabling, maintenance, inspection and testing, and shall ensure maximum safety to operators, and to maintenance and testing Engineers. All panel doors shall be mechanically interlocked to prevent opening before the gear is isolated. Each panel door shall be fitted with approved type of lock. The general arrangements of the boards shall be indicated in the appropriate drawings. However, it shall be the responsibility of the Contractor to submit with his working drawings, for Engineer’s study and approval, the proposed arrangement and physical layout of the board together with the manufacturer’s specifications and full technical details of the switch gear and all ancillary equipment he proposes to use. The Contractor shall ensure that his offer shall include all items, whether or not explicitly specified, but which are considered necessary for a complete, safe and satisfactory installation. The Contractor shall also ensure that the boards offered shall be of suitable layout and dimensions for the locations specified. A complete set of plans indicating details and fixing dimensions together with the necessary number of foundations bolts for each board shall be submitted. If necessary, the board shall be arranged for delivery to site in sections. However, busbars should be assembled in the cubicle at the manufacturer’s works and bolted together on site. Lifting lugs shall be provided for each section. The board shall be installed complete in all respects and shall be tested and commissioned to the satisfaction and approval of the Engineer. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



16000.2.3 Air Circuit Breakers ( A. C. B. ) All A.C.B.’s shall be designed and constructed to have a rated service short circuit breaking capacity of not less than 55 KA rms. and shall conform to the requirements, including latest amendments, of I.E.C. 947-2. Fault test shall be carried out on all the breakers appropriate to service rating of utilization category of the aforementioned standards. The thermal and short circuit ratings of the circuit breaker shall be the enclosed ratings relating to the ambient temperature, degree of protection, and environment in which the circuit breakers shall operate in service, and not the rating in free air. The manufacturer should submit the applicable derating curves or tables. All A.C.B.’s shall be of the withdrawal type, and hand operated spring assisted so that the closing speed is independent of the operator. All A.C.B.’s shall have main contacts of the multifinger type with individual self aligning springs for high contact pressure. Isolating contacts shall be of the removable, silver-plated, spring loaded cluster type to ensure perfect alignment at all times. All A.C.B.’s shall be equipped with effective and adequately designed arc chutes and arc shields which shall enclose all current breaking contacts and shall be designed for effective and fast arc chopping. The complete chute assembly shall be capable for being easily removed for routine inspection of the chutes and contacts. The moving portion of each air circuit breaker unit shall consist of a three-pole circuit breaker with operating mechanism, primary and secondary disconnecting devices, auxiliary switches, position indicators and necessary control wiring, all mounted on a substantial steel framework. This framework and all metal parts of the moving portion apart from current carrying parts shall, when inserting the circuit breaker into the cubicle, be solidly earthed before the circuit breaker reaches test position. The circuit breaker shall then remain effectively earthed when it is in the cubicle. To minimize the effect during transport installation and operation, rigid locks/screws should be provided to lock the ACB in the inserted position to the fixed part of the switchgear. 1 - Fully Inserted Position 2 - Tested Position 3 - Isolated Position The protection unit shall be of high accuracy and solid state microprocessor based to achieve the following protection functions : 1) Protection against overload (L) - processing the r.m.s. value. 2) Selective protection against short-circuit (S) - processing the r.m.s. value. 3) Instantaneous protection against short-circuit (I) - processing the Ip/2 value. 4) Protection against earth fault (G) - processing the r.m.s. value. It shall consist of following protection “as minimum” with magnetic trip indication of type of trip. Protection -----------1) Overload

Trip ------Inverse long delay

2) Circuit

Selectable



Set Values ( Adj. by steps ) --------------------------------IL=0.4-0.5-0.6.-0.70.8-0.9-0.95-1x1n tL=5 curves

T05-20/11/2013



through changeover switch 2A Inverse short delay

IS=1-1.5-2-3-4-6-8 X In tS= 7 curves

2B Define short delay

IS= 1-1.5-2-3-4-6-8 X Io tS= 0.1-0.2-0.3-0.4 0.6-0.8-1 sec.

3) Short circuit Instantaneous adjustable 4) Earth fault

IS=1,5-2-3-4-6-8-10 15X In

Selectable changeover switch 4A Inverse short delay

IO=0.2-0.3-0.4-0.60.8-1 X In tO=6 curves

4B Definite short delay

IO=0.2-0.3-0.4-0.60.8-1 X In tO=0.1-0.25-0.40.6-0.8-1S

Each protective function to be cut out by hand through the relevant trip current threshold selector switch (in OFF position ) The protection unit to be provided with the following functions and devices: -

Control of the limit temperature inside the release case ( 70 deg. C )

-

Push-button for resetting the protection operation and microprocessor malfunction indications.

-

Functional test push-button (causing the circuit-breaker to trip)

-

Hand planning of protection functions.

-

Electromagnetic tripping device for circuit-breaker.

-

Input and output connections multiple connectors to be provided with mechanical lock against casual disconnection.

-

Protection cover against tempering with the adjusting devices.

-

The operation to be done without any auxiliary external power source. The current transformer to provide power for the release and the electromagnetic tripping device directly from the network.

-

Single simultaneous adjustment on the three phases and, on the neutral.



T05-20/11/2013



-

Tripping characteristics to be unaffected by the ambient temperature.

-

Constant characteristics and operational reliability even in ambients with the presence of strong disturbances and polluting agents.

-

Possibility of carrying out the functional test even with circuitbreaker isolated, the test circuit to be supplied through a battery contained within the release case.

-

Possibility of an instantaneous or delayed reset after operation due to overload, The delayed reset to simulate the cooling characteristics of a thermal overcurrent device.

-

Prealarm and alarm signal lamp to indicate overcurrent.

The ACB to have ampere measuring unit to measure and continuously display the current value of the most loaded phase. The values of currents on the remaining phase, the neutral and the earth current to be displayed by keeping the relevant push-button depressed. Also the unit to be able to display the highest line current the was stored after the last operation of the relevant “reset” push-button. Test functions indicators: 1 2 3 4

to be provided as a standard on the breaker. The ACB shall have following -

On / Off Spring charged / uncharged Position indicator for connected, test, isolated position Trip indication

The busbar shall be covered by automatic shutters when the ACB is in the withdrawn position. All mechanical interlocks shall be of the preventive type and shall be arranged to prevent maloperation as close as possible to the point at which mechanical force is applied, in order to prevent defeat of the interlocks by distortion of linkages. Electrical interlocks shall also function so as to prevent the closing of the circuit breaker before the interlocking demands are fulfilled. The excess energy in the closing springs at the end of a closing cycle to be utilized to partially recharge the closing springs. In this way the strain on the mechanism is reduced ensuring reliable operation of the mechanism of the circuit breaker over a long period. The opening springs should be automatically charged during the closing operation. The ACB to have operative cycles that can be carried out without recharging the springs: -

With the circuit-breaker open and spring charged: closing-opening.

-

With the circuit-breaker closed and springs charged: opening - closing - opening.

The ACB to assure a reliable mechanical performance for 30,000 operations at least.



T05-20/11/2013



Circuit breakers of the same current and voltage rating shall be fully interchangeable, both electrically and mechanically. it must be impossible to insert a circuit breaker with lower frame rating into a cubicle with higher frame rating. The ACB shall be complete with the following: 1) Charging lever for the closing spring. 2) Spring charged and spring released indication. 3) ON button 4) OFF button

5) Padlock loop for locking in the OFF position. 6) Push-button to release the moving part of draw out circuit breaker. 7) Padlock loop for locking of breaker in ISOLATED position. 8) Position indicator for CONNECTED, TEST or ISOLATED position. 9) The ACB to be provided with automatic screening. The screens for incoming and outgoing main terminals can be opened independently of each other.

16000.2.4 Withdrawable Moulded Case Circuit Breakers (M.C.C.B.) All outgoing MCCB shall be mounted in completely withdrawable apparatus compartment with plug in connectors on the busbar side and cable side. A faulty breaker can be removed without switching off any other outgoing breaker or the incoming breaker and it can be removed without disconnecting the outgoing cables. The apparatus compartment should be in one of 2 distinct positions, service and isolated. Each compartment to have its own door, affixed to the chassis that can be locked. Interlocking to be provided to prevent the cassette from being withdrawn until it is electrically disconnected. The plug in connector to be made of silver plated copper and should comprise of two co-acting oblong contact members held together by a U shaped leaf spring so that electro dynamic forces arising due to the current receives the contact increases at both sides. The MCCB compartment to have interlock such that it cannot be transferred to any position expect when the door is closed, MCCB is switched off and locking mechanism is realized. All MCCB’s protecting outgoing feeder circuits shall be of instantaneous type and shall be designed and constructed to have short circuit breaking capacity of not less than 50 KA, and shall conform to the requirements, including latest amendments, of I.E.C. 947-2. The breaking time of the MCCB shall not exceed 20 M sec. All MCCB’s shall be of thermal magnetic, manually and automatically operated type, and shall be designed to provide positive trip - free operation on abnormal overloads with quick break contacts for both manual and automatic operation. Adequate and rapid arc interrupting devices. An inverse time element shall be provided on each pole of the breaker for common tripping of all poles.



T05-20/11/2013



16000.2.5 Instruments and Meters Three ammeters and one voltmeter to IEC 51, with integral phase shift switch, shall be provided on each incoming feeder. These shall be of the moving iron type and shall be suitably scaled with a circular arc scale of not less than 90 Deg. C. and mounted flush on the panels. The voltmeters shall be fuse protected. The ammeter shall not be damaged by the passage of fault current through the primary of their corresponding current transformer. Three ammeters and one voltmeter to IEC 51, with integral phase shift switch, shall be provided on each incoming feeder. These shall be of the moving iron type and shall be suitably scaled with a circular arc scale of not less than 90 Deg. C. and mounted flush on the panels. The voltmeters shall be fuse protected. The ammeter shall not be damaged by the passage of fault current through the primary of their corresponding current transformer. 16000.2.6 Metering and Protective Transformers All current transformers shall be insulated with the best available materials and shall be capable of continuous and prolonged service without the severe effects of thermal and mechanical stresses of short circuit currents. They should have rated burden sufficient for the relays and meters. Current transformers shall be in accordance with IEC 185. Voltage transformers shall be in accordance with IEC 185 with a rated voltage factor of 1.2 and rated output 30VA, Class 1.0. 16000.2.7 Accessories and Tools The contractor shall supply a complete set of special tools, if recommended by the manufacturer and required for the proper maintenance of the boards. 16000.2.8 Internal and Auxiliary Wiring Internal and auxiliary of maximum size 1.5mm2, 600/1000V grade of fire proof insulation shall be used throughout, and shall be protected against mechanical damages. Each connection shall be terminated on a terminal board mounted in a readily accessible position. 16000.2.9 Labelling On each board, the incoming and every outgoing feeder panel shall be labelled, in English, by means of approved name plates made of aluminium and fixed to the panel doors by screws. 16000.2.10 Main & Sub-main L.V. M.C.C.B. Distribution Panel Boards The contractor shall supply, install, test, connect and commission in the approximate locations indicated on the drawings, main & sub-main L.V. M.C.C.B. distribution panel boards, Form 2 designated MDB & SMDB, as specified in this clause and as detailed in the L.V. distribution schematic drawings. The MDB shall be assembled in the original manufacturer works. 16000.2.11 General Requirements All MDB’s & SMDB’s shall be of 600V/1000V insulation grade and shall be capable of withstanding short circuit fault levels of 35 KA for 1 sec. All MDBs & SMDBs should be type tested according to IEC 439-1. The contractor should ensure that his proposal for MDB is from a



T05-20/11/2013



manufacturer who has available tests report for at least the tests listed below and certified by an independent testing authority.

1.) Short circuit withstand strength for 35 KA 1 sec. 2.) Measurement of the temperature rise of the main busbar systems. MDB’s & SMDB’s shall be of the floor mounted, free standing, front access type, with cable compartment and shall be totally enclosed, complying with IEC 439 and degree of protection IP31. The enclose should be made of Aluzink. The cable and apparatus compartment to be separated by barriers. Each MCCB should have its own door with rotary handle on the outside for manual operation of the MCCB. Provision shall be made for top or bottom entry for the incoming cable and bottom entries for all outgoing cables. The incoming shall be in separate cubicle if the rating is bigger than 800A. The Contractor shall furnish technical details of the proposed equipment to the Engineer for his approval. All MDB’s & SMDB’s shall be installed complete in all respects and shall be tested and commissioned to the satisfaction of the Engineer. Each MDB’s & SMDB’s to have one voltmeter and S/S. 16000.2.12 M.C.C.B.’s MCCB installed in the MDB & SMDB shall be of plug-in type i.e. MCCB can be removed from its fixed base without disconnecting any cables or unfastening screws. The MCCB to be interlocked preventing dismounting with MCCB in the on position. The incoming MCCB shall be 4 poles and outgoing MCCB shall be 3 poles. MCCB shall conform to the requirements of the Standards including latest amendments of I.E.C. 947-2. All M.C.C.B.’s shall be designed and constructed to have a short circuit breaking capacity of not less than 35 KA at 415V, 50Hz. The breaking time of the MCCB shall not exceed 20m sec. All MCCB to have ON, OFF, TRIP position. 16000.2.13 Final L.V. Miniature Circuit Breaker (M.C.B.) Split Bus Distribution

Boards.

The Contractor shall supply, install, test and connect M.C.B. distribution boards in the approximate locations indicated in the drawings. 16000.2.14 General Requirements Split bus MCB Distribution board shall incorporate a main switch for the whole panel board and sub-main earth leakage circuit breaker to protect each part of the panel board against earth leakage. Split bus section shall comply with latest DEWA regulations, unless otherwise shown on the drawing. For wiring of circuits consisting of wire sizes 10mm2 and larger shall be of bolted pressure type, with a pre-insulated sleeve connectors shall be manufactured from a high conductivity copper which shall be electro tin plated. These boards shall be constructed of sheet steel of minimum thickness 1.2mm and have a gland plate of 1.5mm thickness. They shall be enamelled to light grey colour, and shall be manufactured to comply with the requirements of BS 5486, Part 1 and 12.



