Technical Specs Construction (Abu Dhabi)

Section 01090

Standards

Sect Sectio ion n 01090 01090,, Stand Stand ards 1

General

A. The Contracto Contractorr shall: a. Comply with all codes, regulations, specifications and standards referred to throughout the Contract Documents. b. Obtain an original copy of the latest edition of all applicable codes, regulations, standards and technical literature referred to in the Contract Documents, to be kept on the project site, properly indexed and maintained in good order and readily available to the Engineer at all times. Upon completion of the works the said codes, standards, etc., shall be handed over to the Engineer. c. Present an affidavit from the manufacturer certifying that the product complies with specified section. Where requested or specified, submit supporting test data to substantiate compliance in conformity with specified standards with a statement from the manufacturer that nonconformities have been observed. B. All references to codes, regulations, specifications and standards referred to in the Contract Documents shall, unless otherwise stated, mean the latest edition, amendment or revision of such reference standard in effect as of the date of submission of these Bid Documents by the Contractors. C. Where a reference standard referred to herein is in the form of a recommendation or suggestion, suggestion, such recommendation or suggestion shall be deemed to be mandatory under this Contract unless conflicting with particular specifications contained herein. D. For Products or workmanship specified by association, trade, or other consensus standards, comply with requirements of the standard, except when more rigid requirements are specified or are required by applicable codes. E. Should specified reference standards standards conflict with Contract Documents, Documents, request clarification from the Engineer before proceeding. F. References to published standards shall be construed as reference to a recognized recognized equivalent one, subject to the Engineer's approval. G. Neither the contractual relationship, duties, nor nor responsibilities of the parties in Contract nor those of the Engineer shall be altered by the Contract Documents by mention or inference otherwise in any reference document. H. All materials to be used in the permanent permanent Works shall be new and of the best quality. The workmanship shall also be of the best quality, all to be to the approval of the Engineer. I. All packed material shall be brought brought to the Site in its original packing and labeled showing the trade name of material, date of manufacture, date of expiry, place of manufacture, name of manufacturer, conditions under which material shall be stored, weight, volume, method of application and mixing if applicable, precautions to be taken when used etc. J. Civil Defense Standards together with the USA Standard NFPA must be observed. observed. K. Legal SI units and symbols only shall be used for the dimensioning and quantification quantification of the entire works. L. Where the standards are not dated in these specifications, the latest amended issue in force at the time of the tender shall be applicable to the whole contract.

Contract 106 , Volume II

Page 47 of 589

Section 01090

2

Standards

Quality Quality Control

BS 4778

Part 2

BS 5701 BS 7850

Vocabulary – Concepts and related Definitions Definition s Guide to Number–Defective Charts for Quality Control

Part 1

Total Quality Management: Guide to Management Principles

BS EN ISO 9001:2000

Quality management Systems - Requirements

BS EN ISO 9004:2000

Quality Management Systems - Guidelines for Performance Improvements

BS ISO 10005

Quality Management: Guidelines for Quality Plans.

BS ISO 10013

Guidelines for developing Quality Manuals.

BS ISO 10015

Quality Management: Guidelines for Training.

ISO 8402

Quality Management and Quality assurance - Vocabulary.

ISO 10006

Quality Management: Guidelines to quality in Project Management.

ISO 10007

Quality Management: Guidelines for Configuration Configurati on Management.

ISO 10011-1

Guidelines for auditing Quality Systems: Auditing.

ISO 10011-2

Guidelines for auditing Quality Systems: Qualification criteria for Quality Systems Auditors (Proposed (Proposed to revise to ISO 19011). 19011).

ISO 10012-1

Quality assurance requirements for measuring equipment: Meteorological confirmation system for measuring equipment.

ISO 10012-2

Quality assurance requirements for measuring equipment: Guidelines for control of measurement process.

BS EN 30011

Auditing

3

Testin g / Inspection Inspect ion Serv Services ices ASTM C802 C802

Practice for Conducting an Inter laboratory Test Program to Determine the Precision of Test Methods for Construction.

ASTM C1021 C1021

Practice Practice for Laboratories Laboratories Engaged Engaged in the Testing Testing of Building Building Sealant.

ASTM C1077 C1077

Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation.

ASTM C1093 C1093

Practice for Accreditation of Testing Agencies for Unit Masonry.

ASTM D290 D290

Recommended Practice for Bituminous Mixing Plant Inspection.

ASTM D3740 D3740

Practice for Evaluation of Agencies Engaged in Testing and/or Inspection of Soil and Rock as Used in Engineering Design and Construction.

ASTM D4561 D4561

Practice for Quality Control Systems for Inspection and Testing Agency for Bituminous Materials.

ASTM E329 E329

Practice for Use in the Evaluation of Inspection and Testing Agencies as Used in Construction.

ASTM E543 E543

Practice for Determining the Qualification of Nondestructive Testing Agencies.

ASTM D3740 D3740

Practice for Evaluation of Agencies Engaged in Testing and/or Inspection of Soil and Rock as Used in Engineering Design and Construction.

ASTM E329 E329

Practice for Use in the Evaluation of Inspection and Testing Agencies as Used in Construction.

ASTM E548 E548

Practice for Preparation Criteria for the Evaluation of Testing Laboratories and Inspection Bodies


Page 48 of 589

Section 01090

4

Standards

Soils Material Material

AASHTO T86

Sampling

AASHTO T191

Density in place (sand (sand core method). method).

AASHTO T204

Density in place (drive (drive cylinder cylinder method). method).

AASHTO T205

Density in place (rubber balloon method).

AASHTO T-2 & T-86

Sampling.

AASHTO T- 87

Sampling preparation.

AASHTO T-27, 11, 88 88

Sieve analysis. analysis.

AASHTO T-89

Liquid limit.

AASHTO T-90

Plastic limit & Plasticity index.

AASHTO T-93, 217 AASHTO T-99 AASHTO T-180

Moisture content Standard Proctor compaction. Modified Proctor compaction.

AASHTO T-176

Sand equivalent. equivalent.

AASHTO T-100

Specific gravity.

AASHTO T-193

CBR.

AASHTO M-145

Classification.

5

Excavation, Excavation, Backfilli ng, Trenching

DIN 4124 BS 6031:1981

Code of Practice for Earthworks.

AASHTO T-93 & 217

Moisture Content.

AASHTO T-191,204 & 205

Density in Place

ASTM D1557 D1557

Test Methods for Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using 4.54 Kg Rammer and 457 mm Drop.

BS 1377, Part 1 to 9

Methods of tests for soils.

BS 6031:1981


Abu Dhabi Municipality Municipality Specification for Backfilling Backfilling of Trenches & Excavations in Asphaltic Roads, Tiled/Paved Parking and Sidewalks. DIN 4124

Excavation

BS 6031:1981



Page 49 of 589

Section 01090

6

Standards

Hdpe Pressure Pressur e Pipelines Code

Description

PrEN 496

Plastic pipes and fittings – Measurement of dimensions and visual inspections

BS EN 681

Elastomeric seals.

BS EN 727

Vicat softening point determination.

BS EN 743

Longitudinal heat reversion

BS EN 728

Oxidation induction time determination.

BS EN 921

Resistance to internal pressure determination.

BS EN 1446

Ring flexibility determination.

BS EN 1610

Construction and testing of drains and sewers.

BS EN 12256

Mechanical strength and flexibility of fabricated fitting test method.

BS EN ISO 527

Tensile property determination.

BS EN ISO 9967

Creep ratio determination.

BS EN ISO 9969

Ring stiffness determination.

BS ISO 1133

Resin melt mass flow rate [MFR] and melt volume flow rate [MVR] determination.

BS EN ISO 527

Tensile strength determination

BS EN ISO 1183

Density and relative density determination.

BS EN ISO 3451 BS EN ISO 4599

Ash determination. determination. Resistance to environmental stress cracking determination.

ISO 4433

Chemical resistance

BS ISO 11922

Dimensions and tolerances –thermoplastic pipes for fluids –metric.

ISO/DIS 13967

Short-term stiffness determination.

ISO 161-1

Thermoplastic pipes- nominal outside pressures and pressures

ISO 527

Tensile strength at yield

ISO 528

Tensile strength at break

ISO 537

Flexural creep modulus

ISO 4427

PE pipes for water supply - specifications

DVGW-GW 320-1

Maximum permissible pulling force for pipes manufactured in PE100

D 518

Thermal conductivity

D 618

Methods of Conditioning Plastics and Electrical Insulating Materials for Testing.

D 638

Tensile strength determination

D 1599 D 1928

Failure pressure determination Time to failure under constant internal pressure Sample preparation

D 2122

Method of Determining Dimensions of Thermoplastic Pipe and Fittings.

D 2412

Test Method for External Loading Properties of Plastic Pipe by Parallel-Plate Loading.

D 2444

Test Method for Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight).

D 2837

Obtaining HDB for thermoplastic pipes

D 3350

Standard Specification for Polyethylene Plastic Pipe and Fittings Materials.

F 412

Definitions of Terms Relating to Plastic Piping Systems.

F 477

Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.

F1248

Environmental stress cracking test

D 1598

AWWA C 906


PE pressure pipe and fitting for water distribution

Page 50 of 589

Section 01090

7

Standards

Chain Lin k Gates Gates

BS 443

Specification for testing zinc coatings on steel wire and for quality requirements.

BS 1722

Fences Part 10 Specification for anti-intruder anti-intrud er fences in chain link and welded mesh.

BS 4102

Specification for steel wire and wire products for fences.

8

Sheet Sheet Piling

DIN 4124

Building pits & trenches

DIN 1055

Design loads for structures / buildings

9

Masonry

BS 5075

Specification for Air Entraining - Part 2 - Admixtures

BS 6073

Specification for Pre-cast Concrete - Part 1 – Masonry Units.

BS 6073

Method for specifying Pre-cast Concrete - Part 2 - Masonry Units.

10 Metal Metal Fabric Fabrication ation ASTM A53 A53

Hot-Dipped, Hot-Dipped, Zinc-coated Zinc-coated Welded and Seamless Seamless Steel Pipe. Pipe.

ASTM B211M B211M

Aluminum-Alloy Aluminum-Alloy Bar, Bar, Rod, and Wire.

ASTM B221M B221M

Aluminum-Alloy Aluminum-Alloy Extruded Extruded Bar, Bar, Rod, Wire, Wire, Shape, and Tube. Tube.

ASTM B483 B483

Aluminum and Aluminum-Alloy Aluminum-Alloy Drawn Tubes Tubes For General General Purpose Purpose Applications. Applications.

BS 4: 1993

Part 1

Hot-rolled steel sections.

BS 729 : 1971

Hot dip galvanized coatings on iron and steel articles.

BS 1470 : 1987

Wrought aluminum and aluminum alloys for general engineering engineeri ng purposes. Plate, sheet and strip.

BS 1474 : 1987

Wrought aluminum and aluminum alloys for general engineering engineerin g purposes. Bars, extruded round tube and section.

BS 1615 : 1987

Anodized Aluminum Alloy.

BS 3571

Part 1

1985 - General recommendations for manual inert-gas metal-arc welding: Aluminum and aluminum alloys.

BS 4174 : 1972

Self-tapping screws and metallic drive screws.

BS 4360 : 1990

Weldable structural steel.

BS 4592


Part 1

Expanded Metal Gratings

Page 51 of 589

Section 01090

Standards

11 Sewerage & Drainage Abu Dhabi Municipality Building Regulations ATV M 143 DIN 1986

Drainage Systems.

DIN 1229 DIN EN 124

Gully and Manhole Covers

DIN 4032

Concrete Pipes and fittings Dimensions, Technical conditions and Delivery

DIN 4035

Reinforced concrete pipes, reinforced concrete pressure pipes and suitable fittings.

DIN 4060

Elastomeric sealants for pipe joints in drains and sewer.

DIN 4262

Part 1

DIN 7865 DIN 8075

PVC-U and PE-HD pipe. Elastomeric Join Sealing Strip for Joints in Concrete.

Part 1

HDPE testing.

ASTM C76

Reinforced Concrete Storm Water Drain Pipe.

ASTM C361M

Specification for Reinforced Concrete Low- Heat Pressure Pipe [metric].

ASTM D412 ASTM C443

Test Method for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomers-Tension. Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets.

ASTM C497M

Method of Testing Concrete Pipe, Manhole section, or Tile [metric].

BS 5911

Pre-cast concrete pipes, fittings and ancillary products Part 100:1988 - Specification for un-reinforced and reinforced pipes and fittings with flexible joints

BS 6906

Methods of test for geo-textiles

BS 8010

Pipelines

DIN 16869

and Centrifugally Cast and Filled Glass Fiber Reinforced Polyester Resin Pipes DIN 19565

DIN 1187

Plastic Drainage Pipe PVC-u

DIN 16929

Chemical Resistance of PVC-u

DIN 19534

PVC-u for Sewerage

ASTM C581-94

Standard practice for determining chemical resistance of thermosetting resins used in glass fiber reinforced structures intended for liquid service.

ASTM D2321-89

Recommended Practice for Underground Installation of Flexible Thermoplastic Sewer Pipe.

ASTM D2584-94

Test for ignition loss of cured reinforced resins.

ASTM D2924-93

Standard test method for external pressure resistance of reinforced thermosetting resin pipe.

ASTM D2992-96

Standard method for obtaining hydrostatic design base for reinforced thermosetting resin pipe and fittings.

ASTM D3262-96

Standard specification for reinforced plastic mortar sewer pipe.

ASTM D3681-96

Test method for chemical resistance of reinforce thermosetting resin pipe in a deflection condition.

BS 3396

Woven glass fiber fabrics for plastics reinforcement:

BS 3496:1989

'E' glass fiber chopped strand mat for the reinforcement of polyester and other liquid laminating systems.

BS 3532:1990

Method of specifying unsaturated polyester resin systems

BS 3691:1990

E-glass fiber roving for the reinforcement of polyester and epoxy resin systems.


Page 52 of 589

Section 01090

Standards

BS 3749:1991

E glass fiber woven roving fabrics for the reinforcement of polyester and epoxy resins systems.

Part 1:1970

Polyester resin mouldings reinforced with chopped strand mat or randomly deposited glass fibers.

BS 5480:1990

Specification for glass reinforced plastics (GRP) pipes joints and fittings for use for water supply or sewerage.

BS 6906

Methods of test for geo-textiles.

ENISO10319

Determination of the tensile properties.

BS 6906

Part 4

Determination of the puncture resistance (CBR puncture test)

BS 8010

Part 1 &Part 2

Pipelines

ISO 160

Asbestos Cement Pipes and Joints

ISO 161/1-1978

Thermoplastics pipes for the transport of fluids - Nominal outside diameters and nominal pressures - Part 1 : Metric Series.

ISO 1167-1973

Plastic pipes for the transport of fluid - Determination of the resistance to internal pressure.

ISO 2045-1973

Single sockets for un-plasticized polyvinyl chloride (PVC-u) pressure pipes with elastic sealing ring type joints - Minimum depths of engagement.

ISO 2048-1973

Double sockets for un-plasticized polyvinyl chloride (PVC-u) pressure pipes with elastic sealing ring type joints - Minimum depths of engagement.

ISO 2505-1981

Un-plasticized polyvinyl chloride (PVC-u) pipes – Longitudinal reversion - Test methods and Specification.

ISO 2507-1982

Un-plasticized polyvinyl chloride (PVC-u) pipes and fittings -Vicat softening temperature - Test methods and Specification.

ISO 3126 – 1974

Plastic Pipes - Measurement of dimensions.

ISO 3127-1980

Un-plasticized polyvinyl chloride (PVC-u) pipes for the transport of fluids – Determination and specification of resistance to external blows.

ISO 3472-1975

Un-plasticized polyvinyl chloride (PVC-u) pipes - Specification and determination of resistance to acetone.

ISO 3473 - 1977

Un-plasticized polyvinyl chloride (PVC-u) pipes - Effect of sulphuric acid – Requirement and test method.

ISO 3606-1976

Un-plasticized polyvinyl chloride (PVC-u) pipes - tolerances on outside diameters and wall thickness.

ISO 4065-1978

Thermoplastic pipes - Universal wall thickness table.

12 Concrete ASTM A615

Deformed and Plain Billet Steel Bars for Concrete Reinforcement.

DIN 1045

Scheduling, Dimensioning, Bending, and Cutting.

BS 4449

Specification for carbon steel bars for the reinforcement of concrete.

ACI 302

Guide for Concrete Floor and Slab Construction.

BS EN 13395-2:2002

Part 2

Products and Systems for the protection and repair of concrete structures-Test methodsDetermination of Workability, Test for flow of grout or mortar

ACI 305R – 91

Hot Weather Concreting.

ASTM C1202

Rapid determination of Chloride Permeability of concrete.

ASTM C94

Ready mix Concrete.

ASTM C232

Test for bleeding of concrete.


Page 53 of 589

Section 01090

Standards

DIN 1164

Portland, Portland blast furnace, blast-furnace slag and trass cement.

BS 4027

Sulfate Resisting Portland cement.

BS 12

Specification for Portland cement.

BS 4550

Methods of testing Cement.

1978

Part 0

General introduction

Sect. 3.1: 1978

Part 3

Physical tests Introduction

Sect. 3.2: 1978

Part 3

Physical tests - Density test

Sect. 3.8: 1978

Part 3

Physical tests – Heat of hydration

1978

Part 4

Standard coarse aggregate for concrete cubes.

1978

Part 6

Standard sand for mortar cubes.

BS 3148

Methods of tests for water for making concrete.

BS 4027

Specification for sulfate- resisting Portland cement.

BS 4254

Specification for two-part polysulphide-base sealants.

BS EN 934

Admixtures for concrete, mortar and grout.

EN 934-2

Concrete admixtures definition and requirements.

BS 5215

Specification for one-part gun grade polysulphide-base sealants.

BS 5328

Part 3

Specification for the procedures to be used in producing and transporting concrete.

BS 5328, 1990

Part 4

Specification for procedures to be used in sampling, testing, and assessing compliance of concrete.

ACI 308

Standard Practice for Curing Concrete.

ASTM C171

Sheet Materials for Curing Concrete.

ASTM C309

Liquid Membrane-Forming Compounds for Curing Concrete.

ASTM D2103

Polyethylene Film and Sheeting.

BS 8110

Code of practice for design and construction.

DIN 4226

Part 1-4 Aggregates for concrete.

BS 882 : 1992

Specification for aggregates from natural sources for concrete.

BS 812

Testing aggregates

1990

Part 100 General requirements for apparatus and calibration.

1994

Part 104 Method of qualitative & quantitative petro-graphic examination of particle shape.

Sect. 105.1:1989

Part 105 Method for determining of particle shape.

Sect. 105.2:1990

Part 105 Method for determining of particle shape. Elongation index of coarse aggregates

1990

Part 109 Method for determining of moisture content.

1990

Part 113 Method for determining of aggregate abrasion value (AAV).

1989

Part 114 Method for determining of Polished stone value (PSV).

BS EN 932

Tests for general properties of aggregates.

932-1 : 1997

Method for sampling.

932-3 : 1997

Procedures and terminology for simplified petro-graphic description.

BS EN 933

Tests for geometrical properties of aggregates.

933-1 : 1997

Determination of particle size distribution. (Sieving method)


Page 54 of 589

Section 01090

Standards

933-2 : 1996

Determination of particle size distribution. Test sieves, nominal size of apertures.

933-3 : 1997

Determination of particle shape. Flakiness index.

933-5 : 1998

Determination of percentage of crushed and broken surfaces in coarse aggregate particle.

933-7 : 1998

Determination of shell content. Percentage of shells in coarse aggregates.

BS EN 1097

Tests for mechanical & physical properties of aggregates.

1097-1 : 1996

Determination of resistant of wear (micro-deval)

1097-2 : 1998

Methods for resistance for fragmentation.

1097-3 : 1998

Determination of loose bulk density and voids.

BS EN 1367

Tests for thermal & weathering properties of aggregates.

1367-2 : 1998

Magnesium sulfate test.

1367-4 : 1998

Determination of drying shrinkage.

BS EN 1744

Tests for chemical properties of aggregates.

1744-1 : 1998

Chemical analysis.

BS EN 480

Admixtures for concrete, mortar and grout Test methods.

DIN 53327

Testing of pigments

BS 1014

Specification for pigments for Portland cement.

480-1 : 1998

Reference concrete and reference mortar for testing.

480-2 : 1997

Determination of setting time.

480-4 : 1997

Determination of bleeding of concrete.

480-5 : 1997

Determination of capillary absorption.

480-6 : 1997

Infrared analysis.

480-8 : 1997

Determination of conventional dry material content.

480-10 : 1997

Determination of water soluble chloride content.

480-11 : 1997

Determination of air void characteristics in hardened concrete.

480-12 : 1997

Determination of alkali content of admixtures.

DD EN 206 : 1997

Concrete, performance, production, placing and compliance criteria.

BS EN 450-1 : 1995

Fly ash for concrete. Definitions, requirements and quality control.

BS 7542 : 1992

Method of test of curing compounds for concrete.

BS 1305

Specification for batch type concrete mixes.

BS 8000

Workmanship on building sites. Code of practice for concrete work.

1990

Part2 Mixing and transporting concrete. Sect. 2.1

1990

Sect. 2.2 Site work with in-situ and pre-cast concrete. Part 9

Code of practice for cement/sand floor screeds and concrete floor toppings.

DIN 4030

Part 1,2

Assessment of water, soil and gases for their aggressiveness to concrete .

DIN 1048

Part Testing of concrete. 1,2,3,4,5

DIN 4235

Part Compaction of concrete by vibration. 1,2,3,4,5

BS 1881 :


Testing concrete

Page 55 of 589

Section 01090

Standards

1983

Part 101 Method of sampling fresh concrete on site.

1983

Part 102 Method for determination of slump.

1993

Part 103 Method for determination of compacting factor.

1983

Part 104 Method for determination of vibration time.

1984

Part 105 Method for determination of flow

1983

Part 106 Method for determination of air content for fresh concrete.

1983

Part 107 Method for determination of density for fresh concrete.

1983

Part 108 Method for making test cubes from fresh concrete.

1983

Part 109 Method for making test beam from fresh concrete.

1983

Part 112 Method of accelerated curing for test cubes.

1983

Part 114 Method of accelerated curing for test cubes.

1986

Part 115 Specification for compression testing machines.

1983

Part 116 Method of determination of compressive strength.

1983

Part 117 Method of determination of tensile splitting strength.

1983

Part 118 Method of determination of flexural strength.

1983

Part 120 Method of determination of compressive strength of concrete cores.

1983

Part 121 Method of determination of static modules of elasticity in compression.

1983

Part 122 Method of determination of water absorption.

1983

Part 124 Method of analysis of hardened concrete.

1986

Part 125 Method for mixing and sampling fresh concrete at laboratory.

1990

Part 127

Method of verifying the performance of concrete cube compression machine using the comparative cube test.

ASTM C 142

Clay lumps and fabric particles of aggregates.

ASTM C 123

Tests for lightweight pieces in aggregates.

ASTM C 127

Specific gravity and absorption of coarse aggregate

ASTM C 128

Specific gravity and absorption of fine aggregate

ASTM C 131

Resistance to degradation of small size coarse Aggregates by abrasion and impact in the Los Angeles machine.

ASTM C 535

Resistance to degradation of larger sized coarse Aggregates by abrasion and impact in the Los Angeles machine.

ASTM C 289

Potential reactivity of aggregates chemical method.

ASTM C 227

Potential alkali reactivity of cement-aggregate combination (mortar method).

ASTM C 1260

Potential alkali reactivity of cement-aggregate combination (NRI method).

ASTM C 88

Soundness of aggregates by use of sodium sulfate or magnesium sulfate.

13 Pre-Cast Units ACI 301

Structural Concrete for Buildings.

ACI 318

Building Code Requirements for Reinforced Concrete.

ASTM A36/A36M

Structural Steel.

ASTM A153

Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

ASTM A666

Austenitic Stainless Steel, Sheet, Strip, Plate, and Flat Bar for Structural Applications.


Page 56 of 589

Section 01090

Standards

14 Ductile Iron Pipes & Fitti ngs DIN 28600 to 28649

for pressure ductile cast iron pipes and fittings.

DIN 19690 to 19692

for non-pressure ductile cast iron pipes and fittings.

DIN 30674 to 30675

for Coating.

EN-598, EN 545, ISO 2531 & 4179, BS 4772 : 1995

Ductile Iron Pipes, Fittings, Accessories and their joints for Sewerage Applications Requirements and Test Methods.

15 Signboards ASTM B584

Copper Alloy Sand Casting.

BS 1088

Plywood, WBP For External use.

16 Corrosion Protection BS743 : 1970

Specification of materials for damp proof courses.

BS8102

Code of practice for protection of structures against water from the ground. NRCA (National Roofing Contractors Association) Waterproofing Manual.

ASTM C578

Preformed Cellular Polystyrene Thermal Insulation.

ASTM C581

Standard practice for determining chemical resistance of thermosetting resins used in glass fiber reinforced structures intended for liquid service.

ASTM D790

Test- Flexural Properties-Glass Reinforced Plastic (GRP) Fabrications.