T05-20/11/2013



All boards shall be factory fabricated and shall be totally enclosed corrosion proof. Busbars shall be rated for 200A, tinned copper. In general these shall be of the flush mounted type, unless otherwise instructed by the engineer. Each board shall be provided with a cover and lock. The boards shall have facility for circuit identification inside the board. 16000.2.15 M.C.B.’s All M.C.B.’s shall be of current limiting, hammer trip system and trip free mechanism, designed and type tested to 871: PT 1 with undelayed magnetic and delayed thermal trips, of fixed setting. They shall be DIN rail mounted inside the enclosure to allow removal or mounting of MCB without disturbing other MCB. These shall be of type 2 characteristic for all general lighting and small power circuits, and of type 3 characteristic for circuits supplying pumps, A/C units, street lighting etc. Category of duty shall be M6. All MCB shall have a trip position indication, and facility for label carrier. Each MCB should have protection against contact with live parts in accordance to IEC 364. Terminals of MCB to be of dual function for connection of busbar or wire. MCB to be suitable for operation at an ambient temperature of max + 55 Deg. C. The life expectancy to be at least 10,000 operations. 16000.2.16 Residual Current Circuit Breakers In addition to the over current and short circuit protection afforded by M.C.B.’s every circuit supplying 13A socket outlets, Water heater, water cooler, window type A/C unit, cooker unit, shall be equipped with a Residual Current Circuit Breaker conforming to BS 4293: 1983 to provide protection against shock and earth leakages. The sensitivity of these units shall be 30 MA. In addition the incomer of each FDB shall be equipped with a TP + N 300 MA RCCB. The (RCCB’s) up to 63A to be current-operated residual current devices using the core balance transformer principle and a permanent magnetic tripping device trip free construction. The enclosure to be made of grey moulded plastic with white test button. The RCCB’s to be designed for easy and quick mounting by snap-on fastening onto DISN-rails in accordance with EN 50 022, 35mm. It should have dual terminals suitable for flexible and solid conductors. The life expectancy to be at least 10,000 operations. It should be suitable for operation in ambient temperature of upto + 550C. It should be provided with protection against unintentional direct touch. 16000.3

CONDUITS AND FITTINGS

16000.3.1General The Contractor shall supply and install a complete system as shown on the Drawings, and as herein specified. The system shall include conduits, fittings(couplings, bends, cover plates, reducers, adaptors, etc.) and all necessary parts to install a complete conduit system. Conduits and fittings shall be distinctively marked as manufactured for electrical purposes. Conduits runs are shown diagrammatically to outline the general routing of the system. The installation shall be made to avoid interference with pipes, ducts, structural members, or other equipment. Should structure or other interferences prevent the installation of the conduits, or setting of boxes, cabinets, or other electrical equipment, as indicated on the Drawings, deviations



T05-20/11/2013



must be approved by the Engineer, and after approval, shall be made without additional charges. The number of raceways shall not be less than that indicated on the Drawings. Conduits and conduit fittings shall be so designed and constructed that they ensure reliable mechanical protection to the cables contained therein, and shall withstand the stresses likely to occur during transport, storage and installation. They shall be marked with the marker’s name or trade mark. Marking shall be indelible and easily legible. Conduits shall have a minimum 20 mm ( outer diameter ) size and shall be adequate for proper and easy wire pulls, and in no case shall the wires occupy a cross-sectional area of more than 30% of the inner conduit cross-section. Additional extra conduits to be provided for all electrical and low voltage system wiring for future purposes. The inside and outside surfaces of conduits shall be smooth and free from burrs, flash, and similar defects. Thickness of wall shall be uniform. The interior and ends of conduit fittings shall have no sharp edges, surface and corners over which the cables are likely to be drawn shall be smooth and well rounded. Conduits and fittings shall have adequate mechanical strength. Conduit when bent or compressed, or exposed to impact or extreme temperatures, either during or after installation, shall show no cracks and shall not be deformed to such an extent that introduction of the cables are likely to be damaged while being drawn in. Conduit entries of fittings shall be so designed that a reliable joint can be made between the conduit and the fittings. Conduits and fittings shall be MARSHALL - TUFFLEX ( U.K. ) or approved equal. All accessories and fittings such as bends, straps, double straps, junction boxes, bushes, etc. shall be provided and as required. 16000.3.2 Conduits and Fittings - Non-metallic Non-metallic conduits shall be heavy gauge high impact rigid PVC type A (Metric) or Type AN (Imperial) unless otherwise indicated, having a maximum continuos service temperature of 70 deg. C or more. Conduits and fittings shall comply with BS 4607. Conduits shall be manufactured by Marshall Tuflex (England) Plastitube (England) or approved equal. 16000.3.3 Conduits and Trunking - Metallic Conduits shall be constructed from solid drawn mild steel outside and inside hot dipped galvanized. The galvanized coat of zinc shall be of uniform thickness applied to outside and inside including the threads. Each conduit shall be straight, free from blisters and other defects, cut square and taper reamed. Coupling shall be galvanized both inside and outside including threading to ensure galvanic protection on all surfaces.



T05-20/11/2013



The galvanized coating shall be of such quality and uniformity that a sample of the galvanized conduit will not show a fixed deposit of copper after four immersions of dips in a standard copper sulphate solution. The galvanized coating on the conduit shall be sufficiently elastic to prevent cracking or flaking when a sample of finished conduit is bent 90 degrees at a minimum temperature. Metallic conduits shall comply with BS 4568. Conduits and trunking shall be manufactured by Davis (UK) or approved equal. 16000.3.4 Conduits - Flexible Flexible conduits shall be constructed by square locked galvanized steel with a PVC outer covering. Non-metallic flexible conduits shall be manufactured by Egatube (England), Marshall Tufflex (England), Plastitube (England) or approved equal. Metallic flexible conduits shall be manufactured by Burn Tubes (England), Simplex (England), or approved equal. 16000.3.5 Boxes - Metallic Boxes shall be constructed of cast metal as specified hereinafter. Boxes used for hanging fixtures shall be suitable for ceiling roses. Boxes for installation in concrete tight. Shallow boxes shall not be used unless building construction is such that it is impossible to use standard depth boxes. Boxes covers shall be constructed of feroalloy cad/zinc electro-plated with aluminium cellulose lacquered. Blank covers shall be constructed of sheet steel with gasket and stainless steel screws except for damp and wet locations. In damp and wet locations blank covers shall be constructed from cast ferroalloy with gasket and stainless steel screws. Floor boxes shall be water tight one piece cast iron colour coated inside and out for additional corrosion resistance. Threaded steel cover shall be electro-galvanized. Boxes shall have adjusting screws. Boxes shall be manufactured by M.K. (U.K.), ASHLEY (U.K.) or approved equal. 16000.3.6 Boxes - Non Metallic Boxes shall be standard PVC as specified under conduits and fittings or phonolic material except for recess lighting outlets which shall be high degree type. High degree type boxes shall be manufactured from Noryl, a theromoplastic with a higher softening temperature. Boxes shall withstand a 10 Kg. Load directly suspended at 100 deg. C for 24 hours. Boxes shall incorporate pillars with threaded steel inserts. All boxes shall be provided with grounding ( earth ) terminals. 16000.3.7 Installation of Conduits



T05-20/11/2013



Conduits embedded in ceiling slab, in walls and underfloor shall be non-metallic type. Conduits exposed above false ceiling shall be non-metallic type. Exposed conduits other than above false ceiling shall be rigid steel type. All conduit work and plastering shall be completed before wires are pulled in unless otherwise permitted by the Engineer. Conduit shall be plugged with cork and boxes covered appropriately before plastering to avoid filling with plaster. Conduit runs between outlets shall not contain more than three quarter bends, or the equivalent. The maximum run between two outlets shall not exceed 25 metres, for straight runs and 10 metres for runs with one or more bends. Pull boxes shall be provided otherwise, whether so indicated on the Drawings or not. Position of pull boxes shall be to the approval of the Engineer. Conduits shall be installed without causing any damage to the structural members. All bends shall be carefully made to prevent distortion of the circular cross section. Bends made on site in conduits shall have an inside radium of not less than nine diameters. Where bends of less than nine diameters are necessary standard factory elbows shall be used, however the conduit size chosen shall be such as to permit a cable bending radius within the factory elbow of at least eight times the cable diameter. Conduits in slab shall be installed as close to the middle of the concrete slabs as practicable without disturbing the reinforcement. The outside diameter shall not exceed one third of the slab thickness and conduits shall be placed not closer than three diameters from the centre to centre. Conduits in slabs shall be placed parallel to the main reinforcement steel in the slab. Top of any conduit shall be at least 2 cm below the finished floor surface, unless otherwise indicated or authorized. Conduits running parallel to beam axis shall not run above beams. Exposed conduits shall be installed parallel or at tight angles to Walls and ceiling beams. All changes in direction shall be made as far as possible with approved bends, elbows and pull boxes. The spacing between parallel runs shall be uniform throughout. Unless otherwise indicated, conduits shall be held securely in place by standard factory spacer bar saddles, spaced not more than 1 metre apart for non-metallic and 1.5 metres for metallic conduits. Expansion couplings shall be installed at 8 metres in runs of exposed conduit work. Unless otherwise indicated, raceways exposed above false ceilings shall be supported from the slab above the ceiling in the manner as exposed raceways. Raceways shall not be supported from false ceiling supports. Couplings, expansions coupling, strap saddles, spacer bar saddles, spring clip saddles, conduit clips, adaptors, etc., shall all be standard factory conduit accessories. Flexible metallic conduits shall be used only for connections to motors, or other equipment subject to vibration or adjustment or to make connections to lighting fixtures in false ceilings. Each connection shall contain at least one quarter bend so that no vibration can be transmitted behind the flexible connection. In damp and wet locations all couplings, expansion coupling, strap saddles, spacer bar saddles, spring clip saddles, conduits clips, screws, adaptors shall be corrosion proof, approved for use in damp and wet locations.



T05-20/11/2013



In damp and wet locations flexible conduits shall be liquid-tight. All conduits shall be carefully cleaned before and after installations. All ends shall be reamed free from burrs and inside surfaces shall be free from all imperfection likely to injure the cable. After installation of each complete new conduit run, the run shall be snaked with a band to which shall be attached an approved tube cleaner equipped with an approved cylindrical mandrel of a diameter not less than 85 percent of the nominal diameter of the conduit. All conduits through which the mandrel will not pass shall be removed and replaced by the Contractor at his own expense. All fields cuts in conduits shall be square, and cut ends shall be filled and shall have burrs, removed. An insulating bushing shall be installed on each end of conduit, unless the connector is designed to prevent contact with the cut end. All connections shall be mechanically strong and tight, and made up properly with approved connectors. No running threads shall be permitted. Conduits for TV system shall be at least 10 cms. Bending radius. Two bends might be necessary for the transition from floor to wall. 16000.3.8 Installation of Boxes Boxes of ample capacity shall be provided at every junction conduit system and as required by the Specifications. All boxes shall be securely fastened. Blank plates shall be installed on outlets boxes in which no apparatus is installed does not provide a suitable cover for the box. Device boxes shall be used for all wiring devices. Non-metallic boxes shall be used only for concealed conduit work, and for conduit work above false ceiling. Exposed boxes for switches, socket outlets and other devices shall be cast metal boxes. Cast metal boxes shall be installed in such manner that the conduit connections and the gasketted cover are dust-tight. All unused openings shall be closed with pipe plugs and compound. Boxes for similar equipment shall be mounted at uniform height within the same or similar area. Mounting shall be as shown on the Drawings. Device boxes shapes and sizes shall be determined by the type and size of wiring devices for which they serve. Device outlet boxes, shall be made of galvanized steel and shall be from the same manufacturer as the wiring devices. Lighting outlet boxes shall be circular outlets shall be plain with horizontal conduit connections where used exposed, or above false ceiling, and shall be loop-in type where used embedded. Where so indicated lighting outlets shall be provided with ceiling roses of approved type and a flexible cord with a bayonet type lamp holder. Loop in type junction boxes shall be made of a high temperature resistant material. Boxes fixed inside false ceiling shall be provided with mounting brackets for rigid fixing to structure members or other means of support. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



16000.3.9 Sleeves Sleeves shall be provided for exposed conduit or cables passing through interior floor slabs and walls. All openings shall not be sealed with mastic compound. The compound shall not cause any corrosion or harmful effects to the conduit. Sleeves passing through floor slabs shall be flush with the bottom of the slab, extended approximately 3 cm. Above the surface of the floor and be water-tight between sleeves and floor slab. Sleeves passing through exterior walls and slabs shall be wall entrance seals or water-tight construction. They shall be water-tight between slab and sleeve, and between sleeve and conduit and cable. These wall entrance seals shall be of malleable iron with black paint finish and PVC sleeve, with water-tight sealing gland. Sealing gland design shall be such that they may be tightened any time after installation. Wall entrance seals have oversized sleeves of proper length to position the sealing-gland housing with the wall faces. After the cable has been pulled through the duct, a seal shall be made round it, within the duct with a bituminous mastic compound, making the seal water-tight. 16000.3.10 Adhesive and Joints Conduits shall be jointed and terminated utilizing the appropriate components as supplied by the conduit manufacturer. Permanent adhesives to produce a rigid water-tight joint shall be used with standard couplers and accessories. A flexible (non-hardening) adhesive shall be used where expansion facilities are required. 16000.3.11 Expansion Joints Expansion coupling shall be provided at every 6 meter run of exposed conduit work, at expansion joints or as required to compensate for thermal expansion and contraction of both exposed and embedded conduits. 16000.4 WIRES AND CABLES 16000.4.1General The Contractor shall supply and install all wires and cables necessary for the complete Electrical System, as indicated on the Drawings, and as herein specified, in an acceptable and workmanlike manner. 16000.4.2 Single Core Power Cables Single core power cables running in concrete trenches such as those running from the transformer room to the electrical room equipment shall be single core, complying with the specifications indicated hereinafter Conductors shall be plain annealed copper complying with BS 6360. Insulation shall consist of extruded PVC complying with BS 6746, with minimum 2.8 mm thickness for the 6030 mm2 conductor.