ASTM D4060

Abrasion resistance, Wear Index 1: Epoxy coating.

ASTM E84

Test Method for Surface Burning Characteristics of Building Materials.

NFPA 255

Test of Surface Burning Characteristics of Building Materials.

UL 723

Tests for Surface Burning Characteristics of Building Materials.

ASTM D16

Definitions of Terms Relating to Paint, Varnish, Lacquer, and Related Products.

ASTM D 2016

Test Method for Moisture Content of Wood

BS EN ISO 1461 : 1999

Hot-dip galvanized coatings on fabricated iron and steel articles. Specifications and test

BS5493:1977

Code of practice for protective coating of iron and steel structures against corrosion.

BS6150:1991

Code of practice for painting buildings.

BS7079

Preparation of steel substrates before application of paints and related products.

DIN55928

Corrosion protection of steel structures.

AWWA C204

- Chlorinated Rubber-Alkyd Paint Systems for the Exterior of Above Ground Steel Water

AWWA D102

- Painting Steel Water Storage Tanks.

NACE

(National Association of Corrosion Engineers) - Industrial Maintenance Painting.

NPCA

(National Paint and Coatings Association) - Guide to US Government Paint

PDCA

(Painting

SSPC

(Steel Structures Painting Council) - Steel Structures Painting Manual.

SIS 05 900-1967

Rust grades for steel surfaces and preparation grades prior to protective coating,

BS EN ISO 12944 – 1


1998

and

Decorating

Contractors

of

America)

-

Painting

-

Architectural

General introduction.

Page 57 of 589

Section 01090

Standards

12944 – 4

1998

Types of surface and surface preparation.

12944 – 5

1998

Protective paint systems.

12944 – 6

1998

Laboratory performance test methods.

BS 7079 Part A1

1996

Photographic examples of appearance

Part A2

1996

Visual assessment of surface cleanliness

Part D2

1993

Methods for surface preparation. Abrasive blast – cleaning.

Part D3

1993

Methods for surface preparation. Hand and power tool cleaning

BS EN ISO 11124 - 1 : 1997

General introduction and classification.

BS EN ISO 11124 - 2 : 1997

Chilled iron grit.

BS EN ISO 11124 - 3 : 1997

High carbon cast steel shot.

BS EN ISO 11124 - 4 : 1997

Low carbon cast steel shot.

17 Blast Cleaning Abrasives & Surface Rough ness Characteristic s BS EN ISO 11125 - 1 : 1997

Sampling.

11125 - 2 : 1997

Determination of particle size distribution.

11125 - 3 : 1997

Determination of hardness.

11125 - 5 : 1997

Determination of %-age defective particles & microstructure.

11125 - 6 : 1997

Determination of foreign matter

11125 - 7 : 1997

Determination of moisture.

BS-EN-ISO8503-1: 1995

Specifications and definitions for ISO surface profile comparators for the assessment of blast cleaned surfaces.

8503 - 2 :1995

Method for grading of surface profile of abrasive blast – cleaned steel. Comparator procedure.

8503 - 3 :1995

Method of calibration of ISO surface profile comparators and for the determination of surface profile.

18 Paint , Varnis hes & Powder Coatin g Tests BS EN ISO 1517 : 1995

Surface dry test

BS EN ISO 1519 : 1995

Bend (cylindrical mandrel) test

BS EN ISO 9514:1995

Preparation and conditioning of samples and guidelines for testing.

BS EN ISO 1520 : 1995

Cupping test

BS EN ISO 2409 : 1995

Cross-Cut test

BS EN ISO 2431 : 1

996 -

BS EN ISO 3251 : 1995

Determination of non-volatile matter of paints, varnishes and binders for paints and varnishes.

BS EN ISO 4622 : 1995

Pressure test for stackability


Determination of flow time by use of flow cups

Page 58 of 589

Section 01090

Standards

BS EN ISO 4623 : 1995

Filiform corrosion test on steel

BS EN ISO 6270 : 1995

Determination of resistance to humidity (Continuous Condensation)

BS EN ISO 6860 : 1995

Bend test (Conical Mandrel)

BS EN ISO 6272 : 1994

Falling weight test.

BS EN 24624 : 1993

Pull off test

BS 3900

1982

Part C5

1997 Determination of film thickness

Part C6

1983 Determination of finess of grind

Part C9

Methods for evaluation of the compatibility of a product with a surface to be painted.

Part D5: Measurement of specular gloss of non metallic paint films at 20 , 60 and 85 1997 °

Part E2

1997 Scratch test

Part F4

1997 Resistance to continuous salt spray.

1985 Part F10

°

°

Determination of resistance to cathodic disbonding of coatings for use in marine environments

Part F15 1995 Determination of resistance to humidity (intermittent condensation) Part G6

1995 Determination of resistance to fungal growth

BS 3900 J1: 1993

Sampling.

J2: 1993

Determination of particle size distribution by sieving.

J3: 1998

Determination of gel time

J4: 1995

Determination of storage stability

J5: 1993

Determination of loss of mass on heating

J8: 1993

Calculation of powder explosion limit

J09: 1993

Determination of flow properties of a coating powder / air mixture

J10: 1998

Determination of deposition efficiency

J12: 1998

Determination of compatibility of coating powders.

19 Pipeline Const ruc tion B y Non-Disru ptiv e Method ATV standard A125

“ PIPE DRIVING” .

BS 2494

Materials for elastomeric seals for joints in pipe work and pipelines.

BS 5228

Part 1

Code of practice for basic information and procedures for noise control.

BS 5228

Part 2

Guide for noise control legislation for construction and demolition, including road construction and maintenance.

BS 5911

Part 120 Specification for reinforced concrete jacking pipes with flexible joints.

BS 6164

Code of practice for safety in tunneling in the construction industry

BS 8005

Part III

Sewerage - Guide to planning and construction of sewers in tunnel.

BS 8110

Parts I & Structural use of concrete. Code of Practice for design and construction. Abu Dhabi Municipality: Guidelines and Requirements for Planning and Design of NDRC. WD Specification for construction and repairing of Roads.

END OF SECTION


Page 59 of 589

Section 01500

Dewatering

Section 01500, Dewatering 1

General

A. The Contractor shall allow in his rates for excavation for keeping the excavation at all times, whether above or below the groundwater table, free from storm water, percolating water, subsoil water, sewage, irrigation water or sewage effluent by pumping bailing or other means. B. Any data provided by soil reports are for the Contractor’s guidance only and it shall be the Contractor’s sole responsibility to obtain further details required by him for preparing his tender. No claim shall be entertained for additional costs or extension of time that may result from lack of information. C. Not less than 30 days prior to start of dewatering operations, the Contractor shall submit working drawings and detailed information for the Engineer’s approval showing the intended plan for dewatering operations. The submittal shall include at least the following: a. Details of locations and capacities of dewatering wells, well points, pumps, sumps, collection and discharge lines, standby units b. Water disposal methods c. Monitoring of settlement. D. The Contractor shall fully comply with the requirements of Abu Dhabi Municipality or any other Government Departments in regard to the Works for maintaining excavations, dewatering and the discharge of groundwater arising from dewatering.

2

Execution

A. Dewatering shall be carried out only to a depth sufficient for the required excavation. B. The Contractor shall ensure that, at all times during construction, no ground water shall come into contact with any concrete surface or reinforcement and that any structure shall be capable of withstanding any hydrostatic pressure to which it may be subjected during construction and until completed. C. Any water removed from the excavations shall, wherever practicable, be pumped directly into the sea or to storm water sewers, if approved, via an efficient system of discharge lines. D. No water or sewage effluent shall be discharged into any pipe line, water course, onto roads, tracks, footpaths, yards or any other open area unless approved by the appropriate Authority and the Engineer. Such permission shall not be granted unless the Contractor shall have provided efficient settling basins or sand traps to retain all sand and other solids likely to settle. The permission to discharge liquids shall be liable to be withdrawn at any time in the event of circumstance arising and which in the opinion of the Engineer shall make such a discharge undesirable. The Contractor shall have no right to claim in respect of withdrawal of such permission. E. The static water level shall be drawn down to a minimum of 300mm below the bottom of the excavation so as to maintain the undisturbed state of the foundation soils and to allow the placement of any fill or backfill to the required density. F. The Contractor shall install and operate the dewatering system so that the groundwater level outside the excavation is not reduced to the extent that would damage or endanger adjacent roads, services, structures or property. G. The Contractor shall include for the diversion of all watercourses encountered in the works until the complete drainage scheme for the site is completed and put into operation. H. Notwithstanding any previous approval, the Contractor shall be fully responsible for the effects of his works and for maintaining dry excavations. I. The Contractor shall, where extensive dewatering is required, be fully qualified to perform the dewatering operations or shall furnish the services of an experienced, qualified and equipped dewatering Subcontractor to design and operate the dewatering and groundwater recharging systems required for the works, all subject to the Engineer's approval. J. The Contractor shall take all precautions to avoid undermining any part of the Works or other properties by pumping or else but should undermining occur he shall make good same to the satisfaction of the Engineer at the Contractor’s expenses. In all cases where permission to use existing sewers, pipes or drains for the discharge of liquids has been granted, it will be on the condition that the Contractor cleans out such facilities after completion of the Works at the respective site.


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Dewatering

K. Where required by the Engineer, the Contractor shall establish a specified number of groundwater level monitoring stations at each site, which will be observed during the work. These shall be located as directed by the Engineer and consist of acceptable open tube piezometers. Settlement gauges shall be provided to the site; times and locations to monitor settlement of new and existing facilities shall be as directed by the Engineer. L. The release of groundwater to its static level shall be performed so as to maintain the undisturbed state of natural foundation soils, prevent flotation or movement of structures, pipelines and sewers. M. The Contractor shall not remove any dewatering systems without the Engineer’s acceptance. N. Monitoring and settlement measurement systems shall be maintained in operation until the Engineer approves removal; well points and like items may be abandoned in place. O. Discharge pipelines and dewatering ports shall be removed immediately upon completion of dewatering operation.

3

Work ing Adjacent To Existing GRP Pipelines

A. The Contractor shall: a. Take all necessary precautions to limit the draw down of groundwater over existing sewers to the minimum practicable and install dewatering well points remote from existing sewers. b. Use cut-off walls to reduce the potential for groundwater flow along pipe trenches. Dewatering shall not result in the flow of water along the pipe zone material. Submit for the Engineer’s approval, details of proposed method of working and temporary works installations to achieve this. c. Monitor the ground water level over the existing sewers. d. Undertake a deflection survey and CCTV survey of the existing sewer before commencing dewatering works when excavation is to be undertaken within 10 meters of an existing sewer: e. Measure vertical and horizontal pipe deflections at 2-meter intervals and at each side of a joint. Repeat the deflection survey on completion of the work and removal of the dewatering installation. f. Reinstate existing sewer where method of working causes a change in the deflection of the existing sewer or adversely affects the sewer in any way. The maximum deflection of the reinstated pipe: 3 per cent.

END OF SECTION


Page 84 of 589

Section 02110

Earthworks & Excavation

Section 02110, Earthworks & Excavation 1

General

A. All activities shall conform to applicable codes for environmental requirements, disposal of debris, burning debris on site and use of herbicides. B. Ground levels for determining quantities of excavation and / or depth of trench excavation shall be taken after works of clearing site are completed. C. The Contractor shall coordinate clearing works with concerned Authorities and/or other utility companies.

1.1.1 Preparation and Prot ection A. Prior to start execution of the works, the Contractor shall verify existing site conditions. B. The Contractor shall locate, identify and accurately record actual locations of utilities and services by horizontal dimensions, elevations or inverts. C. The Contractor shall notify respective Authority or utility-company to remove and/or relocate services and utilities if required. D. The Contractor shall clearly identify and protect existing plant life designated to remain as final landscaping. E. The Contractor shall clearly identify survey benchmarks and survey control points on site. F. The Contractor shall maintain and protect all existing utilities and services to remain. G. The Contractor shall maintain and protect benchmarks, survey control point, existing structures, fences, sidewalks, paving, and curbs from any damage or displacement. H. The Contractor shall comply with the directives set forth in the Specifications for maintaining and supporting services and structures. I. The Contractor shall identify a salvage area for placing removed materials.

1.1.2 Clearing A. In the event that the Contractor is granted permission to remove existing plants, he shall follow the instruction of the Abu Dhabi Municipality Agriculture Section. Any holes left by removal of trees and shrubs shall be filled and compacted to the satisfaction of the Engineer. Any debris shall be disposed of to an approval tip. B. No tree shall be removed from the Site without prior approval from the Engineer and ADM Agriculture Section and/or other concerned Authorities. C. The Contractor shall clear areas required for access to site and execution of the Works. D. Undergrowth and deadwood shall be removed without disturbing the subsoil. E. The Contractor shall apply herbicide to remaining stumps to inhibit growth. F. Herbicide shall be used only if approved and in strict accordance with the manufacturer's recommendations for its intended use. G. All practicable steps should be taken in terms of health and safety requirements whilst using such material.

1.1.3 Removal of Overburden A. The Contractor shall remove debris, rock, building material, other detrimental deposits, extracted plant life, etc. from site to an approved disposal area provided and paid for by the Contractor. B. Existing pavement and curbstones shall be removed if required for the execution of the works. C. Curbstones together with their concrete hunching and foundation shall be broken out and disposed off from site. D. Paving slabs and their foundation shall be broken out and disposed off from site. E. Paving slabs bedded in sand shall be carefully removed and stored, should the Engineer approve their subsequent re-use in the works or elsewhere. F. Existing road signs shall be carefully taken down and handed over to the appropriate Authority. G. Ground levels, for the purpose of measuring works executed, shall be taken after removal of overburden.


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1.1.4 Topsoil Excavation A. The Contractor shall carefully strip the topsoil from any agricultural land, garden and the like to the depth as directed by the Engineer and over the entire working width. B. Topsoil shall be deposited separately from other excavated material for re-use. C. Wet topsoil shall not be excavated. D. After completion of works and before placing topsoil, the entire area effected by the Contractor’s activities shall be scarified to a depth of 300mm and shall be made up to the required level to receive top soil. E. When excavating through roots, the Contractor shall perform the work by hand and cut roots with sharp axe.

1.1.5 Soil Materials A. The Contractor shall perform the work in accordance with related Section requirements and Abu Dhabi Municipality and Works Department standards. B. The Contractor shall submit soil samples in air-tight containers, 4.5 kg sample of each type of fill to approved testing laboratory. C. Name of imported materials source shall be submitted. D. Testing of compaction and analysis of materials shall be performed as per standards specified. E. If tests indicate materials do not meet specified requirements, material shall be changed and retested. F. The Contractor shall provide materials of each type from same approved source throughout the Work.

1.1.6 Trial Holes A. During the course of the Works the Engineer may instruct the Contractor in writing to excavate trial holes for the purpose to obtain information on the subsoil strata. The instruction shall state the dimensions required and payment will be made against the relevant item of the Bill of Quantity. B. Payment will not be made if trial holes have been made to verify the quality of works executed and tests and/or inspection of trial holes provide negative results. In this case the Contractor shall be solely responsible for any resulting consequences. Rate shall include costs for backfilling, compacting and making good all surfaces and works disturbed.

1.1.7 Filling Works A. Filling Works shall be executed in accordance with applicable Abu Dhabi Municipality standards. B. The Contractor shall fill areas to required contours and elevations with materials approved by the Engineer. C. Fill material shall be placed by continuous layers and compacted in accordance with the Specifications or as directed by the Engineer. D. Optimum moisture content of fill materials shall be maintained to attain required compaction density. E. The Contractor shall slope grade away from building with minimum 1.5/100, unless otherwise noted or instructed. F. Grade changes shall be shaped gradual. Slope into level areas shall be blended. G. Upon completion, the Contractor shall remove all surplus materials from the Site. H. Elevation of top surface shall be not more than +/- 20 mm from required elevation.

1.1.8 Requirements A. Structural Fill:  Maximum 150 mm compacted depth.  Compact to minimum 95 percent of maximum density. B. Pervious Structural Fill:  Maximum 150 mm compacted depth.  Compact to minimum 95 percent of maximum density. C. Subsoil Fill:  Maximum 300 mm compacted depth.  Compact to minimum 90 percent of maximum density. D. Topsoil Fill:  300 mm compacted depth. Contract 106 , Volume II

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

2


Compact to minimum 90 percent of maximum density.

Excavation 2.1.1 Definitions

A. Reduced level: shall be the level to which the original surface level is to be reduced, prior to the excavation to formation level or the level taken after clearing and grubbing. B. Formation level: shall be the level to which either excavation or filling is to be carried out in order to receive the blinding, foundation, base or other initial construction of the Works. C. Structural Excavation: means excavation in open cut (excluding trench excavation) down to the levels specified as being the final levels of excavation. D. Trench Excavation: means excavation of trenches into which pipes, fittings, cables, ducts are to be laid. E. Extra Excavation: means excavation, generally in small quantities, below or outside trench excavation or structural excavation. F. Over Break: means excavation slips etc. outside the specified limits for structural, trench and extra excavation. All costs related to over break (including reinstatement and refill with approved back fill material or concrete) are to be borne by the Contractor. G. Selected Fill: means backfill material obtained from a source approved by the Engineer. H. Unsuitable material: is any material found during excavation and not suitable for backfilling or for forming a sound foundation for pipes, structures etc. I. Services: shall mean any wall, fence, structure, chamber, panel, pole, cable, pipe, conduit or duct.

2.1.2 General A. The Contractor shall verify that survey benchmarks, control points and intended elevations for the Work are as indicated on drawings or as instructed by the Engineer. B. Required lines, levels, contours, and datum locations shall be verified and identified. C. The Contractor shall take and record levels in the manner specified or agreed with the Engineer before disturbing any part of the Site or beginning the works thereon. The Contractor shall give the Engineer two working days notice so that the recording of levels can be performed in his presence. D. The Contractor is to examine the Site and to familiarize himself with the nature of the ground, excavation methods to be applied and physical obstructions and conditions on Site that may affect his work and prices. His rates shall allow for all operations (including rock excavation and dewatering) and costs required and encountered when carrying out the Works in accordance with the Contract. E. Claims due to lack of knowledge of site condition will not be entertained. F. Starting excavation shall not be permitted until pipes, fittings, manholes etc. are on the immediate site, ready for installation. G. Existing utilities, services and structures shall be maintained and supported in accordance with the regulations of respective Authorities, the Specifications or as directed by the Engineer. H. The Contractor shall not make any battered excavation or trenches in public highways, private gardens or within 30m from any building or structure. I. The Contractor shall support excavations as required, all in accordance with the Specifications. J. Excavation shall be limited to such sizes, depths and inclinations as may be necessary to construct the Works or as directed by the Engineer. o K. 45 bearing splay of foundations shall not be encroached during excavation. L. All open excavation and trenches shall be kept free from water whether affected by tides, floods and storms or otherwise so that the Works will be constructed in dry conditions. M. The Contractor shall verify work associated with lower elevation utilities is complete before placing higher elevation utilities. N. Where dewatering is required, the Contractor shall provide qualified and experienced crew to perform the dewatering operation, or furnish the services of a dewatering subcontractor approved by the Engineer to design and operate the dewatering works. O. The Contractor shall not install pipelines, manholes or commence any permanent works until the Engineer has inspected and accepted the excavation, trenches and preparation of formation level. P. Usage of blasting or any explosive during the works is strictly prohibited. Q. The Department reserves the right to stop the works at any time if in its opinion it is considered that working methods are not safe.


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2.1.3 Structural Excavation A. Subsoil shall be excavated to accommodate building foundations, paving, structures and construction operations. B. The Contractor shall excavate to working elevations for piling work and consider special requirements for piling. C. Excavation to formation level shall be hand-trimmed as specified not to disturb original soil. D. Unsound foundations, loose matter, soft spots and lumped subsoil, boulders, and rock up to 0.25 3 m measured by volume shall be removed. E. The Contractor shall compact as specified disturbed load bearing soil in direct contact with foundations to at least original bearing capacity or as instructed by the Engineer. F. Top perimeter of excavation shall be graded to prevent surface water from draining into excavation. G. The Contractor shall notify the Engineer of unexpected subsurface conditions and discontinue affected Work in area until notified to resume work. H. The Contractor shall remove excavated material from site if site conditions dictate and return if required for backfill.

2.1.4 Trench Excavation A. The line and level of trenches shall be as shown on drawings, or as directed by the Engineer. B. Before commencing excavation, but after removal of overburden, the alignment of the trench shall be pegged out accurately and the ground level shall be agreed with the Engineer. C. The Contractor shall make sure the extent of all trenches in open cut is the minimum necessary or practicable for the construction of the Works. D. Unless otherwise approved by the Engineer, the maximum allowable length of open trench is 400m. E. Subsoil shall be excavated to required depth as per design drawings or otherwise directed by the Engineer. F. The Contractor shall form that portion of the trench which extends from the formation to a point 300 mm above the crown of the pipe when laid in its correct position in vertical sides with the minimum practicable distance apart unless otherwise specified by the pipe manufacturer and/or accepted by the Engineer. G. The top edge of the trench shall be shaped as straight as practicable. H. Trench excavation shall be carried out by such methods and to such lines, dimensions and depths as required for the proper construction of the Works and as specified in DIN 4124. I. Trench excavations shall have vertical sides, strutted properly. J. Subject to any specific requirements of the Contract, the backfilling and temporary surface reinstatement of trench excavation shall be commenced and be completed as soon as reasonably and practicable after the pipes have been laid, joined and tested. K. Pipe laying shall follow closely upon the progress of trench excavation and the Contractor shall not permit unreasonably excessive length of trenches to be open while awaiting testing of the pipeline. L. If the Engineer considers that the Contractor is not complying with any of the foregoing requirements, he may prohibit further trench excavation until he is satisfied with the progress of laying and testing of pipelines and backfilling of trench excavation. M. For deep trenches to be excavated close to roadways, buildings, boundary walls, existing services etc., the Contractor shall consider the following: a. The method of excavation, shoring of trenches shall be designed to avoid damages to such existing facilities. b. The use of vibratory equipment may be restricted. c. Any damage to such buildings, roads, services, boundary walls or other installations caused by the Contractor’s works shall be made good to the satisfaction of the owner(s) and the Engineer. d. All costs related to such repairs, reconstruction etc. are deemed to be included in the Contractor’s rate. I. Excavation to formation level shall be hand-trimmed as specified not to disturb original soil. N. Unsound foundations, loose matter, soft spots and lumped subsoil, boulders, and rock up to 0.25 3 m measured by volume shall be removed. O. The Contractor shall comply with the orders of the Engineer on the restoration of the trench width, or the use of an alternative bedding material, or taking any other remedial action as in his opinion is


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necessary in the event of any trench for pipelines exceeding the maximum allowable widths as specified or shown on the Drawings.

2.1.5 Suppor t of Excavatio n and Trenches A. The Contractor shall submit for the Engineer’s approval the proposed support of excavations and trenches at least 2 weeks prior to the commencement of any excavation work. The following shall be submitted: a. Detailed calculations and drawings of the supporting system. b. Slope stability calculations, details of lateral earth pressures c. Soil investigation results and water table. d. Anticipated surcharge and equipment loads during installation, removal and backfilling. e. Details of supports including stress analysis for supporting members. B. The supporting system shall comply with DIN 4124 and other relevant Sections of the Specifications. C. The nature of the ground to be excavated, the level of water table at the site and the proximity of buildings and roads shall be taken into consideration. D. Additional excavation necessary to provide space for supports and working area shall be considered as Over-Break and is deemed to be included in the unit rates. E. Remedial measures repairs and related costs encountered due to settlement slip falls damages are to be carried out and paid for by the Contractor. F. The Contractor shall not remove temporary works supporting the excavations until in the opinion of the Engineer the permanent work is sufficiently advanced to permit such removal. G. Any advice, permission, acceptance or instruction given by the Engineer relative to such support or its removal will not relieve the Contractor from his responsibilities under the Contract. H. The Contractor shall remove supporting system under the personal supervision of a competent site engineer.

2.1.6 Hand Trimming A. When excavation to specified levels for the foundation of structures, for trenches or to the specified limits for the face of any structure requires to abut undisturbed soil, the Contractor shall not excavate the last 150 mm until immediately before commencing the construction work. B. Should the Contractor have excavated to less than 150 mm of these specified limits, he shall excavate further so as to remove not less than 150 mm of material immediately before commencing the construction works. Any additional works and costs related thereto are considered as over-excavation. C. Where no bedding material is specified or instructed to be laid beneath the pipe, the bottom of the trench shall be carefully trimmed true to level and grade so as to not disturb subsoil and ensure a continuous support for the pipe barrel. D. Pockets for couplings and / or flanges shall be excavated below the invert level. E. The trench bottom shall be pricked over with a rake and any stone or flint likely to cause the pipe to bed unevenly or to damage the pipe and its coating or greater than 20 mm in size shall be picked out of the pipe bed. F. Before commencement of any construction work, all shattered and loose material shall be removed from the excavation by hand so as to ensure that the Work rests on a solid and perfectly clean foundation or abuts against solid soil.