T05-20/11/2013



Sheet shall be of an extruded layer of black PVC of minimum 2.2 mm thickness for 630 mm2 conductor. 16000.4.3 XPLE Cables ( 600/1000V ) Conductors shall be either plain annealed or tinned copper complying with BS 6360 unless indicated aluminium in which case it shall comply with BS 6791. Insulation shall consist of cross-linked polythene applied by extrusion to form a compact homogeneous body. Bedding shall comprise at least two layers of suitable tape to give a substantially uniform thickness to armoured cables. Armour shall consist of a single layer of galvanized steel wires complying with BS 1442 or aluminium strip complying with BS 2897. ( N.B. : Single-core armoured cables have nonmagnetic armouring of aluminium wire or strip. The outer sheet shall be an extruded layer of black PVC complying with BS 6746 for Type 1 compound. Core identification shall be provided by the application of number or colours, e.g. coloured lines. The ends of each length of cable shall be marked red and green. At the end marked red, the sequence of core colours shall be clockwise, at the end marked green, the sequence shall be anti - clockwise. 16000.4.4 Wires and Cables - Light and Power Conductors shall be of high conductivity annealed copper with concentric stranding for stranded conductors, to BS 6360 or approved equal. PVC shall be compounded to BS 6746 or approved equal. Minimum conductor size used shall not be less than 2.5 mm2. Wires and cables for lighting and power systems in conduits shall be single core, PVC insulated, shall be of grade not less than 450/750 volts, to BS 6004. Wires in boiler rooms (if any) shall be MICC cables to BS 6207. Armoured cables shall be PVC insulated, extruded PVC sheathed, multicore unless otherwise indicated, galvanized steel wire or double tape armoured, and overall extruded PVC sheathed, and shall be of grade not less than 600/1000 volts to BS 6346. Single core armoured cables shall have a hard drawn aluminium wired armouring. Conductors shall be solid-stranded. Flexible cords for connection of fixtures to circuit-wiring shall have finely stranded copper conductor with a PVC insulation, type NYFAF, 380 V grade. Wires and cables shall be manufactured by DELTA (England ). 16000.4.5 Flexible Cords



T05-20/11/2013



Cords used for water heater connections shall be of high conductivity tinned copper wires, (4mm2 unless otherwise indicated) insulated with ethylene propylene rubber, three cores twisted together, filled and sheathed with chlorosulphonated polythylene, (EPR CSP), 300/500 V rated and shall withstand an operating temperature of 85 deg. C, to BS 6500. Cords used for pendant lighting point and between lighting outlet above false ceiling to lighting fixture shall be circular three core (1mm) silicon rubber insulated, glass fiber braided 300/400 V rated, and shall withstand an operating temperature of 150 deg. C, to BS 6500. Cords used for extract fans shall be of high plain annealed copper conductor (1 mm2), PVC insulated, circular three cores twisted together, PVC overall sheathed 300/500 V rated, shall withstand an operating temperature of 70 deg. C to BS 6500. Cords shall be manufactured by DELTA (England). 16000.4.6 Wires and Cables - Telephone Wires and cables will be supplied and installed by the local telephone company. The Contractor shall attend and afford all facilities to the Telephone Company and shall take prior written approval of the adequacy of the conduit system proposed for the telephone system before installation of the conduit system. 16000.4.7 Cables - Interphone & Bells Wires shall be rated for a minimum 250 volts service. The conductor shall be tinned annealed 1 strand, high conductivity copper, insulated with 0.5 mm thick PVC compound Conductor shall have a minimum of 0.7 mm2 cross-section. Cables shall be manufactured by DELTA (England). 16000.4.8 Cables - Sound System Wires for loudspeakers shall be rated for a minimum 250 volts service. The conductor shall be tinned annealed 1 strand, high conductivity copper, insulated with 0.5 mm thick PVC compound. Conductor shall have a minimum of 0.7 mm2 cross-section. Cables for microphone shall be 2 x 0.5 mm2, screened. Cables shall be manufactured by BICC (England), AEI (England), SIEMENS (Germany), or approved equal. 16000.4.9 Control Cables Control cables where used underground direct burial shall comprise stranded annealed copper conductor of minimum 2 mm2 cross-section insulated with high dielectric polyvinyl chloride, nylon sheathed with a tape binder applied over the assembly, overall PVC jacketed. Number of conductors shall be equal to the maximum number of functions plus 20% spare. Cable shall be 300/500V insulation grade. Junction boxes shall include all necessary terminal connector boards with proper labels. Contractor cables where used in ducts underground or in conduits above ground shall comprise stranded annealed copper conductor of minimum of 2 mm2 cross-section for cables in duct and D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



0.75 mm2 for cables in conduits insulated with high dielectric polyvinyl chloride, and PVC sheathed. Control cable shall be Alpha (USA) or approved equal. 16000.4.10 Cables - Central Antenna System Cables shall be coaxial type with inner conductor of solid accurately dimensioned electrolytic copper, insulation of high grade solid polythylene, outer conductor of longitudinally overlapping copper foil tightly enclosed in copper/wire braiding, outer sheet of a pliable PVC. Characteristics impedance shall be 75 ohms. Inner conductor shall have minimum of 0.7 mm diameter. Overall diameter of cable shall not be less than 7 mm. Cable shall have a tensile strength on outer conductor of 20 kgs. For one minute. For distribution cable losses shall not be more than 19.5 dB at 800 mH2 and for main riser cable losses shall not be more than 11.5 dB at 800 mH2. Cable shall be manufactured FUBA (GERMANY), HIRSCHMANN, or approved equal. 16000.4.11 Installation of Wires And Cables All wires shall be installed in accordance with the applicable provisions of the approval codes and as indicated on the Drawings. The number of wires and sizes of conduits indicated on the Drawings are a guide only and are not necessarily the correct number and sizes necessary for the actual equipment installed. The Contractor shall install as many wires and conduits as required and necessary for a complete electrical system, and shall provide adequately for the equipment actually to be installed. Where more than one conductor is used per phase, each phase, neutral in any and ground wires shall be run in each metallic or non-metallic conduit. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. At every outlet and pull box, wires and cables passing through, shall be left slack by an amount equivalent to 15cm. of cable length to allow inspection and connection to be made therein. No cable bend shall have a radius of less than eight times its diameter. The Contractor shall not change any circuit number, especially from a phase to a different phase. If such a change is necessary due to modification on site, the Contractor shall bring this matter to the attention of the Engineer. All conductors to be contained within a single conduit shall be drawn in at the same time. A wire pulling compound shall be applied to conductors being drawn through conduit. Pulling compound shall be soap tone or approved material. Only cables forming part of a list installation if any may be run in a lift shaft. Wires and cables for feeders, sub-feeders, control, and branch circuit wiring shall be colour coded as follows: D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Colour

Phase

Red Yellow Blue Black Green

A or 1 B or 2 C or 3 Neutral Equipment earth

Wire and cable sizes shall be as indicated on the Drawings; however in no case shall their size be smaller than that required by the wiring regulations. Unless otherwise indicated, no conductor for light and power wires shall be smaller than 2.5 mm2. All branch circuits for lighting and appliances shall be single conductor cables run inside conduits, unless otherwise indicated. Feeders and sub-feeders shall be either single conductor wires pulled inside conduits or multiconductor cables run exposed on walls or in trenches as shown on the Drawings. Single cables shall be fixed directly to walls or ceilings. Where 2 or more cables are run in parallel they shall be fixed on galvanized steel perforated trays or on other approved special cable supporting and protecting arrangement. Cables shall be fixed to the supporting structures with approved galvanized cast steel clamps at distances not exceeding 20 diameters. Armoured cables used in shafts shall be of the steel wire armoured type and not the tape type. No joints or spices shall be accepted on main feeders. 16000.4.12 Identification of Wires And Cables Each wire shall be labelled at both termination points. Individual conductor circuit identification shall be carried throughout, with circuit numbers or other identification clearly stamped on terminal boards and printed on directory cards in distribution cabinets and panel boards. In junction boxes, cabinets and terminal boxes where the total number of control, indicating and metering wires is three or fewer and no terminal board is provided, each wire including all power wires, shall be properly identified by means of a plastic-coated, self adhesive, wire marker. Wires including motor leads and other power wires too large for connection to the terminal boards shall be identified by wire markers as specified above. In manholes, pull boxes, junction boxes and at both terminals, each wire and cable shall be properly identified by a laminated plastic tag located so as to be easily seen. Wires and cables shall be identified by cable number indicated on the Drawings.

16000.4.13 Connectors and Terminal Blocks For the wiring of circuits consisting of wire sizes 6 mm2 and smaller such as for lighting branch circuits, self insulated pressure type connectors shall be utilized for all splices or joints. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



For the wiring of circuits consisting of wire sizes 10 mm2 and larger shall be of the bolted pressure type, with a pre-insulated sleeve. Connectors bodies shall be manufactured from Polymide. 16000.4.14 Cable Trays Cable trays shall be manufactured from mild steel sheet of a minimum thickness of 2 mm. They shall be light or heavy duty as required with return flanges and hot-dip galvanized finish. Bends, corners, etc. shall be specially manufactured for the purpose. All supports and accessories like hangers, channels, bolts and nuts, cable ties and conduit clamps shall be furnished as to function to the manufacturers standard. Metallic elements shall be hot dip galvanized. The Contractor shall provide technical catalogues and shop drawings to illustrate the sufficiency of the supports and tray sections thicknesses. The installation shall have a design assuming double the actual load in addition to the safety factor recommended supports and tray sections thicknesses. Cable trays and accessories shall be manufactured by or Davis (UK) or approved equal.

16000.4.15 Cable Ladders Cable ladders shall be manufactured from 14 Swg. Mild steel with hot dip galvanized finish. All parts such as flat elbows, offset reducers, straight reducers, cross pieces, drop outs etc., as well as accessories shall be furnished as to function and to the manufacturer’s standards. Cable ladders parts and accessories shall be manufactured by Davis (U.K.) or approved equal. 16000.4.16 Cable Glands Cable glands shall be provided at the terminal of armoured cables at the enclosure of a distribution board or any other equipment. Cable glands shall be indoor or outdoor type ordinary or weather proof according to the location of the termination to the approval of the Engineer. Cable glands shall be of machined brass construction and shall have metric threads to I.S.O standards. 16000.5

WIRING DEVICES

16000.5.1 General The Contractor shall supply and install all of the wiring devices as indicated on the Drawings and as herein specified. Wiring devices shall be flush mounted type unless otherwise noted and shall be installed at heights as shown on the Drawings, or as directed by the Engineer.



T05-20/11/2013



Wiring devices fixed on glazed tiles shall include a rubber gasket between the cover plate and the glazed tiles for rigid fixing of the device plates. The gaskets shall not protrude beyond the plate; they shall be neatly cut in the shape of the plate. Samples of devices and plates shall be submitted for choice and approval of the Engineer. Wiring devices shall be manufactured by MK (UK), Crabtree (UK), or approved equal. 16000.5.2 Device Plates Plates shall be rectangular or square in shape to the approval of the Engineer. Plates shall be designed to match associated devices. Plates for cords extension shall be provided with cord-grip bushing, threaded type of same material and finish as of plate. Plates for flush mounting devices shall be constructed of metallic finish, (satin chrome or brass for exposed areas and white PVC for all other areas (servant block etc.) unless otherwise specified or indicated on the Drawings, to the approval of the Engineer. Fixing screws shall be chromium plated and polished. Screw heads shall be finished to suit the plates. 16000.5.3 Switches Switches shall be rocker operated mounted with the operating handle in upward position when in the “ON” position, unless otherwise directed by the Engineer. Switches shall be satin chrome finish if not otherwise specified. Switches shall interrupt the phase wire and neutral simultaneously as applicable. Switches shall be quick-make, quick-break, with silver alloy contacts, trunnions and spring assembly lubricated for the life of the switch neoprene bumpers. Switches shall be 250 volt ac only rated with number of poles and amp ratings as indicated on the Drawings, to BS 3676. (See also switch panels). Switches shall be fully rated for tungsten filament and fluorescent lamp loads, and up to 80% of rated capacity for motor loads. Switches shall be similar to MK or Crabtree satin chrome metal or brass finish, unless otherwise specified or indicated on the Drawings to the approval of the Engineer. 20-Amp double pole switches shall incorporate a pilot light, and shall have the words “ Water Heater “ engraved on it when used for that purpose. 20-Amp double pole switches shall be MK or Crabtree to the approval of the Engineer. 30-Amp double pole switches shall incorporate the inscription indicating the purpose of its use. 30-Amp double pole switches shall be MK or approved equal. 45/50-Amp double pole switches shall incorporate a pilot light, and shall have the work “Cooker” engraved on it when used for that purpose. 45/50-Amp double pole switches shall be MK or Crabtree to the approval of the Engineer. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



16000.5.4 Switch Assemblies ( Switch Panels ) Switch assemblies (switch panels) shall be of the gridswitch system, comprising rocker-operated grid switches and cover-plates of matt chrome unless otherwise indicated. Switch assemblies shall comprise 20-amp lighting switches and other units if so indicated on the Drawings. Switches shall be MK or Crabtree to the approval of the Engineer. Switch assemblies shall have the words “Danger 415 Volts” engraved in red in it. Coverplates shall be MK or Crabtree unless otherwise specified or indicated on the Drawings, to the approval of the Engineer. 16000.5.5 Socket Outlet Socket outlets shall be mounted with correct polarity, such that the switch shall cut the hot wire. Socket outlets shall be of the standard, 3-pin, switched, single phase, metallic finish (brass or satin finish) unless otherwise specified. 13-Amp socket outlets shall be flat pin type, to BS 1363, simplex or duplex as indicated. 13-Amp socket outlets shall be MK or Crabtree unless otherwise specified or indicated on the Drawings to the approval of the Engineer. 15-Amp sockets shall be round pin type to BS 546. 15-Amp sockets shall be MK or Crabtree to the approval of the Engineer. 30-Amp sockets shall be round pin type, cover made of brass, and shall be provided with corresponding plugs. 30-Amp sockets shall be Walsall or approved equal. 16000.5.6 Door Contact Lighting Switches Switch shall be of a spring return action type and an adjustable plunger, suitable for safety room doors. Switch shall be similar to BRYANT or approved equal. 16000.5.7 Lighting Contractor Control Push Buttons Push buttons shall be double contact type with spring return action. Body shall be made of moulded plastic with clear baked acrylic protection. 16000.5.8 Low Current Jack Outlets Jack socket outlet shall be recess mounting type similar to Wallsall Catalogue Ref. P99A58 to the approval of the Engineer. 16000.5.9 Flex - Outlet



T05-20/11/2013



Flex-outlet shall be MK or Crabtree unless otherwise specified or indicated on the Drawings, to the approval of the Engineer. 16000.5.10 Cable - Outlet Cable outlet shall comprise a moulded cover plate with a side groove for 3 x 16 mm2 multicore flexible cord a cable clamp, 3 terminals for 16 mm2 conductors. Cable outlets shall be Crabtree or MK to the approval of the Engineer. 16000.5.11 Fused Connection Unit Fused connection unit shall incorporate 20-amp double pole switch, 13-amp fuse, and a neon indicator. When so indicated, units shall also include a cord outlet (flex - outlet ). Unit shall be MK or Crabtree to the approval of the Engineer. 16000.5.12 Industrial Sockets All industrial sockets shall have polycarbonate housing, impact proof and shall be enclose din IP 54 enclosure, splash proof. All industrial sockets shall conform to IEC 309 standards, and shall be suitable for surface mounting. 16 amperes 240 V sockets shall have a 2 pole + earth connection and shall be MK or approved equal. 32 amperes 240 V socket shall have a 2 pole and earth connection and shall be MK or approved equal. 32 amperes 415 V socket shall have a 3 pole + neutral + earth connection and shall be MK or approved equal. 16A socket outlets shall have a top conduit entry suitable for diameter 20 mm conduit, and 32A socket outlets shall have a conduit entry of diameter 25 mm. 63 amperes 415 socket shall have a 3 pole + neutral + earth connection and shall be MK or approved equal. 16000.5.13 Protective Socket Cover Weatherproof socket outlets shall be provided with protective socket covers. Protective socket cover shall be manufactured from high impact resistant “NORYL”. The cover shall be designed to fall by gravity over the socket whether a plug is inserted or not. Cover shall be similar to Egatube “Guardian” to the approval of the Engineer. 16000.5.14 ELCB Protected Socket Outlet ELCB protected socket outlet shall be 13-amp switched type with added protection against the risk of fire and electrocution by tripping out in the event of current leaking to earth in excess of 10 mA.