2.1.7 Slips, Falls and Excess Excavation A. The Contractor shall take every precaution to prevent slips or falls of earth and other materials into open excavation or trenches. B. The Contractor shall fill all voids formed as a result of: a. Slips or falls b. Excavation being made in excess of the minimum necessary or practicable for the construction of the Works c. Any over-excavation whether or not necessary beneath the formation of a structure d. Any combination of the above. C. Concrete Class B5 shall be used to fill all voids. D. Filling with other materials shall not be allowed unless otherwise approved.


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2.1.8 Maintaining and Support ing Services and Structu res A. Prior to start of excavation, the Contractor shall, by means of exposing or others, ascertain the location / nature / depth and dimensions of any services located within the working space required for the Works. B. The Contractor shall record the information on forms approved by the Engineer. Such records shall be made available to the Engineer at least 30 days before breaking up ground and early enough in order to review of the design for pipelines and structures. C. All Services affected by the Contractor’s work, other than those diverted permanently, shall be reinstated to the satisfaction of the owner and the Engineer at the Contractor’s expenses. D. The Contractor shall be solely responsible for ascertaining from his own inspection of the Site and from the respective Authorities and other public or private bodies the position of the Services whether underground or overhead, within or near the Site. E. The Contractor shall support or temporary divert the Services at his own expense and to the satisfaction of the appropriate authority and the Engineer such that the Works shall proceed with all due expedition and without delay. F. Mechanical excavations are not allowed close to service routes. G. Manual excavations close to all types of services must be carried out only in presence of supervisors from the concerned Authorities and according to their specification and requirements and under the Contractor’s responsibility. H. The Contractor by himself shall contact the concerned Authorities and take the necessary arrangements to be sure of their presence before commencing the excavation works. I. The Contractor shall replace all diverted and supported services at his own cost on completion of his work unless the Authority instructs otherwise, in which case the Contractor shall be paid extra over costs involved in implementing the Authority’s instructions regarding the diverted services or structures. J. As soon as Services have been damaged, the Contractor shall forthwith call the attention of the Engineer and the appropriate Authority thereto and shall comply with any instruction given by them. K. The Contractor shall arrange for and pay any repair works, replacement or costs resulting from such damages. Repair works shall be carried out only with the explicit permission and in accordance with the instructions of the appropriate Authority. L. If the appropriate Authority chooses to carry out repairs to damaged services themselves or by using their own nominated sub-contractors the Contractor shall reimburse all the costs incurred for such works and if he fails to do so such monies may be deducted from any monies due or which shall become due from the Department to the Contractor. M. In addition to any reimbursement of costs, the Contractor will be required to pay the appropriate Authority a sum of money as a penalty for damage caused to any of that Authority’s services. N. Trees within the Right of Way may be cut down only after having received the owners and the Engineer’s written permission. Any damage to trees, whether accidental or otherwise, shall be the Contractor’s sole responsibility and shall be reported to the Engineer.

2.1.9 Removal of Unsound Found ations and Soft Spots A. The Contractor shall excavate further if on reaching the specified levels, the inspected exposed ground, or part of the ground is considered naturally unstable by the Engineer or became unacceptable due to exposure to weather conditions or due to flooding or have become puddled, soft or loose during the progress of work. Replace the further excavation with concrete Class B5 or with such materials as the Engineer may direct. B. The Contractor shall remove the backfill over its full depth and for the full width of the pipe trench shown on the Drawings, where a pipe is being laid into a port in an existing structure manhole chamber or thrust block, and where the backfill material to the previous excavation beneath the pipe formation is not concrete. The resulting void shall be filled with concrete Class B5 to a level as approved by the Engineer. C. The omission by the Engineer to give an instruction under this Clause will not relieve the Contractor from any responsibility for defects in the Works due to the construction being placed upon an unsuitable formation if prior to the construction of the work the Contractor failed to advise the Engineer in writing.


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2.1.10Disposal of Excavated Material A. Excavated material that is not required or is, in the opinion of the Engineer, unsuitable for re-use in the Works shall be disposed to an approved location. The Contractor shall give the Engineer adequate notice of his intention to spoil. B. Subject to any specific requirements of the Contract, the disposal of excavated material within the site shall be at the Contractor’s discretion but shall be so arranged as to be acceptable to the Engineer. C. The Contractor shall ensure that no excavated material, which is suitable for and is required for reuse in the Works, is disposed off outside the site without written approval of the Engineer. D. The term “excavation” shall be deemed to include for disposing off excavated material in any of the following ways: a. Backfilling to excavation and completed structures and trench excavation using suitable excavated material and including placing in temporary spoil tips and any double handling required. b. Transporting selected excavated material to locations within the Site where embankments are to be constructed or where filling around structures is specified to be constructed as embankment including tipping ready for spreading and compacting. c. Disposal of unsuitable material and surplus excavated material outside the site to the locations approved by Abu Dhabi Municipality. The works shall include loading, hauling = 50 km in all direction, unloading, spreading, compacting and leveling. d. Double handling of top soil, intermediate storage, returning to original site, spreading, compacting and leveling e. Removing of lumped soil, boulders and rocks as specified. E. The Contractor shall be responsible to obtain the written approval from Abu Dhabi Municipality to the material disposal locations. F. Topsoil and excavated material suitable for plantation shall be deposited in temporary separate spoil tips within the Site.

2.1.11Stockp iling of Excavated Material A. The Contractor shall stockpile materials on site as approved by the Engineer. B. The Contractor shall stockpile material in sufficient quantities to meet Project schedule and requirements. C. Differing materials shall be separated with dividers or shall be stockpiled apart to prevent mixing. D. Surface water shall be directed away from stockpile site to prevent erosion or deterioration of materials. E. The Contractor shall stockpile material in area designated on site to a height not exceeding 2.5m above ground level. F. After removal of stockpiles, the area shall be left in a clean and neat condition. Site surface shall be graded to the satisfaction of the Engineer. G. Any excavated material stored on site for backfilling or any other purpose shall be deposited and compacted in such a manner that will avoid damage or inconvenience. H. Excess or unsuitable material shall be removed from site. I. Embankments and stockpiles shall be sloped to angle of repose or less until shored.

2.1.12Working In Roadway A. The Contractor shall be responsible to obtain the necessary permits for working in or close to roadways. He shall program his activities in such a manner that cutting of roadways and construction works are being carried out during periods with little traffic. Similarly piece meal works, allowing for temporary leaving specific sites and returning, are to be considered. All costs for such works and rescheduling etc. are to be included in the Contract Price. B. The Contractor shall provide maintain and operate temporary traffic controls of a type approved by the Traffic Department and the Engineer. C. The Contractor shall be responsible for acquainting himself with the requirements of Works Department and Road Section of Abu Dhabi Municipality (see Municipality’s Guidelines-Appendix1) as regards backfilling of trenches in roads and he shall be deemed to have included in his rates for compliance with all such requirements whether specifically mentioned herein or not. D. Cutting of asphalt or concrete paving shall be carried out by saw to achieve neat edge at the cut. Cutting by compressor and breakers is not permitted. The alignment of the cut shall be straight. In Contract 106 , Volume II

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case deviations occur then the cutting shall be repeated until the edge of the cut is acceptable to the Engineer. E. All trench excavation and other work carried out within the limits of any roadway shall be completed as rapidly as possible and not more than half the width of the carriage way shall be obstructed at one time. F. The Contractor shall at all times take special precautions to prevent settlement in the vicinity of the open excavation and trenches. The Contractor shall make good any settlement and repair any damage resulting from such settlement at his own cost and all to the satisfaction of the Engineer or the landowner. This is in no way limiting the Contractor’s responsibilities under the Contract.

2.1.13Rock Removal A. Excavation in rock shall not be paid separately. Costs for rock excavation are deemed to be included in other related rates. B. The Contractor shall submit working method for rock fracturing and removal and specify equipment used. C. Blasting or explosives for rock fracturing is strictly prohibited. D. Prior to the commencement of the works, the Contractor shall conduct survey and document existing conditions of buildings in the vicinity of locations of rock removal and take photographs of existing conditions. E. The Contractor shall drill holes and utilize expansive tools, wedges and mechanical disintegration compound to fracture rock. F. The Contractor shall cut away rock at bottom of excavation to form level bearing. G. In utility trenches, the contractor shall excavate to 150 mm below invert elevation of pipe and 600 mm wider than pipe diameter. H. The Contractor shall replace over-break and voids with lean concrete class B5 as directed by the Engineer.

3

Backfilling 3.1.1 Preparation

A. The Contractor shall verify that: a. Pipelines, manholes, sub-drainage, damp proofing, or waterproofing installation has been inspected. b. Underground tanks are anchored to their own foundations to avoid flotation after backfilling. c. Unsupported walls are structurally capable to support imposed loads by the fill. B. The Contractor shall compact sub-grade to density requirements for subsequent backfill materials. C. The Contractor shall identify and cut out soft areas of sub-grade not capable of compaction in place and shall backfill with approved fill and compact to density equal to or greater than requirements for subsequent fill material.

3.1.2 Materials 3.1.3 General A. The soil material used for backfilling shall be as approved by the Engineer. B. The backfill material shall be a uniform, readily compactable soil and shall exclude material from swamps, marshes, vegetable matter, timber or similar material liable to decomposition, material susceptible to spontaneous combustion. C. Clay or soils having an Plasticity Index > 9% or a Liquid Limit > 40% shall not be used. D. Proctor tests shall be carried out on the material to be used for backfilling prior to start of backfill operations in order to establish the Optimum Moisture Content and maximum compaction.

3.1.4 Material for Backfill ing in Roads & Paved Areas A. All materials for backfilling of excavations in roads and paved/tiled areas shall conform to the specifications defined in the ‘Abu Dhabi Municipality Specification for Backfilling of Trenches & Excavations in Asphaltic Roads, Tiled/Paved Parking and Roads.


Page 121 of 589

Section 02110


3.1.5 Bor row Material A. Borrow material shall mean fill material used in load bearing areas, where it constitutes the new sub-grade and/or replaces existing sub-grade and shall carry and support pavement, shoulders or other structures etc. and material for replacing unsuitable soil in trench excavation. B. Borrow material shall consist of suitable and satisfactory material obtained from borrow pits proposed by the Contractor. C. The Contractor shall be responsible to determine the quality and quantities of the material in the borrow site(s) required to meet the needs of the Contract. D. Borrow pit sites shall be approved by the Department and shall not be taken from roadway excavations. E. The Contractor shall take samples of borrow material and submit same to the Engineer for testing. F. Only borrow material, approved by the Engineer, shall be used. Any material, which has not been approved, shall be removed from the Site and disposed off by the Contractor at his own expense. G. The Department may at any time revoke approval of a borrow site and the Contractor shall immediately cease removing borrow material from said borrow site. The Contractor shall then locate a new borrow site as specified. H. The Contractor shall not be entitled to any claim for extension of time or additional payment for any costs or expenditures by reason of the necessity of changing borrow sites due to the shortage of material or due to the Department’s decision to revoke approval of the borrow site. I. The Contractor shall leave borrow pits in a condition acceptable to the Department, to the Engineer and concerned parties. J. Where fill shall be measured to determine quantities of borrow material, the Contractor shall prepare cross-sections and longitudinal sections and submit to the Engineer for approval.

3.3 Execution A. Backfill pits, open excavation and trenches in roads and paved/tiled areas, including areas designated as future “roads and paved/tiled areas” as directed by the Engineer, in accordance with the Abu Dhabi Municipality Specification for backfilling of trenches and excavations in asphalted roads, tiled/paved parking and sidewalks. A. Backfill open excavation and trenches to contours and elevations with fill materials approved by the Engineer. B. The Contractor shall commence backfilling of excavations as soon as practicable after the permanent works have been tested, inspected and accepted by the Engineer. C. The Contractor shall systematically backfill to allow maximum time for natural settlement. Do not backfill over porous, wet or spongy sub-grade surfaces. D. Backfilling shall not be carried out without the consent of the Engineer. E. Unless otherwise specified or directed, the compaction shall be to a density of not less than 90% of the Maximum Dry Density as obtained by Standard Proctor compaction test or as approved by the Engineer. F. When tested in place, borrow material shall have a minimum density (in % of Maximum Dry Density) of 90 % with a minimum CBR of 50 % to a minimum depth of 45 cm below the formation level or to the top of the approved compacted existing sub-grade which shall have a minimum CBR of 40 %. G. After compaction the surface shall be leveled longitudinally and transversely and rolled to achieve a uniformly compacted and even surface free from undulations, soft spots and depressions all within the accepted tolerances. H. Suitable material for backfilling shall be deposited and compacted in layers not exceeding 150mm thickness (measured before compaction) if compacted by hand. If compaction is carried out by mechanical means, the thickness of layers depends on the type of equipment employed and shall be approved by the Engineer. I. Supports shall be carefully removed as the filling proceeds but the removal of such supports shall not relieve the Contractor of his responsibility for the safety and stability of the Works. J. Trenches shall be backfilled as follows: a. Employ a placement method that does not disturb or damage foundation perimeter drainage and utilities in trench. b. In the case of trenches other than in roads and paved/tiled areas, backfill the trench with selected excavated material in layers not exceeding 150mm to obtain minimum 95% compaction of the relevant maximum dry density of the material.


Page 122 of 589

Section 02110


c.

K. L. M. N. O. P. Q.

R. S.

Carefully backfill and compact by hand the trench with selected excavated material free from large stones etc. to the following minimum levels above the crown of the pipe:  300 mm in the case of concrete, vitrified clay and asbestos cement pipes laid on granular bedding  500 mm in the case of concrete, vitrified clay and asbestos cement pipes laid on other beds and in heading  600 mm in the case of GRP or other plastic pipes d. Backfill and compact in layers the remaining trench to existing ground contours and levels unless otherwise directed by the Engineer. Unless otherwise specified or directed, the compaction shall be to a density of not less than 90% of the Maximum Dry Density. e. Depending on width of trench and depth of pipeline a surcharge of suitable material shall placed over the entire trench width to compensate for any future settlement of soil inside the trench. This shall be executed before the issue of the Provisional Acceptance Certificate. The Contractor shall fill all abandoned pipelines to be left in with concrete Class B5 if directed by the Engineer. Optimum moisture content of backfill materials shall be maintained to attain required compaction density. The Contractor shall backfill simultaneously on each side of unsupported foundation walls until supports are in place. Reshape and re-compact fills subjected to vehicular traffic during construction. Any deficiency of backfill shall be made good as ordered by the Engineer at the Contractor's expense. All existing services, utilities etc. that have been disturbed during the Works shall be reinstated according to requirements of concerned Authorities, all to the satisfaction of the Engineer. Tolerances for backfilling under paved areas shall be +/- 20 mm from required elevations for subgrade, +/-10 mm for granular sub-base, all in accordance with the ‘Abu Dhabi Municipality Specification for Backfilling of Trenches & Excavations in Asphaltic Roads, Tiled/Paved Parking and Roads.” Before issuing the Final Acceptance Certificate the Contractor shall reinstate the level of the areas affected by his works to its original condition or as otherwise directed by the Engineer. For top surface of general backfilling it is +/- 5 mm from required elevations.

3.4 Field Qualit y Contro l A. All sampling and testing of material and work shall be carried out by the Contractor under the direction of the Engineer in accordance with the specifications and standards specified. B. The Contractor shall provide all material, labor, plant and testing equipment required to carry out the tests. Costs for all testing are deemed to be included in the rates and Contract price. C. Random tests of field density of backfill shall be taken at formation level and at each layer of backfill and at locations and frequency as directed and required by the Engineer. D. If tests indicate Work does not meet specified requirements, the Contractor shall remove Work, replace, compact, and retest, all at the Contractors expense. E. Where instructed by the Engineer, the Contractor shall arrange for an approved independent testing laboratory to carry out tests to determine in-situ the density of the backfill material. F. Compaction of soil materials shall be performed in compliance with the following standards: Descriptio n


AASHTO Standard

Sampling

T- 86

Density in place (sand cone method)

T-191

Density in place (drive cylinder method)

T-204

Density in place (rubber balloon method)

T-205

Page 123 of 589

Section 02110


G. Testing and analysis of soil materials shall be performed in compliance with the following standards: Descriptio n Sampling Sample Preparation Sieve Analysis Liquid Limit

Plastic Limit & Plasticity Index Moisture Content Standard Proctor Compaction Modified Proctor Compaction Sand Equivalent Specific Gravity CBR Classification

AASHTO Standard T- 2, T- 86 T-87 T-27,T-11,T-88 T-89

T-90 T-93, T-217 T-99 T-180 T-176 T-100 T-193 M-145

END OF SECTION


Page 124 of 589

Section 02220

Sheet Piling

Section 02220, Sheet Pili ng 1

Material 1.1 Steel

A. Steel sheet piling shall be procured from a reputed manufacturer and shall be of the sections, numbers, and lengths specified on drawings complete with all necessary corners, junctions, supporting system both in plan and cross-section. B. Steel quality shall conform to the following table: Steel (Class)

Yield strength 2 (N/mm )

Tension strength 2 (N/mm )

Strain failure (%)

Design stress 2 (N/mm )

St Sp 37 St Sp 45

235 265

360 - 440 440 - 530

25 22

<= 140 <= 160

1.2 Protectiv e Coating A. Protective coating shall be applied as specified elsewhere herein and shall consist of: B. Three coats high build solvent free Polyamine Cured Type, each >= 200 micron DFT, total >= 600 micron or a. One layer of polyurethane coating with a total DFT of >= 600 microns or b. One layer of VE-Glass flake coating with a total DFT of >= 1000 micron or c. Ceramic type coating e.g., highly modified epoxy resin loaded with sub-micron ceramic particles with a total DFT of >= 500 micron C. The consistency of the coating material shall be such that stirring produces a smooth, uniform mixture with good airless spraying characteristics, which can be applied to vertical surfaces as a reasonably level film without running or sagging. D. Any damage to the coating due to slinging or faulty handling must be repaired to the discretion of Engineer prior to driving.

1.3 Others A. To improve the water-tightness of joints between sheet piles, elastic sealing strips may be used.

2

Design

A. During the mobilisation period, the Contractor shall employ a specialized firm for soil investigation. Costs shall be included in his rates. B. The structural calculation shall consider soil conditions, including groundwater, life load, dead load etc. C. Profiles for sheet piles shall be selected to ensure that piles can be driven and the piling system is able to carry the load encountered. D. In case of hard sub strata where driving is possible only with a very high piling energy, the Contractor shall employ suitable methods to loosen the strata. E. If required sheet piles shall be temporally supported by waling, anchors etc.

3

Submittals

A. The Contractor shall submit to the Engineer, for the Engineers approval: a. Detailed drawings, layouts, cross sections showing the projected shoring system, the proximity of any roads, or crane tracks, buildings, embankments, viaducts and waterways, utility services b. Detailed drawings of sheet piling system including waling, supports, etc. c. Details of sheet piles proposed including test certificates d. Structural analysis approved by the Municipality’s Structural Engineer e. Information regarding any underground workings, surface traffic loading(s), capital plant or heavy machinery which could be affected by piling operations or might, in turn, affect ground stability by vibration f. Soil investigation report, soil analyses and geo-technical reports by approved laboratory


Page 125 of 589

Section 02220

g. h. i. j.

4

Sheet Piling

Details of seasonal rainfalls, standing water levels, tidal waters and the depths of offshore reaches. Open, buried stream / river velocities, currents, etc., shall be given where appropriate Details of dewatering system if required Description of working methods, details of equipment used Detailed time schedule including periods of dismantling.

Execution

A. The piles shall be driven true to lines and levels shown on the proposed drawings. Piles deviating excessively from the theoretical line shall be extracted and replaced if necessary and re-driven by the Contractor at his expense. B. Holes in the piling for tie rods, anchor bolts etc., shall be made at site after the piling has been driven to the final levels. C. Heads of sheet piles, embedded for permanent work, shall be trimmed to the levels shown on the proposed drawings and to neat appearance. D. Due consideration shall be given to the surrounding areas that may be affected by steel sheet driving. E. Any settlement, sink holes or disturbance of utilities or services in the vicinity of the Site shall be the sole responsibility of the Contractor and shall be repaired and made good to the satisfaction of the Engineer and concerned parties. F. Nuisance to the public, caused by excessive noise, shall be kept to the minimum.

END OF SECTION


Page 126 of 589

Section 02607

Manholes

Section 02607, Manholes and Chambers 1

Submittals 1.1 Manufacturers and Suppli ers

A. Submittals for manufacturers / suppliers shall include manufacturers of all material, fittings, specials as well as concrete batching plants, coating applicators and the like whose services will be employed for the execution of the works a. Name, Address b. Experience, References c. Supplier(s) details d. CV’s of specialists, experts employed.

1.2 Shop Drawings A. The following details shall be provided: a. Formwork drawings b. Details for PVC / HDPE liner c. Joint sealant, details of water-stops d. Tanking system including protective membrane e. Bar bending schedules for reinforced items f. Details of handling for pre-cast units g. Details for spacers for reinforcements h. Any other items required by the Engineer.

1.3 Product Data A. The following details shall be provided: a. Manhole covers and frames, internal liner / coating for manholes, external protective system b. Joint sealant, rubber rings and water-stops c. Any other items required by the Engineer.

1.4 Samples A. The Contractor shall submit samples of material for testing as required by the Specifications and the Engineer

2

Material

A. Manholes shall be constructed in waterproof plain or reinforced concrete B35 as shown on drawings and or as instructed by the Engineer. B. Joints between pre-cast concrete elements shall be executed as shown on drawings considering the following: a. Primer shall be applied prior to placing sealant and shall be from the manufacturer of sealant b. Two strips of 10mm thickness, 30mm wide sealant shall be placed on primed surface and place pre-cast concrete unit immediately c. Place backing rod if specified by manufacturer or instructed by the Engineer d. Sealant shall be an elastomeric polyurethane complying with the following criteria Properties Type Service temperature Non-volatile content Movement capability Shore A hardness Adhesion in peel


Limits Gun grade elastomeric urethane cured with chemical reaction, excellent cohesion, resilient exposed chemical and UV-resistant o Up to 80 C 100% 25% 30 +/- 5 >= 18 pounds / linear

Page 127 of 589

Section 02607

Manholes

C. As far as practicable all components of manholes i.e. base unit, shafts, adjustment rings, intermediate slabs and cover slabs shall pre-cast. D. All internal surfaces of manholes / chambers shall receive epoxy coating as specified. E. Surfaces, coming in contact with soil, shall receive a torch-applied membrane as specified in these specifications. Membrane shall be protected by plywood / protection board as specified.

3 A. B. C. D. E. F.

G.

H. I. J.

K. L. M.

Covers, Gratings And Frames MH-Covers, Gratings and frames shall be Ductile Cast Iron complying with EN 124. All covers and gratings shall be in single piece irrespective of its use and class. Covers shall be the standard product of a reputed manufacturer. The clear opening specified is to be considered as a guideline. Covers shall be designed to prevent rocking under traffic. Solid ductile cast iron manhole cover and frame assemblies shall comply with the following minimum requirements: a. Surfaces of covers, frames and gratings shall be smooth, true to pattern and free from sand holes, potholes, projections and other distortions. All edges shall be rounded to radius of minimum 2mm b. Coating material shall be resistant to abrasion and suitable for the local environment. Coating shall be as specified in these specifications and shall be carried out by approved coating applicator in Abu Dhabi c. Grit blasting and application of coating works shall be in accordance with recommendation of the manufacturer, international standards and these specifications d. Maintenance of coating works shall be carried out in accordance with the manufacturer’s instructions for minor scratches and abrasions as directed by the Engineer e. Recoating works shall be carried out in the event of damage with the same material of black solvent free epoxy as directed by the Engineer f. Unless otherwise shown on the drawings or specified the class of covers and frames shall be Class D400 in locations subject to vehicular traffic and Class B125 in other locations g. Seats of cover and frame shall be machined h. If EPDM rubber seal ring to be provided to the seats of MH-Frame and/or Cover, the contact distance to machined surface (min. thickness of metal in this area) shall not be less than 10mm i. EPDM rubber ring shall be integrated type, inscribed permanently as recommended by manufacturer and approved by the Engineer. Cover and Frame badging shall include: Ductile iron, standard, clear opening, class, foundry logo and name, foundry batching number to covers and frames in addition to the following cover face badging in Arabic and English: a. STORM DRAINAGE - For all storm water drainage and sub-soil drainage b. IRRIGATION - For all irrigation c. ABU DHABI MUNICIPALITY - For foul, storm drainage, sub-soil drainage and irrigation. Badging of covers and frames for chambers of electricity, telephone or other services shall be subject to the approval of concerned Authorities. Coated covers and frames shall not be handled and transported until full curing has been achieved. An original of the approved coating specialist's quality control report for each itemised component shall be provided with each delivery. The report shall bear an original company stamp and signature. Covers and gratings shall be equipped with cast-in lifting eyes, prising slots, and one way fit adjuster holes. The MH-Covers and Frames shall meet the requirements of load test. Load testing shall be conducted as part of the approval procedures as well as during manufacturing process. Testing shall be in accordance with the appropriate Standards and to the satisfaction of the Engineer. a. Provide shop testing and inspection of manhole covers and frames as specified in these specifications b. Test sample covers and frames by an approved laboratory c. Testing frequency per batch delivery shall be as follows or 2% of total number of covers in each size and class which is greater: 1. 1 - 50 units One unit for each size and class. 2. Up to 250 units Two units for each size and class.