T05-20/11/2013



ELCB protected socket outlet shall be suitable to fit in place of 13-amp duplex socket outlet. ELCB protected socket outlet shall otherwise be similar to 13-amp switched socket outlet. ELCB protected socket outlet shall be MK, Crabtree or approved equal. 16000.5.15 Fan Coil Power Outlet Power outlets for fan coil units ceiling mounted shall be flush mounting 13-amp fused connection units incorporating double pole switch, neon indicator and fuse of a appropriate rating. Device shall be MK or Crabtree to the approval of the Engineer. Outlet for fan coil units installed at low level shall be a recess mounting 13-amp, fused connection unit incorporating a double pole switch, neon indicator, fuse of appropriate rating and flex outlet. Outlet shall be MK or Crabtree to the approval of the Engineer. 16000.5.16 Telephone Outlets Telephone outlets shall be cord grip type and shall consist of terminal block of high insulating phenolic block with non-ferrous screws and straps. Telephone outlets shall comply with the latest ETISALAT requirement. Telephone outlets shall be MK or Crabtree unless otherwise specified or indicated on the Drawings to the approval of the Engineer. 16000.5.17 TV Outlets TV outlets cover shall have a low attenuation (1 db) for all frequencies. TV outlets shall be supplied with matching plugs and cord of 1.2 metres. TV sockets shall be FUBA or approved equal. 16000.5.18 Start-Stop Pushbutton Stations Stations shall incorporate two pushbuttons which shall be momentary contact type devices one for stop, coloured red, one for start, coloured green. Pushbuttons shall be moulded from trac-resistant material, and shall be provided with button shrouding ring. A pilot light shall be incorporated with a green polycarbonate lens which shall be lit when the “Start” is actuated. Legend plates shall be incorporated with the inscriptions “ON” and “STOP” for the Stop-button. Push-button stations shall be recess mounting type provided with an enamelled heat gauge steel box. The cover shall be fully gasketted and fixed by chromium plated retaining screws. Units shall be similar to Crabtree “A” range push-buttons stations GE Simplex (England), MEM (England), or approved equal. 16000.5.19 Jack Socket Outlet



T05-20/11/2013



Jack outlet shall be recess mounted type similar to Wall sall Catalogue Ref. P99A58 to the approval of the Engineer. 16000.5.20

Cable Outlet

Cable outlet shall comprise a moulded cover plate with a side groove for 3 x 16 mm2 multicore flexible cord a cable clamp, 3 terminals for 16 mm2 conductors. Cable outlets shall be Crabtree or MK to the approval of the Engineer. 16000.5.21 Control Stations Control stations shall be spring type, with silver plated contacts. Contacts shall be 5 amp rated. Plate shall be constructed from aluminium gray baked enamel painted. ON OFF maintained contact station shall have two push-buttons, one GREEN for ON and one RED for OFF. A green pilot light shall be incorporated which shall lit when push-button ON is depressed. The words ON & OFF shall be engraved on the push-buttons in white. START-STOP momentary contact type station shall have two push-buttons, one GREEN for START and one RED for STOP. A green pilot light shall be incorporated which shall lit when push-button START is depressed. The work START and STOP shall be engraved on all motor control stations. UP-STOP-DOWN momentary contact type stations shall have three push-buttons and no pilot lights. Push-buttons shall be moulded from trac-resistant material, and shall be provided with button shrouding ring. Key switch shall be a cylinder lock operator type station with three positions UP-OFF-DOWN. These words shall be engraved on the station. Stations in damp and wet locations shall be enclosed in a Feraloy box and covered with stainless steel plates. When line voltage is 380-415 and the control is line- to- line connected as described in the device in a clearly visible manner once the cover is removed. 16000.5.22 Floor Mounting Devices Floor mounting devices shall accommodate a floor receptacle, a cable outlet or a telephone outlet as shown on the Drawings. Receptacle shall have a hinged insert constructed from aluminium, with a special locking screw. Edge rings shall have interior adjusting screws. Where used for carpet floors a clear plastic carpet plate shall be used. Telephone outlets shall be split bell nozzle type Unused openings shall be covered with floor plate with removable plug insert. Devices shall be coordinated with floor boxes. Floor mounting devices shall be similar to Steel City floor mounting devices as manufactured by Midland-Ross (USA) or approved equal.



T05-20/11/2013



16000.5.23 Pedestal Mounting Devices Pedestal mounting devices shall be devices mounted on pedestal cast iron boxes, hammer grey finished, and shall be provided with gasket. 16000.5.24 Key Switch Key switch shall be cylinder lock operator type control station with three positions. UP-OFFDOWN. Legend plates shall be incorporated. 16000.5.25 Fireman’s Emergency Switch Fireman’s emergency switch shall be 16 Amp double pole or four pole as applicable. It shall incorporate a neon light. Opening of cover shall not be possible when live. It shall be protected against dust and splash of water to IP54. It shall be Legrand or approved equal. 16000.6 MOTORS & STARTERS 16000.6.1 General The Contractor shall supply and install the motors and the starters under other sections when so mentioned as shown on the Drawings as herein specified. Motor starting method and corresponding furnished starter shall be concordant. 16000.6.2 Ratings of Motors Motors shall be suitable for operation on a 220 - 240 Volt single phase or 380-415 Volt 3-phase, 3-Wire, 50Hz System as shown on the Drawings and shall be dirtproof fan cooled induction motor type unless otherwise indicated or specified. All motors shall have a service factor of 1.15. Motors of ratings smaller than 1 HP shall be single phase and those of rating 1 HP and above shall be three phase. Motors of rating larger than five horsepower shall be star-delta starting type, unless otherwise permitted or required by the Local Authorities. Motors of rating five horse power and smaller shall be direct on line starting type. Contractor Every motor shall be of sufficient capacity to operate the driven equipment under all load and operating conditions without exceeding its rated name-plate current or power or its specified temperature limit. The horsepower ratings for motors shown on the Drawings must be considered as an indication only. For the use of motors other than that specified, The shall assume the cost of and responsibility for, satisfactorily accomplishing all changes (Including engineering costs of redesign by the Engineer) in the work as indicated and specified. All derating resulting from site conditions shall be allowed for the design. Motor performances shall comply with the requirements of IEC 34-1.



T05-20/11/2013



16000.6.3 Types of Motors All motors shall be of a type approved for starting characteristics and ruggedness as may be required under the actual conditions of operation. All motors shall have class F insulation as minimum requirements. The motors shall be designed so that the maximum temperature rise at continuos run under full load and operation conditions shall be in accordance with NEMA Standards for Motors and Generators and based on the local ambient temperature. 1600.6.4 General Design Of Motors Motor windings shall be braced to withstand successfully the stresses resulting from the method of starting. The windings shall be treated thoroughly with approved insulating compound suitable for protection against moisture and slightly acidic or alkaline conditions. Bearing shall be of the self-lubricating type designed to ensure proper alignment of motor and shaft and to prevent leakage of lubricant. Bearings for open motors shall be of the sleeve or ball type, as specified under the respective items of mechanical equipment. Vertical motors shall be provided with thrust bearings adequate for all thrusts to which they can be subjected in operation. Indoor motors located in relatively clean surrounding, free from any abrasive or conducting dust or chemical fumes, shall be enclosed ventilated drip proof type. Otherwise motors shall be totally enclosed fan cooled type. Vertical motors if any shall be provided with thrust bearings adequate for all thrusts to which they can be subjected in operation. Vertical motors of open type shall be provided with drip hoods of approved shape and construction. When the drip hood is too heavy to be easily removed provision shall be made for access for testing. 16000.6.5 Motor Terminal Boxes and Leads Motors shall be furnished with oversize conduit terminal boxes to provide for making and housing the connections and with flexible leads of sufficient length to extend for a distance of not less than 10cm. beyond the face of the box. The size of cable terminals and conduit terminal box holes shall be as approved by the Engineer. An approved type of solderless lug shall be supplied. Totally enclosed motors shall have cast-iron terminal boxes. 16000.6.6 Motor Shop Tests Motor shop test shall be made in accordance with AIEE Test Code as specified in the ANSI C50 for Rotating Electrical Machinery or approved equal. NEMA Report-or-test forms shall be used in submitting test data. Complete tests of each motor supplied shall be made and certified test data sheets shall be submitted, unless witness shop tests are required by the Detail Specifications pertaining to the equipment. Each motor shall be tested for efficiency and power factor at 50, 75 and 100 percent



T05-20/11/2013



of its rated horsepower, for temperature rise, torque, starting current and dielectric strength and for compliance with all specified performance requirements. 16000.6.7 Motor Starters Motor starters shall built and sized in accordance with IEC Standard, 158-1, BS 775 and IEC 292-1 & 2 or approved equal. Starters shall be non-reversing, magnetic type unless otherwise indicated or specified. Shall starters shall be provided with thermal cut out devices in each phase calibrated for close protection of the motors against overloads. These devices shall trip the starters in case of overload and shall not allow it to be reset except manually. The thermal overload relays shall be adjustable from 90 to 110 percent of nominal rating. A single calibration adjusts all three legs. The overload relay shall be ambient compensated. The starter shall be provided with auxiliary contacts for the connection of interlocking and other circuits as required for the controls. Unless otherwise indicated, all starters shall be provided with START-STOP pushbuttons, and RED and GREEN pilot lights, all located on the starter front cover. An overload reset button shall be provided inside the cover. Push-buttons shall be momentary contact or maintained type as applicable for function of control. The starter shall have horsepower ratings at least equal to rating of motors they serve. Voltage of control circuit shall not exceed 240 volts for starters in motor control centres or panels. Individually mounted starters or combination starters may have their control voltage on 380-415 volts provided local regulations or local inspectors do not forbid the use of same. The Contractor when utilizing such voltage for control shall provide a clear warning of existence of such voltage within the station. If 240 volts are required by the local regulations or local inspectors, a neutral conductor shall be brought within the feeder of the starter of approved cross-section, at no extra charge. Starters shall be electrically held in, providing inherent under voltage release. Starters when not part of a motor control centre and are located indoors shall be encased in a General purpose enclosure, unless otherwise indicated. “Star-Delta” starters shall have additional “Star” and “Delta” contactors which shall be electrically and mechanically interlocked to close the motor in “Delta” connection with the supply after the “Star” contactor has opened. A timing device shall be fitted to provide and adjust time in “star” before changing over to the “Delta” connection. “Star-Delta Starters shall provide close transition. Schematic wiring diagram of all starters shall be provided on the interior of the starter front cover. Autotransformer starters if any shall have 2 coil construction with taps for 50, 65 and 80% starting voltage, shall be designed for medium duty, per NEMA standard ICS 2-214 or approved equal. Closed transition shall be provided. Three melting alloy overload relays shall be provided for overload protection except if used for fire pumps in which case provisions of approved Regulations shall be applied. Motor circuit protective devices are rated in accordance with IEE Regulations. Alternative proposals based on manufacturer’s recommendations shall be subject to the Engineer’s D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



approval. The Contractor shall in any case be responsible to assure that the circuit protective devices shall carry the starting current with no tripping, and if reducing trip rating results in a reduction in frame size, the contractor shall make sure that the new rating withstands the available short circuit current. 16000.6.8 Individually Mounted Combination Starter Combination starters shall comprise motor starters as specified hereinbefore and a moulded case circuit breaker in a NEMA 1 enclosure unless otherwise indicated. The circuit breaker may be magnetic only in lieu of thermal magnetic to the approval of the Engineer. Combination starters shall be manufactured by GE SIMPLEX (UK), CRABTREE (UK) or approved equal. 16000.7 LIGHT FIXTURES 16000.7.1 General The Contractor shall supply and install lighting fixtures including accessories, fixing hardware necessary for installations, as shown on the Drawings, and as herein specified. Fixture, housing, frame or canopy, shall provide a suitable cover for fixture outlet box or fixture opening. Fixtures shall not cause a temperature exceeding 90 deg. C on any outside surface. Fixtures shall comply with all applicable requirements as herein outlined unless otherwise specified or shown on the Drawings. Fixtures shall be completely wired and constructed to comply with the IEE wiring regulations requirements for Lighting Fixtures and with IEC publication 162 unless otherwise specified. Certain fixtures are shown in provisional position. They shall be exactly located as soon as the final layout of equipment is known. Fixtures that are used canopy or directly exposed to weather shall be considered as being outdoor type. 16000.7.2 Construction Indoor fixture shall be constructed of 0.5 mm thick steel minimum. If other metals are used they shall be of the required thickness to have at least the same mechanical strength. Cast portions of fixtures shall be not less than 1.5 mm thick. Metal parts of the fixture shall be completely free from burrs and tool marks. Solder shall not be used as a mechanical fastening device on any part of the fixtures. Fixture joint shall be metered welded and ground smooth. Fixtures with visible frame shall have concealed hinges and catches. Recessed fixture shall be constructed so as to fit into ceiling without distorting either the fixture or the ceiling. Plaster rings shall be provided for plaster ceilings. The Contractor shall coordinate the dimensions with the false ceiling tile dimensions.