Page 128 of 589

Section 02607

3. Up to 500 units 4. Over 500 units

Manholes

Three units for each size and class. Four units for each size and class.

3.1.1 Grab Bars A. Grab bars shall be made of high tensile reinforced deformed steel bars laminated with Vinyl Ester Resin and corrosion resistance CSM-Glass to 5mm and C-Veil. 0.5mm flow coat of Vinyl Ester resin shall be applied as outer layer. B. The ends of GRP-Laminated grab bar embedded in concrete shall be silica sanded with 2-3mm thickness for good bonding to concrete. C. Dimension as shown in the Drawings.

3.1.2 Lifting Keys & Devic es A. For covers, having a weight of = 75kg, the Contractor shall supply prying and lifting keys (2 No’s for every 50 covers supplied) suitable for opening and locking covers. The keys shall be cast from malleable iron GTW-40 DIN 1692 and shall be hot dip galvanized. B. For covers exceeding 75kg in weight per unit, 4 No’s special lifting devices shall be provided by the Contractor, or one for every 50 covers supplied, whichever is greater. The device shall be designed to enable lifting the cover out of its frame by hydraulic action and to uncover the entrance to manholes in one working process. It shall be light, and operated by one laborer. It shall be manufactured from non- corrosive material. Wheels shall be rubber-padded.

4

Execution 4.1.1 General

A. Manholes and chambers shall be constructed in accordance with the drawings in the positions indicated thereon or wherever else instructed by the Engineer. Manholes and chambers along with all construction joints shall be watertight B. Pipes entering and leaving manholes and chambers shall be laid soffit to soffit unless otherwise shown on the Drawings or instructed by the Engineer. C. Making holes are not allowed through the shafts and liners. D. Items provided by other sections of Work shall be verified for proper size and location. E. Built-in items shall be verified for proper location, and for being ready for roughing into Work.

4.1.2 Manhol es and Chamber Constru ction A. B. C. D. E. F. G. H. I. J. K. L. M. N. O.

The Contractor shall ensure that the excavation is stable and safe and carried out as specified. Check that the bearing capacity / soil compaction of formation under manhole is as specified. The formation shall be free from water, leveled and compacted to a 98% of max. dry density. Blinding layer SRC concrete class B-15 shall be placed as shown on drawings. Pre-cast concrete units shall be cast and cured as specified. Manhole base shall be placed on accurate level and correct direction. Concrete shafts shall be placed as specified and shown on the drawings. Intermediate slabs and rings shall be placed if required as shown on the drawings. Manhole and chamber covers shall be set in paved areas accurately to the level and slopes of the surrounding surface. In case of cast in-situ concrete the contractor shall ensure the accuracy and stability of shuttering works and location of water-stops. Joint sealant shall be placed between each two concrete elements as specified and shown on the drawings. All concrete surfaces of chambers and manholes shall be protected externally by approved tanking system as specified. All internal surfaces shall receive protection as specified. Manholes and chambers shall be tested for water tightness as specified. Immediately prior to the inspection of the Works, all covers and frames shall be cleaned thoroughly to the satisfaction of the Engineer.

END OF SECTION


Page 129 of 589

Section 02732

Pipelines

Section 02732, Pipelines 1

General

A.

These specifications apply for pipelines applicable under this Contract manufactured from PVC-u, GRP and concrete.

2

Submittals

A. During the mobilization period the Contractor shall submit for the Engineer's approval the pipe data for every diameter and each class separately as listed in the following tables. B. Only resins approved by the Department shall be used. C. Submittals shall include the manufacturer s design calculations, complete and detailed specification and test results, detailed specification for the handling and installation of the proposed product(s) required for the Works. As well as all items required by the Specifications. Submit full details irrespective of whether all or part of the data was submitted with the bid. D. Should any details of the products be altered in any way during manufacture from those proposed and approved by the Engineer, the Contractor shall submit for the Engineer's approval the revised details and test results before incorporating such products into the permanent works. E. The results of all quality control tests, carried out on the products, shall be submitted to the Engineer as soon as practicable after testing but in no case later than the time of delivery of the relevant products to the Site. '

GRP Pipes A 1 2 3 4 5 B 1 2 3 4 5 C 1 2 3 4 5 6 7 8 9 10 11 12 D 1 2 3 4 5 6

Manuf actu ri ng Detail s Name of Manufacturer Manufacturing process for pipes Joint type Markings Manufacturing process for bends Summary of Design Criteria Nominal internal Diameter Class of Pipe Maximum Working Pressure Designed Test Pressure Internal Vacuum Pressure Pipe Wall Structur e Nominal Total Wall Thickness Inner Liner:Resin (by weight) Glass (by weight) Thickness Structural Wall:- Resin (by weight) Chopped Glass (by weight) Hoop Glass (by weight) Aggregate (by weight) Thickness External Layer:- Resin(by weight) Glass (by weight) Thickness Initial Pipe Properties Nominal Stiffness Longitudinal Tensile Strength Hoop Flexural Modulus Hoop Tensile Strength* Barcol hardness Standard pipe length


Unit

mm bar bar bar

: Type : Type : Type : Type : Type : Type : Type : Type

mm % % mm % % % % mm % % mm 2

kN/m 2 kN/m 2 GN/m 2 kN/m m

Page 130 of 589

Section 02732

PVC-u Pipes A 1 2 3 4 5 6 B 1 2 3 C 1 2 3 4

Manuf actu ring Detail s Name of Manufacturer Manufacturing process for pipes Manufacturing process for bends and fittings Joint type Details of all additives used in the manufacture Marking Details Summary of Design Criteria Maximum Working Pressure* Design Test Pressure Internal Vacuum Pressure* Pipe Details Class of Pipe Nominal External Diameter Wall Thickness Standard Pipe Length

Pipelines

Unit

2

kN/m 2 kN/m 2 kN/m mm mm m

Note: 1. (*) Shall be provided for each class and diameter F. In addition to all data required in the tender data sheet, Contractor shall submit the following: a. Full details of the pipe, fittings, joints and the assembly thereof b. Joint materials, gaskets, lubricants and details. Lubricant shall be non-toxic c. All data on curve and bends for both horizontal and vertical alignment d. Reinforcement steel drawings of pipe cage assemblies e. Procedures for building pipes into concrete structure f. All testing procedures and details, with diagrams of deflection measurement apparatus g. Manufacturer's instructions related to handling transportation and testing; indicate special procedures required to install Products specified h. Manufacturer’s Certifications of compliance with standard specifications for all pipe products G. Detailed description of working methods, equipment and instruments used for pipe laying, pressure testing, joint testing, deflection measurements. Description of working methods shall be supplemented with drawings, copies from catalogues of equipment etc.

2.1.1 Quality Assurance A. The quality control and assurance systems implemented by the manufacturer must meet the requirements and specifications specified herein. B. All products and other material to be supplied shall be new and of first-class ingredients and construction, designed and guaranteed to perform the service required. C. Products for one section of work must be furnished by a single manufacturer.

2.1.2 Marking of Produc ts A. Each type of pipe, special and fitting shall be clearly stenciled, printed or machine labeled in accordance with the information required by the relevant governing standard.

2.1.3 Delivery , Handling and Storage A. Handle and store products in accordance with the manufacturer's recommendations subject to the approval of the Engineer. B. Products shall not come in contact with any sharp projections causing damage to the products during transportation loading and unloading. Ensure that products are well secured during transit and adequately supported along their length. Do not allow pipe to overhang at the end of a vehicle during transportation. C. Ensure that products of plastic materials are lifted using fabric or large diameter rope slings positioned at a quarter of the pipe length from each end. Do not allow the use of wire rope chains or unpadded forks or clamp on forklifts to lift pipes. Steel chains or hooks should not come into contact with plastic pipes.


Page 131 of 589

Section 02732

Pipelines

D. Store products on a flat level area and raised above the ground on timber bearers so that the lowest point of any pipe or fitting is not less than 150mm above the ground. Provide timber bearers at spacing recommended by the pipe manufacturer. Ensure that products supplied either on pallets or crated, remain on the pallets or in their crates until required. E. Stack non-crated pipes to the approval of the Engineer. a. Stack spigot and socket pipes so that successive pipe layers have sockets protruding at opposite ends of the stack. b. Stack pipes of different sizes and thickness separately. c. Do not allow stacked pipes to exceed 2 meters in height or as recommended by the manufacturer whichever is the lesser. F. Store products of plastic materials under UV reflecting cover and out of direct sunlight at all times. Adequately support the pipes along their length. Maintain a free flow of air around the pipes at all time. G. Visually inspect each pipe and fitting before dispatch from factory, after off-loading at site and finally prior to installation. H. Products damaged during transportation, handling, storage and installation will be rejected and shall be removed from site forthwith. I. Joint gaskets, O-rings, membranes, coatings, lubricants and other material, likely to be affected by climatic conditions shall be kept in wooden boxes, stored in cool, air-conditioned rooms and shall not be exposed to direct sunlight. Seal rings shall not come into contact with oil, grease or other detrimental matters. J. Goods of different quality and dimensions shall be stored separately. K. Adequately protect all products against damage during transportation, handling and delivery. Provide packaging and protection to ensure that all products reach the site undamaged. L. Ensure that all packages are suitable for storage. M. Protect the flanges of products with soft wood discs affixed with service bolts that shall not be used during permanent fixing. N. Ensure that the pipe spigot and socket ends are wrapped with shock absorbing material and suitably supported to prevent damage.

3

Material 3.1.1 Un-Plastic ised Polyvi nyl Chlor ide Pipes PVC-u

A. B. C. D. E. F.

Recycled material shall not be used for the manufacture of PVC-u products Manufacturers shall provide corporate guarantee for performance of 60 years UV-inhibitor shall be used in all PVC-u Products exposed to sunlight / UV-Rays Seal rings for joints shall be EPDM rubber rings. Plain ends of pipes at joints with rubber seals shall be chamfered Solvent welded joints may be used for cable conduits and water supply systems up to OD 80mm Diameter OD (mm)

6 m cover between Final Ground- level and Invert

> 6 m cov er between Final Ground- level and Invert

Class 10

Class 16

160 225 280 315 400 500 G. PVC-u pipes for house connections shall comply with DIN 8061/8062, class PN 6 or BS EN1401-1, SDR 34.


Page 132 of 589

Section 02732

Pipelines

3.1.2 Polyethy lene Pipes (PE 100) for use in Pressure Mains Storm Irrigation Specification 1. Pipes shall be manufactured from polyethylene containing only those antioxidants, UV stabilizers and pigments necessary for the manufacture of pipes conforming to specification ISO4427 and for its end use, including weld ability when it is possible Irrigation Network Pipe Material

Pump Stations & valve chambers

Pump Stations& valve chambers

Trunk mains

Distribution

>= 225mm

>= 32mm to 225mm OD

PE 100

(Sub main and lateral)

LLDPE

2.