T05-20/11/2013



Outdoor fixtures (under canopy or directly exposed to the weather) shall be constructed of an appropriate weather resistant material including gasketing preventing entrance of water into wiring, and shall be marked by the manufacturer “suitable for Outdoor Use”. Fixtures with hinged diffuser doors shall be provided with spring clips or other retaining devices to prevent the diffuser from moving. Bathroom fixtures shall have non-metallic body and shall be marked as being suitable for damp locations. Lamp-holders of such fixtures shall be provided with a protective shield to prevent contact with the lamp cap. All plastic diffusers shall be of acrylic or plexiglas unless otherwise noted. Fixtures with exposed metal parts shall be provided with a means for connecting an equipment earthing conductor for such fixtures. Incandescent fixtures shall be equipped with porcelain medium base with nickel-plated shells. Sockets shall be bayonet type for lamps up to and including 150 watts and right hand screw type for lamps 200 watts and above. Fixtures with visible frames shall have concealed hinges and catches. Pendant fixtures and lampholders shall be provided with ball type aligners. 1600.7.3 Construction - Fluorescent Fixtures Fluorescent fixtures shall be provided with white click-in type lampholders. Industrial type fluorescent fixtures shall have turret type lampholders. Pendant individually mounted fixtures 60cms. Long and smaller shall be provided with twin stem hangers. Stems shall have ball aligners and provision for a minimum of 2.5 cm. vertical adjustment. Fixtures with no diffusers shall be basic batten unit with open reflectors. Opal diffusers shall be manufactured from acrylic or plexiglass. Diffuser shall be one piece, nonglued. Clear prismatic diffuser shall be manufactured from acrylic or plexiglas. Diffuser shall be one piece, non-glued, with genuine prisms. Corrosion resistant fixtures shall comprise polyester resin fibre-glass reinforced body, dust and splashproof. Damp resistant fixtures shall comprise polyester resin fibre-glass reinforced body, dust and jet proof. Fluorescent fixtures shall be similar to Simplex lighting or approved equal. 16000.7.4 Finish



T05-20/11/2013



All hardware shall be bonderised, cadmium-plated, given a corrosion resistant phosphate treatment or other approved rust inhibiting prime coat, to provide a rust proof base before application of finish. Finish shall be baked enamel. Non reflecting surfaces such as fixture frames and trims, shall be finished with baked enamel paint, unless otherwise specified. The colour of the paint shall be as indicated on the Drawings or as directed later by the Engineer on site. Light reflecting surfaces shall be finished with baked white enamel paint having a reflection factor of not less than 85%. All parts of the reflector shall be completely covered by the finish and free from irregularities. Unpainted surfaces shall be finished with a clear lacquer except of anodized or “Axac” surfaces. After finish has been applied and cured, it shall be capable of withstanding a 1cm. radium bend without showing signs of cracking, peeling or loosening from the base metal. Finish shall be capable of withstanding 72 hours exposure to an ultra-violet RS sum lamp laced 10cm. from the surface without discolouration, hardening or warping and shall retain the same reflection characteristics after exposure. 16000.7.5 Wiring Wiring within the fixture and for connection to the branch circuit wiring upto the outlet box of lighting point in case fixture and outlet box are in immediate contact, shall not be less than 1.5 mm2. Insulation shall be silicone rubber, finish shall be of glass braid, suitable for 150 deg. C normal service temperature 300/300 volts. Cable entries to the fixtures shall be dust sealed. 16000.7.6 Installation Fixture shall be installed at mounting heights as detailed on the Drawings or as instructed on site by the Engineer. Fixtures and/or fixture outlet boxes shall be provided with hangers to adequately support the complete weight of the fixture. Design of hangers and method of fastening, other than shown on the Drawings or herewith specified shall be submitted to the Engineer for approval. Pendant fixtures within the same room or area, shall be installed plumb and at a uniform height from the finished floor. Adjustment of height shall be made during installation. Flush mounted recessed fixtures, shall be installed so as to completely eliminate leakage of light within the fixture and between the fixture and adjacent finished surface. Fixtures mounted on outlet boxes shall be rigidly secured to a fixture stud in the outlet box. Hickeys of extension pieces shall be installed where required to facilitate proper installation. Surface mounted fixtures longer than 60 cm. shall have one additional point of support besides the outlet box fixtures stud when installed individually. Fixtures located on the exterior of the building shall be installed with non-ferrous metal screws finished to match the fixtures. Where Edison screw lampholders are used the outlet contact must be connected to the neutral conductor.



T05-20/11/2013



Fixtures installed in false ceiling shall be connected to the relevant lighting outlet through a flexible cord and ceiling rose, unless otherwise specified under “CONDUITS”. Each fixture shall have its corresponding lighting outlet. 16000.7.7 Lamps - General Lamps shall be supplied and installed in all lighting fixtures listed in the Schedule of Lighting Fixture on the Drawings. Lamps used for temporary lighting service shall not be used in the final lamping of fixture units. Lamps shall be of wattage and type as shown in the Schedule of Lighting Fixtures. Lamps for permanent installation shall not be placed in the fixtures, until so directed by the Engineer, and this shall be accomplished directly before the building areas are ready for occupation by the Employer. 16000.7.8 Lamps – Fluorescent Lamps shall be of the normal start energy saving type, unless otherwise indicated. Lamps shall be krypton filled, in place of the traditional argon fill. Lamps shall have bi-pin bases and a minimum approximate rated lift of 8,000 hours. Drawings. Lamps shall have the colour rendering features similar to “TL” D colour 84 lamps, and lamps with WHITE DELUXE colour rendering shall have the colour rendering features of “TL” D colour 83 lamps as manufactured by Philips (Holland). Lamps shall have 96 1m/watt output minimum based on 36 watt lamps or approved equal. Lamps shall have 18w, 36w, 58w ratings in circuits of 20w, 40w, and 65w lamps. Lamps shall have WHITE colour rendering unless or otherwise indicated. 16000.7.9 Lamps - Incandescent Incandescent lamps shall be inside frosted type, unless otherwise indicated. Lamps shall have a minimum approximate rated life of 750 hours. Lamps shall have a medium base bayonet type for lamps upto 150 watts and right hand screw type for lamps 200 watts and above. Lamps shall be manufactured by Philips (Holland) or approved equal. 16000.7.10 Lamps - Mercury Vapour, and Metal Halide Mercury lamps shall be high pressure mercury-vapour fluorescent lamps, with a quartz discharge tube enclosed in an internally coated void outer bulbs. The quartz discharge tube shall contain a small quantity of mercury and a starting gas. The average luminous flux after 100 burning house shall for a 50 W lamp, be a850 lumens horizontal and 2000 lumens vertical. The number of minutes after which the lamp has reached 80% of its final luminous flux shall not exceed 5 minutes for 50 W lamps, and 4 minutes for higher wattage lamps.



T05-20/11/2013



Lamps below 125 W shall be fitted with normal glass and lamps 125 W and above shall be fitted with hard glass. Lamps shall be similar to Philips HPL-N type or approved equal. Metal Halide lamps shall be similar to mercury vapour lamps except that the discharge tube shall contain metal halide compounds and the average luminous output after 100 burning hours for a 375 W lamp shall not be less than 30000 1m. 16000.7.11 Lamps - High Pressure Sodium High pressure sodium vapour lamp shall be suitable for outdoor use. It shall include a sintered aluminium oxide discharge tube enclosed in a clear, tubular hard-glass outer bulb. The average luminous flux after 100 burning hours shall be the following:

For For

0101A.1.1.1.1 For 150 watts 250 watts : 27000 lumens 400 watts : 47000 lumens 0101A.1.1.1.1.1 For 1000 watts

:

14000 lumens

:

125000 lumens

The number of minutes after which the lamp reaches 90% of its final luminous flux shall be the following: For 150, 250 and 400 watts, 5 minutes. For 1000 watts, 6 minutes. The re-ignition time shall not exceed 3 minutes. The lamp shall be able to operate in both high (+50 deg. C) and low (-50 deg. C) ambient temperatures. The lamp shall have a stable operation with supply voltage as low as 200 volts. 16000.7.12 Ballasts - Fluorescent Only single and/or two lamp ballast shall be used in any one fixture. Ballasts shall be high power factor type, with a minimum power factor of 0.85. Voltage rating shall be equal to the normal voltage or be the next higher standard. Ballasts sound performance shall be suitable for the lowest sound level likely to be encountered in the subjected space with sound ratings as shown on the Lighting Fixtures Schedules of the Drawings. Ballast shall have manufacturer’s lowest sound level and case temperature rise rating, special cool operated type and shall be special cool operated type. 16000.7.13 Starters - Fluorescent Starters shall produce a sufficiently high peak voltage for proper ignition of the lamp. Ample preheating of the lamp electrodes prior to ignition shall be provided to have a favourable effect on the life of the lamp with a minimum end blackening. The glow switch and a radio-interference suppression capacitor shall be safely housed in a high quality white polycarbonate canister ensuring excellent insulation. Starters shall comply with IEC 155/155A or approved equal. 16000.7.14 Starters - Fluorescent (Electronic) D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Starters shall be electronic type, enclosed in a polycarbonate box mounted inside the luminaire with the ballast. Starter shall provide immediate ignition (0.5 seconds) of standard fluorescent lamps with negligible watt loss, and shall be noiseless. It shall be similar to the universal vivatronic catalogue ref. G69577 as manufactured by Thorn EMI Lighting, ES 08 as manufactured by Philips or approved equal. 16000.7.15 Ballasts - Fluorescent (Electronic) Ballast shall be solid state electronic controlled type with no noise nuisance, high operating frequency,0.95 power factor, instant non-flickering start, automatic switch-off if lamp is defective, no stroboscopic effect and no electrode flickering. All components shall be mounted on a common wiring board, with a sheet metal housing mechanical protection. It shall require no starter. The unit shall be similar to electronic control gear as manufactured by Philips, Siemens or approved equal. 16000.7.16 Ballasts - Mercury Vapour Ballasts shall be suitable for use in the area to be installed. Ballasts for 400 W lamp shall consist of two parts gear housing and cover. The housing and the cover are made of polymide, which is heat, impact and stress resistant, with very good insulating properties. The ballast box shall be protected to IP 54. All ballast boxes shall include the integral ballast, the ignitor, the capacitors for power factor correction to min. 0.85, a terminal block, and two properly rated fuses. 16000.7.17 Ballasts and Ignition Device - Sodium All sodium lamps shall be equipped with individual control gears comprising a ballast and an ignition device. The ignitor housing shall be able to withstand a +85 deg. C temperature. All control gears shall be equipped with capacitors so as to raise the power factor to 0.85. Ballasts shall have low losses which shall not exceed the following values: For For For For

150 watts lamps, 250 watts lamps, 400 watts lamps, 1000 watts lamps,

20 watts losses 30 watts losses 36 watts losses 60 watts losses

Ballasts shall operate with a voltage range of 210 to 230V, with 50 Hz frequency. 16000.7 18 Fixture Poles



T05-20/11/2013



Poles shall be manufactured from one piece steel of sufficient thickness, dipped in a hot zinc ensuring coating both on the inside and the outside. The buried portion shall have an additional bituminous coating. Poles shall be provided with plastic cable boxes of sufficient dimensions for cable junctioning and installation of fuses. Fuses of appropriate rating and a grounding bolt shall be provided. The access to the cable box shall be through a hinged door without lock but invoidably closed by a key for special head stocked with the pole (the same key for all poles). Poles shall be reinforced at the door section to restore same strength as the other sections and shall be given two enamel paint coatings after weathering them for 6 months. 16000.7 19 Fixture Samples Detailed catalogue cuts for all fixtures or if so required by the Engineer, sample fixtures shall be submitted for prior approval of the Engineer before order for the fixtures are placed. 16000.7.20 Obstruction Lights Obstruction light shall consist of a mounting tube for two fixtures, two optical systems, two lampholder, two lamp fitting and a mounting pole. Each fixture shall consist of a heat resistant aviation-red symmetric glass lens. Colour shall be in accordance with the requirements of the ICAO Annex 14. Lens shall have a 0.20 transmission factor. The lampholder shall be a B22 bayonet lampholder with screw terminals, mounted rigidly to a metal support, 750 volt duty 4 amp rated. The fitting shall consist of a body and a lens holder assembly with a polychloroprene lens-gasket. Body shall have drain holes and shall be provided with 1 inch thread for vertical mounting. Lens shall be fixed to lensholder with a 4 stainless-steel clips. The lensholder shall be provided with a chain long enough to permit removal of the lensholder assembly with lens in place. The lamp shall be a 60W B22 inside frosted unit. Pole shall be of galvanized steel, 60cm. long, fixed to roof parapet with clamps as required. Pole shall be painted with baked enamel. Pole shall be provided with two fixtures. Obstruction light shall be similar to Philips catalogue ref. PS 14 or approved equal. 16000.7.21

Fixtures Description

The Contractor shall supply, and install the following lighting fixtures. The Contractor shall ordinate the type and dimensions of the recess mounting fixtures with the false ceiling type and dimensions. The catalogue reference indicated or the fixture approved might not be suitable for the false ceiling that the contractor proposes to install. It is the entire responsibility of the contractor to choose the correct fixtures to avoid any mismatching for the approval of the Engineer. If the fixtures brought on site after approval are found not to fit the tiles, they shall be replaced at no extra cost. No on-site arrangements to fit in the fixtures of mis coordinated dimensions shall be accepted.



T05-20/11/2013


16000.8


MISCELLANEOUS EQUIPMENT

16000.8.1 General The Contractors shall supply and install the following equipment as shown on the Drawings, and as herein specified. 16000.8.2 Lighting Contactors Contactors shall switch a load at 240/415 volts, 50 Hz, and shall have 3 poles, unless otherwise indicated. Lighting contactors shall have rating of 20 Amperes per pole and shall be suitable for continues duty with all types of lighting loads. Lighting contactors shall have totally enclosed silver alloy double break power contacts, capable of making and breaking any load within the rating of the contactor without the assistance of auxiliary arching contacts. Auxiliary arching contacts are not acceptable. All contacts must be removable without disturbing line or load wiring. All contactors shall be industrial duty and rated 600 volts even though they may be used for commercial duty and/or at a lower voltage. Lighting contactors with time delay service, have an adjustable time delay relay ranging from 60 to 300 seconds. Lighting contactors and timers shall be manufactured by CRABTREE (UK) or approved equal. 16000.8.3 Combination Distribution Units The units shall comprise a distribution fuse board and a main fuse switch or isolator as shown on the Drawings incorporated in one cabinet. The distribution fuse board shall be as described under the pertinent heading. Combination distribution units shall be similar to ottermill. Combination distribution units as manufactured by Ottermill, or approved equal. 16000.8.4 Disconnecting Switches Switches shall be non-fusible single throw, number of poles and rating as shown on the Drawings. Switches shall be quick-make, quick break type, capable of making, carrying and interrupting specified current at its rated voltage. Switches rated more than 200 amps when used with motors shall be plainly marked “Do not Operate Under Load”. Switches rated 200 amps or less, when used with motors shall be motor circuit switch type, of horse-power rating equal to, or more than, that of the associated motor and having interrupting capacity at least equal to the maximum operating overload current of the motor at rated voltage. Motor circuit switches shall incorporate all necessary contacts to isolate auxiliary power supplied (if any) associated with the starter. Isolating switches with no interrupting ratings shall not be used, for any type and rating of motor.



T05-20/11/2013



Enclosures shall be treated with a rust-inhibiting phosphate, primer and finished in grey baked enamel. Switches shall be manufactured by Simplex (U.K.) MK ( U.K. ) or approved equal. 16000.8.5 Switch Fuses Switch fuses shall incorporate fuse units and a switching mechanism in an enclosure. Fuse units shall be designed to BS 88 and IEC, 269 for use with cartridge (non-rewirable) fuse links, and shall be suitable for a prospective fault current of minimum of 20 KA. It shall not be possible for fingers to touch any live metal when inserting or withdrawing the fuse carriers. Terminal shrouds shall be provided to insulate both base contacts. They shall have a unique hinged action to give clear access to the fixed contact and shall not be removable from the fuse base. 16000.8.6 Fuse Switches Fuse switches shall, when mounted individually, be enclosed in a heavy gauge sheet steel case. The case shall be fitted with detachable end plates and shall have cable entry chambers on both sides. The case shall have a pressed steel front plate and door assembly. The door shall be complete with rating plate. ON/OFF indicator, blank designation label and door interlock bracket. The case shall be finished in stoved gray enamel. The moving contact fuse carrier assembly shall comprise double break, silver plated contacts in a glass filled polyester moulding, complete with mounting facilities for H.R.C. cartridge (Nonrewritable) fuse links, complying with BS 88:1975 class QI. The frame shall be made of rigid heavy gauge pressed steel with polyester moulded contact housing with self aligning silver plated fixed contact assemblies and integral arc control chambers. It shall incorporate a heavy duty mechanism with retractable operating handle. The rear contact and terminal assembly shall incorporate silver plated incoming and outgoing terminals wide enough to accept cable sockets of the size required by the cables coming into it. Fuse switches shall incorporate solid neutral links, of frame size rating. They shall incorporate mechanical interlock to prevent the withdrawal or replacement of the moving contact assembly with the switch in the “ON” position and the opening of the door with the switch in “ON” position. 16000.9 TELEPHONE SYSTEM 16000.9.1 General The Contractors shall provide conduits, block wiring and sockets as shown in the Drawing and as per the approval of the Engineer and the Emirates telecommunication Corporation. Approval shall be obtained prior to installation and modifications required by the Authorities shall be done at no extra cost. 16000.9.2 Telephone Distribution Frame



T05-20/11/2013



Suitable floor or floor mounted distribution frame shall be provided. Terminals shall be identified by numbered tags corresponding to the respective lines or extensions. 16000.9.3 Telephone Outlet Telephone outlet shall be as specified under “WIRING DEVICES”. 16000.10 EARTHING SYSTEM 16000.10.1 General The earthing system shall be in full compliance with the requirements of the IEE wiring regulations and these specifications. Unless otherwise specified, all materials used for earthing, shall be of copper or approved copper alloys, and shall be specially manufactured for the purpose. The complete earthing system shall be electrically and mechanically continuous to provide an independent fault current return path to the earthing source. Bolted connections shall be of the multiple bolt type. Bolts, washers and stop nuts shall be of high copper alloy. Ferrous hardware will not be accepted. Where earthing terminal connectors are blazed to equipment, the metal shall be thoroughly cleaned prior to brazing and the impaired surfaces repainted to prevent corrosion. The resistance of earth loop (sum resistance of the site earth and of the branch circuit supply conductor) shall not exceed 0.5 ohms. The whole work shall comply with the local Power Authorities requirements in addition to IEE regulations. 16000.10.2 Earthing Installation Two separate earthing installations shall be provided, One installation shall be the System earthing and the other shall be the Authorities Service Equipment Earthing. 16000.10.3

System Earthing

The System Earthing shall consist of earthing pits connected in parallel if practicable, or shall consist of 95mm2 ring (counterpoise) buried under ground at a depth of 1 meter minimum around the periphery of the building or substation if the latter is a separate structure. Resistance of this earthing installation to earth shall not exceed 2 ohm. To this installation shall be connected: a)

The neutral of the transformer(s) at the local authorities Low Tension pillar or at the main distribution switchboard if the former is not provided.

b)

All equipment earthing of the Electrical Works through a removable link at the Main Distribution Switchboard connecting the main earthing bus to the neutral bus. If no main switchboard is included in the works, a peripheral earth bus shall be provided in the Meters Room to which all the equipment earthing shall be



T05-20/11/2013



bonded. The earthing bus shall in turn be bonded to the Local Authorities Low Tension Pillar Neutral. The main earthing bus of the main switchboard(s) if any shall be connected to the system earthing by a 95mm2 bare copper cable via a 40 x 5mm main earthing busbar fixed on the wall in an approved location. 16000.10.4 Service Equipment Earthing The service equipment earthing shall be a separate earthing installation consisting of earthing pits connected in parallel. These pits shall be at least 8 meters away from the system earthing if practicable otherwise the service equipment earthing shall be bonded to the system earthing and the combined resistance shall be less than 1 ohm. To this installation will be connected, the ring main unit earthing bar, the transformer(s) and HT Switchgear tanks, HT cable sheats, all exposed structural metal works including metal cable trays when the substation is situated above a basement. Connection material and sizes shall be as approved by the Local Authorities. 16000.10.5 Equipment Earthing of the Electrical Works Equipment earthing of the Electrical Works shall consist of connecting all non current carrying metal parts of the electrical installation to the System earth (TN-S system as per IEE Wiring Regulations, latest edition). Non-current carrying metal parts of the electrical installation shall include such items as cabinets, motors casings, exposed metal parts of apparatus, as well as enclosures, doors, grill, protecting or shielding electrical equipment from direct access by unauthorized personnel etc. The series earthing of one piece of equipment to another, will not be permitted unless otherwise indicated. All equipment earthing connections shall be tapped from the applicable earth source. Unless otherwise specified or indicated on the Drawings, cable armour shall be accepted as equipment earth conductors, provided, they comply with the requirements of the Regulations. All receptacles, power apparatus, lighting fixtures and switches shall be earthed. No point on the neutral shall be connected to the earth system except as described under “System Earthing”. Additional earthing pits may be shown on the Drawings at different locations. These pits shall be bonded to the earthing bus of the relevant switchboards or panelboards as applicable in order to reduce the earthing resistance. Neutral at such point shall not be bonded to the earthing system. Shells of all water heaters shall be connected to the neutral and earthing of the corresponding circuit. 16000.10.6

Protective Conductors

Earthing wires (protective conductors) are not shown on the Drawings. All circuits running in conduits or in flexible conduits shall have earthing insulated conductors of minimum sizes as follows: Current carrying conductor

Earthing conductor (Protective Conductor)



T05-20/11/2013



------------------------------------

-------------------------------

(mm2) 2.5 4 6 10 16 25 35 50

(mm2) 2.5 2.5 2.5 6 6 16 16 25

Current carrying conductor

Earthing conductor (Protective Conductor) -------------------------------

-----------------------------------70 95 120 185

50 50 50 50

If more than one circuit is included in a conduit, one protective conductor per neutral or per three phase circuit with no neutral shall be provided. 16000.10.7 Earthing Pit The earthing rod shall be constructed from copper clad steel rod. Copper sheath shall be 99.9% pure electrolytic copper. The steel core shall be of carbon steel, with tensile strength min. 97 min 97,000 psi yield strength at 0.2% offset 85,000 psi, proportional limit 57,000 psi, percent of elongation 13%. Rod shall be cold drawn. 16000.10.8 Automatic Capacitor Bank for Power Factor Improvement Automatic capacitor bank panel with a degree of protection IP54 for improving the power factor to a value equal to or greater than 0.90 as per DEWA regulations comprising of:

a) Three phase capacitors with permanently connected built-in discharge resistors all covered with a zinc electroplated mild steel case.

b) Microprocessor controlled programmable power factor regulator with built-in digital power factor meter and fault indicator.

c) Three phase contactors and fuses. d) Incomer isolator for the bank if separate MCCB is provided in the Main panel (MCCB to be provided for the bank if no MCCB available in the main panel).

The capacitors have to be switched on/off in steps based on the load in the system. Also enclosed is a typical connection diagram of an undervoltage relay with built-in timer and contactor. Approved Manufacturer :

ABB



T05-20/11/2013



16000.11 TESTS AND CERTIFICATES 16000.11.1 General After completion of the Electrical work, the complete systems shall be tested thoroughly before commissioning. Any modification or repairs necessary on completion of the test shall be done at the Contractor’s expense. The tests outlined herein shall be in addition to, and not substitution for, the tests of the individual items at the manufacturer’s plant. Insulation and ground resistance test shall be made before operating tests. Proper rotation shall be determined before permanent connections are made. All test equipment on site shall be provided by the contractor. The Contractor shall make the necessary openings in the circuits, for the testing instruments and shall place and connect all instruments, equipment and devices necessary for the tests. Upon completion of the tests, these shall be removed and all circuits reconnected to their permanent positions. The tests shall be conducted in the presence of the Engineer and W.E.D. representative if so required. He shall be notified seven calendar days or more in advance when any test is so take place and it shall not be started without his permission. Certificates when required shall be submitted for any equipment installed under this contract originating from the authorized inspecting body in the country of manufacturer. Unless otherwise specified, the contractor shall supply the electric current necessary for the tests. The Contractor shall provide all tests equipment. Mobile generator of sufficient capacity shall be provided to arrange alive tests if main supply is not available in the substation of the building. When tests are arranged by generator, the Contractor shall check phase sequence of the main supply switched from power house and arrange the sequence of the 3 Ph motors to be accommodated with the main. The Contractor shall state and guarantee the particulars as specified in his tender documents. Such guarantee shall not be departed from, without written permission from the Engineer. If such guarantees are not respected, the Engineer has the right to reject the faulty equipment. The Contractor shall submit four copies of all test results. Test shall include the following: Insulation megger tests on wires. Continuity and resistance tests. Socket Outlet Proper Wiring test. Operational Tests. Insulation Resistance Tests of Motors. Testing of the Lighting Installation. 16000.11.2 Insulation Megger Test for insulation level shall be made by a 1000 volt magger. A minimum of one megohm (1,000,000 ohms) applying to the complete installation shall be obtained. This means that when all the phase wires at the panelboard are connected together and to the testing instrument, all D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



switches closed, all appliances inserted in the circuit, all neutral wires left in the air, and the other end of the megger is connected to the earthing, then there shall be a minimum of 1 megohm between the whole of the installation taken together and the earthing. 16000.11.3 Continuity and Resistance Test A continuity test to ensure that all connections have been made properly shall be made. This can be done by the use of a bell set. Test shall also include ensuring all switches and other interrupting devices breaking the phase wire and not the neutral wire. Test shall include, in addition to checking continuity of current carrying wires and cables, continuity earthing conductors, This shall be done through a megger which shall produce an alternating current of a magnitude equal to one and a half times the rating of the circuit under test with a maximum of 25 amps. 16000.11.4 Socket Outlet Proper Wiring Test All socket outlets shall be connected properly such that looking at the face of the socket outlet the live connection shall be on the right, the neutral on the left and earth at the top. 16000.11.5 Operational Test The Contractor shall demonstrate the proper operation of circuit breaker, switches and any other equipment as requested by the Engineer or as specified elsewhere in these specifications. Each motor and associated equipment shall be run under normal operating conditions for as long a time as is necessary to demonstrate correct alignment wiring capacity, speed and satisfactory operation. The motor shall be loaded to full capacity or as near thereto as possible. 16000.11.6

Testing of the Lighting Installation

The Contractor shall demonstrate the proper operation of all lighting fixtures. 16000.11.7

Insulation Resistance Tests of Motors

All motors shall be tested for insulation in accordance with the requirements of IEE Standard No. 43. Two copies of the tests data shall be submitted. 16000.12 DIGITAL WATER LEVEL INDICATOR WITH ALARMS The water storage and pumping system of the building shall be provided with continuous level monitoring system with audiovisual alarms for indication of HIGH AND LOW levels in sump tanks, roof-top reservoirs and any other intermediate water reservoirs. The level indicating system shall comprise a pressure transducer based sensor to be fixed to the tank and a digital display unit to be housed either in the pump-room or at the security post. The system will have a common AUDIBLE electronic siren to indicate HIGH and LOW levels, which can be acknowledged by pressing a push-button to silence it. Each water tank or set of interconnected tanks shall be provided with one set of sensor and digital display unit, and, all the display units shall be housed in one panel with a common siren and acknowledgment button. LEVEL SENSOR



T05-20/11/2013



The sensor shall be a two or three wire transmitter working on 24 volts excitation voltage and giving 4-2mA analog signal output proportional to the level of water in the tank, to which it is connected. All wetted parts of the sponsor shall be SS-316 and the range of operation 0-10 metres of water column with an accuracy of + 0.5% of full scale reading. Externally connected sensor shall be used for over-ground tanks and the submersible one for the underground ones. The external sensor shall be connected to the tank away from turbulent zones, preferably to the drain-pipe, with a tee-connection, through an isolating valve. READ-OUT INSTRUMENT READ OUT or DISPLAY unit shall be electronic type operating on 230 Volts + 10 V a.c. at 50 Hz supply and will power the sensor with 24 Volts d.c. supply. It shall provide continuous level indication through bright red L.E.D. seven segment, 3 ½ digit numbers, clearly visible from 10 feet distance. The instrument shall be panel mounting type with a cut-out not bigger than ¼ DIN (96mm x 96mm). The readout instrument shall provide, in addition to display, two relay set-points for HIGH/LOW alarms. The DISPLAY unit will have internal trim-pots to calibrate ZERO and SPAN of the water level without having to dismantle the instrument from panel, which can be achieved by concealing the trim-pots behind the front lens. The HIGH & LOW settings for alarms too, shall be site-settable, using front panel accessible trim-pots with push buttons. Both the level sensor and the instrument shall be capable of continuous operation upto 50 deg. C at upto 95% non-condensing humidity.

16000.14 1.1

CENTRAL BATTERY SYSTEM

SYSTEM DESCRIPTION 1.1.1

GENERAL

The central battery system and associated slave luminaires will cover the Emergency & Exit luminaires as detailed in the drawing and specifications. The Central Battery Panels will be of modular nature with plug-in-components for the ease of maintenance and reduced downtime. 1.1.2

Modular Central Battery Panels

Each central emergency battery supply panels shall be used for supply, automatic testing and monitoring of maximum 20 no. Escape route, EXIT and safety luminaries in each circuit. Minimum one number panel shall be provided in each floor of the building, however exact no. of panels shall be determined as per the detailed design based on the Consultant approved product. Panels shall be located inside control rooms and a trunking shall be provided inside the room as a riser to enable connection of panels located in different areas. Input Voltage Output mains Output Emergency

: : :

230V AC 230V AC 230V AC

The battery backup required for the complete system is for a duration of 3 hours as per D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



Civil Defense requirements with 100% light output on connected fittings. Mechanical Construction Sheet steel powder coated housing to IP 32. Separate compartment shall be provided for batteries. Panel should be suitable for wall mounting and panel door will have transparent window to view optical failure/status indication and shall be provided with printed diagram on the internal cover.

a.

The electronic compartment shall have large cabling compartment with cable entries from top with four or more undrilled removable metal flange plates. All incoming cables and looping circuits shall be connected on protected and fused terminals as per ENVDE0100. All outgoing luminaries circuits shall be connected direct to relevant components via plug in type terminals Electrical Construction

b.

The system shall be of modular construction with all modules being plug in type encapsulated design. The outgoing circuits shall be fed through changeover modules. Each module shall be capable of switching two separate circuits with maximum load of 3 amps. Connection of luminaries of all switching modes shall be possible in each circuit. Change over modules shall have no load and short circuit protection with independent fuses for mains and battery supply and shall have status indication for operation and failure Each panel shall have maintenance free sealed, lead acid batteries, with 10 years service life at 25 degree C, 120% capacity to manufacturer standard and with enough capacity to light up all connected lights with 100% light output on all connected luminaries. The batteries in panels located in now AC rooms shall be rated for 40 ºC ambient temperature with 10 years service life. Where the space required for the batteries does not permit the installation of same in standard enclosure, it shall be installed in a separate cabinet similar to the central battery panel cabinet. c.

Battery Charger The plug-in-type battery charger should be high efficiency temperature controlled charger, working to IU characteristics. It will have built in deep discharge protection for long Battery life. It will be suitable for fast recharging based on Battery status and time controlled trickle charging current. It will supervise the battery status such as low/high battery block voltage, failures within charging circuit and relay the faults to control module. It shall be complete with the following: i. ii. iii. iv.

Earth leakage monitoring LED indication for ‘operation’, charger ON, Booster ON, Mains Operation, Battery capacity 10 %, 50%, 100% Charging failure, Insulation fault Push button to simulate earth leakage failures. Each panel shall be provided with a non-switched spur outlet next to the panel Sub-circuit Monitoring : - An electronically regulated monitoring loop output shall be included to monitor the mains failure at distribution/sub-distribution board. The relevant distribution boards/sub-distribution board should be fitted with sub circuit monitoring device.



T05-20/11/2013


v.


Individual circuit monitoring shall be provided for all luminaires to switch on emergency lights in that area incase of individual circuit failure Control Module : - Each panel will have plug-in-type freely programmable control module with two line liquid crystal display and constant memory back up and has the following main functions: a. Monitor and control all test cycles and functions. b. Indicate every status of the system and the connected luminaire. c. Communicate and program the function of the addressable electronic ballast on every slave luminaire. d. Programming and status of the sub circuit monitoring inputs and the associated luminaries. e. Battery charge current : - It displays battery voltage level, battery charge current, required battery charging time/duration time withdrawn battery current in test or emergency modes, charge failures, interrupted battery charge circuit, luminaire failure with luminaire address, function test, battery test. Both tests can be manually programmed. The control module shall be linked to the central monitoring device installed at the control room and shall have three L.E.D.s for status indication.

1.1.3. Central Monitoring Device The central monitoring shall be via a central group monitoring hardware & software, monitoring & programming unit. The unit shall latest PC from Dell, Compaq, IBM. The unit shall operate with latest visualization software to give detailed address & information of all luminaires connected to system. The program shall be user friendly with visually clear fault indication screens on the monitor. 2.1.

INSTALLATION 2.1.1 The emergency light shall be connected such that in case of power failure in any of the area, the emergency light installed in that area shall be energized. 2.1.2 Wiring of the emergency light shall be carried out using fire resistant FP 200 Cable.

2.2

TESTING AND COMMISSIONING 2.2.1

The Contractor shall be responsible for testing and commissioning of the installation in accordance with all applicable documents in the Contract set. Testing shall be comprehensive and sufficient to demonstrate compliance with each requirement and as per system manufacturer recommendations. A proposed test plan shall be submitted to the CONSULTANT or Owner’s representative for approval before commencement of final test. Final tests shall be conducted in the presence of the CONSULTANT or Owner’s representative.

2.3

TRAINING AND INSTUCTION



T05-20/11/2013



2.3.1 Operator training shall consist of a two days course conducted on-site by a factory trained professional instructor. Training conducted by installers, technicians, or project managers is unacceptable. 2.3.2 Training materials shall consist of the following: -

2.4

Formal course outline and agenda Operator training student guide for each student. Hands-on practice with on-line equipment. Written examinations. The training course shall be a minimum of two continuous business days. Additional equipment Video Imaging training sessions shall be made available to the Owner if necessary, at no additional cost.

WARRANTY 2.4.1 All equipment furnished under this contract shall be warranted for a period of twelve (12) months from the date of final Owner acceptance of the system. a. b.

16000.15

1.1

Respond to service requests on-site, if required. Replace or repair defective components as required.

DIESEL GENERATOR SET

SCOPE OF WORK 1.1.1

The Contractor shall supply, install, test, connect and commission diesel generator set to supply, automatically, in the event of Mains supply failure.

1.1.2

The diesel generator set shall comprise appropriately matched Diesel Engine and Alternator and shall be complete with, but not limited to, Automatic Transfer Switch; Control Panel ; Radiator Cooler ; Residential Silencer ; Starter Batteries and charging system ; daily service and bulk Fuel Tanks ; visual and audible Alarms ; meters and gauges, all controls, protection, wiring and any other equipment and accessories deemed essential for a safe, reliable and satisfactory automatic start-stop operation of emergency standby electricity supply system.

1.1.3

SHOP DRAWINGS: - Include the following with the shop drawings: 1.

Outline drawings of unit and base.

2.

Total weight of unit and base.

3.

Air required for combustion and cooling (1/5).

4.

Heat radiated from engine and generator (kW).



T05-20/11/2013


1.1.4


5.

Weight and dimensions of muffler.

6.

Fuel consumption at 1/4, 1/2, 3/4 and full load, at 10m above sea level.

7.

Outline drawings and details of batteries, rack and charger.

8.

Outline drawing and details of control panel.

9.

Schematic diagrams of all systems, wiring diagrams and layout drawings.

10.

Bill of materials listing all replaceable components by manufacturer and catalog number.

11.

Complete detailed description of engine, alternator, exciter and auxiliary equipment.

12.

Certificate of manufacturer's inspection of the crankshaft, including statement of inspection method.

13.

Tripping curves of main circuit breaker, showing damage and decrement curves on alternator for normal load, overload and short circuit conditions, for alternators rated 100 used large

The permanent generator set shall comply with the requirements of BS EN 60034 P-1: 1998, BS EN 60034-2: 1999, BS 4999, BS 5000, BS 5514, DIN 6271, DIN 6280, NEMA MG1, ISO 3048 Part 1, ISO 8528 Part 1 : 1993, BS 8528 Part 5 : 1993.

1.2 GENERAL REQUIREMENTS 1.2.1

The set shall be designed for permanent power supply.

1.2.2

After starting, the set shall attain rated speed and voltage and be capable of accepting the full rated load. The diesel engine governor shall control the generator speed, and the generator output voltage regulation shall be controlled by the generator automatic voltage regulator.

1.2.3

The rated output of the set shall be suitable for the site altitude and ambient conditions prevalent in SHARJAH

1.2.4

Suitable precautions shall be incorporated in the design to ensure the set shall be suitable for use in environmental conditions prevailing in SHARJAH.

1.2.5

The diesel engine, alternator, radiator and other auxiliary components shall be supplied mounted on heavy-duty robust bed-frame of rolled steel welded construction or steel plate fitted with lifting joints. The entire assembly shall be placed on rubber or spring type anti-vibration base.

1.2.6

The manufacturer shall submit certificates of satisfactory post-production tests carried out on the generator set.



T05-20/11/2013


2.1


1.2.7

Prior to placing orders for the set and auxiliary components, the Contractor shall submit for the Engineer’s study and approval, comprehensive documents inclusive, but not limited to, working drawings, schematics, catalogues, compliance statement, descriptive literature, technical specifications etc. for the generator set, controls and switchgear and components.

1.2.8

The manufacturer shall provide a warranty of one year from date of handing over date, and shall include labor, recommended spare parts, lubricating oil, filters, antifreeze etc.

DIESEL ENGINE The diesel engine shall be of the direct injection turbo-charged residential type complying with the requirements of BS 5514 and BS 7698: 1993. The engine shall be complete with all equipment and accessories deemed necessary for safe and reliable operation of the set. The actual engine fuel heat rate shall not exceed guaranteed heat rate by more than 4%. The engine shall be equipped with, but not limited, to the following equipment and accessories:

2.1.1 The fuel system shall be integral part of the engine and shall be equipped with fuel filter, transfer pump, injection pumps, and lines and spray nozzles. The transfer pump shall deliver fuel under low pressure to individual injection pumps, one for each cylinder. The injection pumps shall be driven from the camshaft and shall be simultaneously controlled by a rack and pinion assembly that is hydraulically actuated by signals from the engine governor. The pumps shall be of variable displacement type and shall alter the volume of fuel delivered to the spray nozzles to match load demands. The governing system shall be based on fuel-efficient and fully monitored Advanced Diesel Engineered Management system. 2.1.2 The engine shall be equipped with fuel injectors in each cylinder head, primary fuel filters between the fuel tank and transfer pump, a fuel/water separator, air filters, lubricating oil cooler, water pump etc. 2.1.3 Engine-mounted radiator and engine-driven blower type cooling fan complete with hoses and accessories to provide close-circuit pressurized water cooling system for the engine with provision for filling, expansion and desecration. Thermostatically controlled by-pass valve to be provided to maintain cooling water at optimum temperature, and electrical immersion heaters shall be incorporated in the system to maintain recommended temperature in the engine jacket and radiator 2.14 Electronic engine governor to control engine speed and transient load response within tolerances specified in ISO 8528. Speed droop shall be adjustable from 0 to 10 %, from no-load to full rated load, with steady state frequency regulation of +/- 0.25 %. 2.1.5 Axial turbine type turbochargers driven by the engine exhaust gases and directly connected to a compressor supplying engine combustion air. 2.1.6 Exhaust System to discharge combustion gases quickly and silently with minimum restriction. D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



2.1.7 The noise level outside the Genset room shall not exceed 75 dBA at 3 meters. Attenuators to be provided for radiator discharge and air intake. The air intake requirements shall be coordinated at site. The vertical noise propagation to the floor above should not exceed 45dB. The generator base mounted springs should be able absorb 95% of the Engine vibrations. Any louvers provided in generator room shall be acoustic type. 2.1.8 An accurately balanced flywheel. 2.1.9 Residential silencer complete with all interconnecting exhaust pipe work and accessories to match engine requirements. 2.1.10 An integral gear-driven pump complete with oil level dipstick and cartridge oil filter for engine lubrication. The lubrication pump shall be of positive displacement type. 2.1.11 A solenoid to control and regulate fuel supply to the engine. 2.1.12 Flywheel-engaged axial 12V/24V starter-motor for starting the engine. The power to the motor shall be supplied by an array of heavy-duty lead acid batteries with sufficient capacity to facilitate 3-4 consecutive 10-second cranking periods. 2.1.13 An engine-mounted panel with the following gauges with digital LCD display: a) b) c) d) e)

Lubricating oil pressure gauge. Cooling water temperature gauge. Battery voltmeter Hours run recorder/meter. Revolution counter.

2.1.14 The Engine control system shall be totally programmable microprocessor based unit with self-diagnostic and event recording capability. 2.1.15 The design of the basic engine shall provide for maximum structural integrity to extend service life. 2.1.16 The electrical engine starting system shall comprise 24V DC starting motor, starter relay, automatic reset circuit breaker to protect against butt engagement, maintenance free lead acid batteries, accessories etc. 2.2

ALTERNATOR The alternator shall be of the self-excited and self-regulated type complying with the requirements of the relevant parts of BS 4999, BS 5000 and BS 7698. Particulars of the alternator and its components shall be as follows; 2.2.1

The alternator shall be close coupled, single bearing, salient pole, revolving field, synchronous machine with windings in the pole faces of the rotating field. The



T05-20/11/2013


2.3

2.2.2

flywheel coupling and associated parts shall be adequately protected by means of suitable guards. The alternator shall be designed to carry 3-phase load of 300% rated current for 10 seconds, and 150% full load current for 2 minutes with field set for normal rated load excitation.

2.2.3

At no load the waveform deviation shall not exceed 5 %.

2.2.4

The alternator enclosure shall be drip-proof to IP 22 in compliance with the requirements of BS 4999: Part 105: 1988.

2.2.5

Single phase 220V AC space heaters to minimize condensation when the alternator is idle.

2.2.6

Self-excited brushless exciter with three-phase armature circuit and a threephase full wave bridge rectifier mounted on the rotor shaft.

2.2.7

The winding insulation shall be minimum Class H to BS 2757.

2.2.8

Radiated interference shall be suppressed to limits specified by BS 800: 1988.

2.2.9

A microprocessor based, fully programmable automatic voltage regulator with protective and diagnostic capability shall be provided to facilitate regulation of 1 % or better between steady-state no-load to full-load 0.8 power factor lagging.

2.2.10

A TP MCCB with long-time only trips to protect against short circuit lasting 10seconds and thermal overload and short circuit conditions and shall be housed in a sheet steel enclosure which shall be mounted near the alternator terminal box. The breaker will calibrated at 50° C with minimum breaking capacity 50KA

MOUNTING BASE 2.3.1

2.4


A robust and load-bearing mounting base shall be provided to support the generator set. The base shall be constructed of formed “C” steel channels of minimum thickness 6 mm complete with necessary steel cross members and priority vibration isolators installed between the set and the supports. Lifting bolts shall be provided at each corner of the base to facilitate lifting of the generator set.

CONTROL PANEL A generator mounted Control Panel or alternatively a separate floor mounted Control Panel constructed of sheet steel to IP 43, shall be provided to house solid-state control elements, push-buttons, meters, indicators, alarms etc. for controls, protection and monitoring systems of the generator set. In addition to the control elements, the Control Panel shall house the following items of equipment and accessories: 2.4.1

Red lamp indicators and, wherever applicable and necessary, alarms/sounders for the following operational fault conditions followed by the generator set shutting down. A robust and load-bearing mounting base shall be



T05-20/11/2013


1) 2) 3) 4) 5) 6) 7) 8)

Low pressure oil. High engine water temperature. Low oil pressure. Hours Run Meter Engine Tachometer Over speed. Engine fail to start Coolant level

2.4.2

Lamp indicators for other running conditions shall also be provided.

2.4.3

The following instruments with digital LCD display; a) b.) c) d.) e.) f.) g.)

AC Voltmeter and voltmeter phase selector switch. AC Ammeter and ammeter phase selector switch. Phase level rheostat Frequency meter kW and kVAR meters. Power Factor meter. Oil pressure gauge.

2.4.4

OFF/AUTO / MANUAL / RESET / RUN / START selector switch.

2.4.5

Timers for following functions

a) b) c) 2.4.6 2.5


Start delay Restoration delay. OFF load cool down

ISO red emergency stop push button.

BATTERY CHARGER A 10 ampere trickle charge type battery charger with 220V AC single phase input supply and 24V DC output supply and incorporating current limiting circuitry shall be provided. The charger shall be housed in a wall-mounted enclosure complete with ON/OFF switch, FLOAT/BOOST selector switch, AC ammeter and voltmeter, CHARGE rate Meter, protective fuses for the incoming and outgoing circuits and failure/malfunction alarm. Batteries shall be nickel-cadmium type, mounted in a suitable rack on the engine base and sized to provide 5 consecutive cranking intervals of second’s duration each, separated by second rest periods, without recharging, at an ambient temperature of 10°C. The voltage level after the last interval shall be adequate to maintain performance of all DC relays and timers in the control system. The battery charger shall be automatic constant voltage static type providing float and equalizing charge rates, with manual control and terminating timer on the equalizing charge. The timer on the equalizing charge shall be adjustable from 16 to 24 hours.



T05-20/11/2013



The charger shall include a voltmeter, charge rate ammeter, float- equalize switch, on-off switch and pilot light. The charger shall be capable of recharging the batteries fully within 2 hours after the 5 consecutive cranking intervals. When the engine is running, the batteries shall be charged from an engine-mounted charging system including alternator, rectification and relays. 2.6

POST-INSTALLATION TESTING After installation of the generator set, the following tests shall be carried out on the set in the presence of the Engineer. Appropriate inductive load banks and all instruments, meters and other testing equipment shall be provided by the manufacturer. 2.6.1

GENERAL INSPECTION AND CHECKS a.

Oil level

b.

Water level

c.

Day tank fuel level

d.

Battery connection and charge condition

e.

Engine to control interconnections

f.

Engine intake/exhaust

g.

Engine room ventilation

2.6.2 OPERATIONAL TESTS a.

Load set at 80% of full load rating for one hour, then

b.

Load set at 100% of full load rating for two hours. After half an hour, the following readings shall be recorded at intervals of 15 minutes for 1.5 hours i.

Line voltage

ii.

Line current

iii.

Frequency

iv.

Fuel pressure

v

Oil pressure

vi Water temperature



T05-20/11/2013



vii

Exhaust gas temperature at engine exhaust outlet.

viii

Ambient temperature.

ix

Kilowatts and KVARS

x

Power factor

xi Generator temperature

NOTE :

2.7

c.

Proper operation of controls, engine shut down, and all safety devices shall be demonstrated.

d.

Operational time from start to acceptance of full load.

e.

Full load test at unity power factor.

f.

Determination of voltage and frequency under the following load changes: i. No load to 70% Full-load. ii. 100% load to load

In the event any or all the above tests fail to meet the specified performance criteria and requirements, the cost of all corrective measures and further tests shall be borne by the manufacturer.

AUTOMATIC MAINS FAILUREE TRANSFER SWITCH (ATS) (FOR FUTURE GENR.) 2.7.1

The Contractor shall supply, install, test, connect and commission a suitably rated and designed 4-pole mechanically and electrically interlocked Automatic Transfer Switch (ATS) complying with the requirements of ES EN 60947-6-1: 1992 and UL 1008. The ATS shall be housed in a sheet steel enclosure constructed to IP 55.

2.7.2 The ATS shall be complete with Microprocessor Controller and any other accessories and equipment deemed essential for high quality high performance ATS. 2.7.3 In the event of Mains supply failure or in the event of substantial fall in Mains voltage, the ATS shall automatically transfer the load circuits supplied from board ESMDB from board LVP to the emergency generator supply. When the Mains supply is restored satisfactorily, the ATS shall automatically transfer the load circuits from the emergency generator supply to the Mains supply. The transfer of load shall be done INPHASE. 2.7.4 The switches shall be transfer-bypass type, with draw out transfer mechanism and controls. Bypass switches shall permit maintenance of the transfer switching and controls without interruption of service. The enclosures shall be (IP42), finished in light gray enamel. The front panel shall be hinged for access for inspection & maintenance. All sections shall be 2mm zinc coated with corrosion resistant treatment. The switches shall be double throw, mechanically D:\Shared Docs\Orion docs\537-OI- Grand store\Vol-2 of 2\02 General Specifications-for all project.doc


T05-20/11/2013



and electrically interlocked, an mechanically held in both positions. Failure of any electrical component or disarrangement of any part shall not permit the switch to remain in a neutral position. The switch shall be equipped with a timer to keep the engine running for an adjustable period of 0 to 5 minutes after the load has been retransferred to the normal source. The switch shall be equipped with an in-phase monitor or equivalent arrangement for retransferring to the normal source. One 4-position off-auto-run-test control switch shall be provided on the front of the enclosure. The run position shall start the engine without operating the transfer switch. The test position shall simulate a power failure and shall transfer the load to the emergency source. The switch shall transfer when the voltage in any phase falls to 75% of rated, and shall retransfer when all phases have remained above 90% of rated, for an adjustable time period of a to 30 minutes. The switch shall be equipped with a timer to delay transfer for an adjustable period of 0 to 30 seconds, to prevent transferring during testing of the standby power system. One 3-position off-auto-test switch shall be provided on the front of the enclosure. All control gear shall be calibrated for operating conditions in a 50°C ambient temperature. 2.7.5 The ATS shall be designed to perform full service switching and shall have the ability to withstand high fault currents until the fault is cleared by other protective devices. 2.7.6 Contactors to BS EN 60947- 4-2:2000 and circuit breakers to BS EN 60947–2:

2003 shall not be used for transfer of power from one source to the other. 2.7.7 The ATS shall be equipped with all visual LED displays for Switch positions and

Power Sources, and with relays and devices to provide time delay features during transfer and re-transfer operations from Mains to generator supply. 2.7.8 The ATS shall be tested for its satisfactory Making and Breaking capacities and

for its Operational Performance in compliance with the tests required and recommended in IEC 60947- 6–1 : 1992. 2.7.9 The main components of the ATS shall comprise the following :

a.

MECHANICALLY HELD MECHANISM The operating mechanism shall comprise a single solenoid which, when electrically energized, mechanically interlocks the switch to either “NORMAL” or “EMERGENCY” positions. All main contacts shall be silver



T05-20/11/2013



coated and shall be designed to close-on and withstand severe short circuit conditions. b.

MICROPROCESSOR CONTROLLER A single built-in microprocessor shall provide the sensing and control logic capabilities, provided on multi-layer printed circuit boards, to communicate through communication modules for all operational aspects of the ATS. The Controller shall be connected to the ATS by an interconnecting wiring harness and shall be complete with close differential under-voltage relays and other sensing and measuring devices.

2.8.

FUEL TANKS The following fuel tanks shall be supplied complete with all interconnecting pipe work and accessories, fuel gauges, HIGH and LOW oil level switches, electrically operated pump and solenoid to pump oil from the bulk to the daily service tank. 2.8.1 1 No. 8-hour capacity daily service fuel tank built-in with at the base of the generator set of welded sheet steel construction. 2.8.2

2.9.

1 No. suitably sized bulk fuel storage tank of welded sheet steel construction

CABLING , WIRING AND CONTAINMENT The diesel generator set and other ancillary equipment shall be complete with all containment system housing interconnecting cabling and control wiring between the various components of the system.

2.10

TESTING AND VERIFICATION 2.10.1 Carry out complete tests in the manufacturer's plant, in the presence of the Engineer. Notify the Engineer fourteen days in advance. 2.10.2 The Contractor shall pay the executive travelling, lodging and food expenses for the Engineer's inspection at the manufacturer plant. 2.10.3 Carry out tests with a controllable and adjustable load bank capable of providing a steady load, free from fluctuations, at 1.0 power factor. 2.10.4 The test procedure shall be as follows; 2.10.4.1 Start the set. Adjust the voltage and frequency to the related value and the load. 2.10.4.2 Maintain full load on the set until the coolant temperature stabilizes, and in any case for a period of not less than six (6) hours.



T05-20/11/2013



2.10.4.3 Read and record the following data at the beginning of the test and each half hour thereafter. Frequency or speed Voltage and current in all phases Load Coolant temperature Ambient temperature at engine block level Lubricating oil pressure Fuel consumption 2.10.5 Do not adjust voltage or frequency during the test. Adjust the load bank as required to maintain full load on the set. 2.10.6 At the end of the run, increase the load to 110% of rated for 1 hour, and takes the above readings every 15 minutes. 2.10.7 Apply full three phase load at unity power factor to the set. The voltage drop shall not exceed 12%, and the unit shall return to stable operation within three (3) seconds, with the terminal voltage within the limit for steady state voltage regulation and remaining constant within plus or minus 1 %. 2.10.8 Demonstrate high coolant temperature shutdown by blocking the air circulation through the radiator. 2.10.9 Demonstrate low oil pressure shutdown by closing a valve in the lubricating oil line to the pressure switch, without interfering with engine lubrication 2.10.10 Demonstrate over-speed shutdown by operating the over-speed contacts. 2.10.11 Perform a mechanical inspection of the set. 2.10.12 Install strip chart recorder to record frequency and voltage variations during load switching procedures. Delay each load change until unit has reached steady state condition. Load switching is to be as follows: No load to full load No load to 20% 1oad No load to 50% load No 1oad to 75% load 20% load to 50% load 50% load to 75% load



T05-20/11/2013



2.10.13 After complete unit is installed on site, this Contractor shall arrange and

pay for to repeat the same test as conducted at the factory at a ambient temperature of 45°C and with a variable load bank. 2.10.14

2.11

In addition, demonstrate the following to the Engineer:

2.10.14.1

Startup, transfer of load to generator set, retransfer to normal source and shutdown on automatic control.

2.10.14.2

Startup and shutdown on Manual control.

2.10.14.3

Startup and shutdown on Test control

2.10.14.4

Startup and shutdown on Engine Start control.

2.10.14.5

Correct operation on timing devices and safety shutdown devices.

2.10.14.6

The site test shall be conducted in the presence of the Engineer and Owner representative.

CATALOGUES, INSTRUCTION MANUALS AND DRAWINGS Three copies of each of the following documents shall be submitted to the Engineer:

2.12

a.

Operating and maintenance manuals for the alternator.

b.

Operating and maintenance manuals for the diesel engine

c.

Catalogues with technical details of all components of the set.

d.

Comprehensive schematic drawings for all components of the set.

e.

Compliance statement

BMS INTERFACE (IF REQUIRED) Generator Vendor shall provide necessary contacts, software to integrate generator to the BMS and to monitor following items:a. b. c. d. e. f.

3.1

Battery Level Voltage Frequency Load Current Diesel Level Generator Status

Installation 3.1.1 Mount the base on vibration isolators, except where the engine is shockmounted to the skid.



T05-20/11/2013



3.1.2 Provide adequate guards on the exhaust manifold, fan and other parts of the equipment for the protection of operating personnel. Guards shall be readily removable and shall not obstruct normal maintenance operations. 3.1.3 Make all electrical connections between the engine, alternator and associated equipment. 3.1.4 Mount the muffler so that it's weight is not supported by the engine. 3.1.5 Provide exhaust piping up to and including the flexible connection on the outlet side of the muffler. 3.1.6 After installation, carry "out further tests under the supervision of a qualified representative of the manufacturer, to the satisfaction of the Engineer. Instruct the Owner's personnel in the correct operation and maintenance procedures for the set. 16000.13 BUILDER’S WORK The expression ‘Builder’s Work’ shall mean the ancillary work carried out by the Contractor in connection with the electrical installation. Builder’s work in connection with electrical installations shall include, but not be limited to, the following:

a) Drilling, cutting or leaving of holes for conduits, cables, trunking and the like, through walls, floors, partitions, roofs, etc. and subsequent making good.

b) Cutting and pinning ends of supports for equipment, switchgear, fittings and the like to walls, floors, partitions, soffits, etc. and making good.

c) Cutting chases for conduit, cable, trunking and the like in walls, floors, partitions, etc. and subsequent making good.

d) Cutting mortices, sinkings, recesses, etc. for lighting points, switch points, socket outlet points, fitting outlet points and the like in walls, floors, partitions etc. and subsequent making good.

e) Cutting and fitting around, boring holes through and making good or

finishing’s upto

trunking, lighting points and the like.

f) The painting of exposed conduit, trunking, cables, equipment, etc. End of Section



T05-20/11/2013

02 General Specifications-For All Project

Recommend Documents