Storm-water network

-

-

<32 OD

Trunk mains

Distribution

All diameter -

All diameter

(Pumping Main)

-

(Pumping Main)

-

-

The properties of the polymer, extruded pipe and fittings shall be as shown in Tables. SPECIFIED RESIN PROPERTIES PE- HD 100 Typ e A O Design max. hydro static stress 8 MPa: MRS [50 years, 20 C] 10 MPa Property Required Test Methods Values European ASTM A 01 02a 02b 02c 03 04 05 B 01 02 03 03a 03b 04 05 06 C 01 02 03

PHYSICAL Density > 950 kg/m3 Melt mass-flow index > 0.03 g/10 min or rate [2.16] Melt mass-flow index > 0.30 g/10 min or rate [5.00] Melt mass-flow index > 8 g/10 min or rate [21.6] Environmental CSR > 250 h [10% stabilizer] Resistance to internal > 165 h pressure Oxidative induction > 20 min O time [OIT][200 C] MECHANICAL Flexural creep > 900 MPa modulus Shore D hardness > 50 (40°C) Tensile strength At yield [50mm/min] > 20 MPa At break [50mm/min] > 30 MPa Elongation at break > 600 % Modulus of elasticity > 1000 MPa 2 Charpy Impact [kJ/m ] No break THERMAL O Vicat softening point >125 C O Thermal expansion <0.20 mm/m/ C O [20-90 C] Thermal conductivity < 0.6 W/mK O [20 C]


BS EN ISO 1183 BS ISO 1133 condition 4

D 1505 D1238/1134

BS ISO 1133 condition 5

D1238/1135

BS ISO 1133 condition 6

D1238/1136

BS EN ISO 4599

D 1693

ISO 4427

-

BS EN 728

ISO 537 -

D 2240/888

ISO 527 ISO 528 ISO 528

D 638 D 638

BS EN 727 -

-

-

-

Page 133 of 589

Section 02732

Pipelines

SPECIFIED HDPE PIPE PROPERTIES Property

A 01 02 03 B 01a

PHYSICAL Density Melt mass-flow index or rate [5.00kg][190 OC] Oven test

04 05 05a 05b 06 07 08 09

MECHANICAL Resistance to internal pressure [20 OC] [water in water][hoop stress 12.4 MPa] [100 hrs]1 Resistance to internal pressure [80 OC] [water in water][hoop stress 5.5 MPa] [165 hrs]1 Resistance to internal pressure [80 OC] [water in water][hoop stress 5.0 MPa][1000 hrs]1 Creep ratio Longitudinal reversion [100OC] Shore D hardness Tensile strength At yield [50mm/min] At break [50mm/min] Elongation at break Ring flexibility Impact strength Ring stiffness

10

Ovality

01b

01c

02 03

C 01

THERMAL Thermal stability, OIT [200 OC]

Required Values and attributes

Test Methods European

ASTM

> 950 kg/m3 1.6 g/10 min

BS EN ISO 1183 BS ISO 1133 condition 1T

D 1505 D1238/1135

Defects shall not develop

BS ISO 12091

-

No failure defects

or

BS EN 921/ISO 4427

-

No failure defects

or

BS EN 921/ISO 4427

-

No failure defects

or

BS EN 921/ISO 4427

-

> 900 MPa <3%

BS EN ISO 9967 ISO 2505 -1

-

> 50

-

D 2240/888

> 20 MPa > 30 MPa > 350 % See standard TIR 10 % to SN or SD required Grade N

ISO 527 ISO 528 ISO 528 EN 1446 BS EN 744 BS EN ISO 9969

D 638 D 638 -

20 min.

BS EN 728

ISO 11922 -1

-

Legend: 1. Either on pipe or from sample pipe using same resin and process.


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Section 02732

Pipelines

SPECIFIED PROPERTIES FOR INJECTION [IM] AND ROTATIONALLY MOULDED [RM] FITTINGS Property

Requir ed Values and attributes

Test Methods European

American

>950 kg/m3 [for IM] >925kg/m3 [for RM] 0.3-0.55g/10min

BS EN ISO 1183

D 1505

BS ISO 1133 condition 1T

D1238/1135

As required See standard See std

ISO/DIS 13967 EN 12061 EN 12256

-

A 01

PHYSICAL Density

02

Melt mass-flow index or rate O [5.00 kg][190 C]

B 01 02 03

MECHANICAL Stiffness Impact Mechanical strength or flexibility

C 01

PERFORMANCE REQUIREMENTS Elevated temp-load cycling No leakage O

Thermal stability, OIT [200 C]

02 03

≥20min

Pr EN 1437 method A hot and cold water

-

BS EN 728

-

[injection

mouldings] ≥10min for rotation mouldings] See standard No failure

Elevated temperature cycling Pr EN 1989 Resistance to internal pressure O [80 C] [water in water][hoop EN 921/ISO 4427 1 stress 5.5 MPa] [165 hrs] 04 Resistance to internal pressure No failure O [80 C] [water in water][hoop EN 921/ISO 4427 1 stress 5.0 MPa] [1000 hrs] 05 Water tightness No leakage EN 1053 Legend: 1. For moulded materials, use either an injection moulded or extruded pipe from same materials.

3.

Only virgin polyethylene compounds shall be used in the manufacture of the pipe and fitting. The pipe shall contain no recycled compounds except those approved by the Engineer and generated in the manufacturers own plant from resin of the same specification from the same raw material. 94. Pipe Stiffness – Minimum pipe stiffness values at 5% deflection shall meet the requirements of Table 02720-07. The hydrostatic design basis [which is equivalent to the MRS] is required for pressure applications. Long term hydrostatic test [in addition to short term tests] shall be carried out to prove the integrity of the pipe. The pipe wall shall not separate into layers when manufactured, during storage or in any performance tests performed in accordance with Table 2. 5. For polyethylene pipe systems the fittings Manufacturer shall confirm suitability of his fittings for installation with pipe manufacturer’s pipes. Fittings shall be installed in accordance with the approved method statement. FABRICATION AND FABRICATION TOLERANCES Polyethylene Pipes (PE) and Fittings 1. PE pipes shall be manufactured using an extrusion process. The pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, voids and other injurious defects 2. Butt fusion fittings shall be in accordance with ASTM D3261 and shall be manufactured by injection moulding, a combination of extrusion and machining, or fabricated from PE pipe Contract 106 , Volume II

Page 135 of 589

Section 02732

Pipelines

conforming to this specification. Fabricated fittings shall be manufactured using a Data logger to record fusion pressure and temperature. Butt fusion fittings shall have a pressure rating no less than that of the pipe. The fittings shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, voids and other injurious defects. Fabricated fittings are subject to pressure de-rating factor as in DVS 2210 of German Welding Institute and must be specified. 3. Electro fusion fittings shall be manufactured in accordance with ASTM F1055 and shall have a pressure rating no less than that of the pipe. The fittings Manufacturer shall certify his electro fusion fittings for use with the resin used for the pipe production. 4. Flanged and mechanical joint adaptors shall be manufactured to WIS 4-24-01 and have a pressure rating no less than that of the pipe. Flange drilling to PN16. 5. Raw materials for the manufacture of pipes and fittings shall be accepted based on the verification of the following parameters by the manufacturer in accordance with the requirements of ISO 4427: a. Density. b. Melt mass-flow rate. c. Thermal stability. 6. Pipes and fittings shall be fabricated to be capable of withstanding the working pressures, test pressures and loadings specified. 7. Pipes and fittings must be designed to achieve a minimum working life of 60 years under all applicable loadings, environmental and installation conditions. 8. Nominal outside diameters of pipes and fittings shall conform to ISO 161-1 and the tolerances on these diameters shall be in accordance with ISO 11922-1. QUALITY CONTROL TESTS Polyethylene Pipes (PE) and Fittings 1. Routine Factory Quality Control Tests: The quality control tests listed below shall be carried out at the required frequencies and records of all tests and inspections shall be maintained by the manufacturer. The Engineer shall be provided with two copies of all test certificates and reports. a. Quality testing of all raw materials to ensure that they comply with the relevant specification. b. Control of processing parameters in terms of temperature, pressure, flow rates, haul-off speed and energy input. c. Visual inspection of the pipes to check general appearance, dimensional compliance and any indication of inclusions or processing flows in pipe barrels and joining ends. d. Production short-term tests to identify any variations in the plant functioning. e. The following tests shall be performed in accordance with the relevant standards in order to ensure the quality of the extruded pipes: Melt mass-flow index of raw material • Density of raw material • Carbon black content • Carbon black dispersion • Long-term stress crack resistance at 80°C • Long-term MRS at 20°C • Appearance • Long term hydrostatic test at 20°C • Welding • Weathering • Oxidation induction time value • Visual inspection of pipes • Dimensional check of pipes • Heat reversion of pipes • Hydrostatic creep strength tests of pipes • Bend test • Burst test •

2. Conditioning When conditioning is required for laboratory tests, condition the specimens in accordance with the appropriate standard.


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3. Tensile Testing [for pipe resin, pipes and welds] shall be performed on an approved tens meter capable of delivering safely and accurately 120 % of the stress required by the sample. The tens meter shall be connected to a computerized system capable of delivering information in data and graphical form. The information required from tensile measurements is strength at yield and peak tensile strength and elongation at yield and peak. Test specimens shall be milled to exact size using approved designated milling machines. The Contractor shall submit statistical analysis based on minimum sample populations of 32. Cumulative analysis based on overall and on individual pipe resin batch based data shall also be provided. Welded samples shall be visually examined after tensile testing for signs of adequate bonding and ductile and brittle failure. Weld samples with greater than 25 % brittle failure shall be rejected.

4. 5.

6.

7.

8.

Tensile graphs showing the familiar parrot’s beak shape [ associated with a great proportion of brittle failure] after the peak tensile strength shall be considered as outright failures. Sampling The selection of samples of pipe, resin and welds for testing shall be as directed by The Engineer. Pipe Flattening or parallel plate test Flatten the three sampled pipes between parallel plates until the vertical inside diameter is reduced by 20% using the rate of loading stipulated in the test method. Examine the specimens with the unaided eye for cracking, splitting, delamination or polymer damage [seen as whitened areas]. Wall buckling is indicated by reverse curvature in the pipe wall accompanied by a decrease in the loadcarrying ability of the pipe. The specimen shall pass if no splitting, cracking, breaking, delamination or polymer damage is observed under normal light with the unaided eye. The wall shall not buckle under test conditions. Retest and Rejection If the results of any test fail to meet the requirements of this specification, the test shall be repeated again once. If, upon retest, failure occurs, the batch quantity of product represented by the test shall be rejected. Inspection The Contractor shall ensure that all deliveries to the site are inspected and checked for conformance with this specification. Deliveries not verified by The Engineer shall be placed in an isolated area suitably signposted. Material deliveries that have not been verified by The Engineer shall not be released for site works, at any time and under any condition. The Contractor shall not store material on site that is not relevant or appropriate for the works. Certification The Contractor shall conduct quality checks at the manufacturer's premises to ensure that inprocess manufacturing quality checks are being conducted correctly and at the stated frequency. Test certificates relating to the batch shall be furnished to The Engineer before acceptance of the delivery. The test Certificates shall contain all the details in the agreed format of reporting. Test Certificates shall not mean Conformity statements.

9. Marking a) Quality of Marking – The marking shall be applied to the pipe in such a manner that it is legible after installation and durable throughout the construction period. b) Each standard and random length of pipe and every fitting shall be marked as required in ISO 4427 and pr EN 12201

1 2 3 4 5 6 7 8

Pipes Number of the standard Manufacturers name & trademark Nominal size [ODx Wall thickness] OD tolerance [A or B] Nominal pressure [PN] Material type [PE-HD 100] Pipe series [SDR] Manufacturers traceability [batch no etc]

Fittings Number of the standard Manufacturers name & trademark Nominal size [OD] Nominal angle Nominal pressure Material [PE-HD 100] Manufacturers traceability[batch no etc]

PIPE JOINTS Contract 106 , Volume II

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Section 02732

Pipelines

Butt Fusion Joi nting of PE Pipes and Fittings: Storm Irrigation Specification 1. The fusion faces are shaved to expose virgin material and aligned under pressure into a heating plate. The parts are heated up to the approved welding temperature under an initial pressure (preheating) which is reduced during a subsequent heat infusion period and joined under pressure after the heating element has been removed. The joint is allowed to cool naturally without disturbance before removal from the welding jig. The weld is sampled and tested at the specified intervals and instances. O

2. Heating temperature is between the ranges 210 C +/- 5%. Use of lower temperatures entails longer heating times. Joint surfaces to be welded shall have a smooth clean cut and aligned at perfect right angle. Forced cooling during the cooling period is not permitted. 3. Only butt fusion machines with a valid manufacturer’s or manufacturer’s approved service centre calibration certificate can be used. H. Other Joining Methods for PE Pipes and Fittings 1. Electro fusion joining: The electro fusion joint is heated internally by a wire coil at the interface of the joint. Heat is created by an electric current passed to the conductive material in the fitting. 1. Mechanical Joint: Many types of mechanical connection styles and methods exist. The Contractor shall submit suitable mechanical joints. All such joints shall be recommended and acceptance tested by the Manufacturer of the fittings. He shall confirm that his fittings are suitable for use with pipe manufacturer’s pipes. Where marked on the drawings end-load resistant fittings of an approved type shall be used. Do not use mechanical fittings with exposed metal (bolts etc.) below ground unless specifically approved by Engineer/Directorate.

3.1.3 Linear Density Poly ethylene (LDPE) Pipe and Fittin gs. Polyethylene pipe shall be manufactured from linear low-density polyethylene incorporating a minimum of 2.8% carbon black, properly dispersed and antioxidants in an amount not exceeding 0.5%. Working pressure shall be minimum 4kg/cm² or more. A random sample of drip pipes shall be subjected to the Teepol crack resistance test. The sample shall be immersed in a bath containing a solution of 10% Teepol and 90% water maintained at 50 degree C. The pipe should resist the solution without showing any fatigue or crack f or a period of 150 hours. Polyethylene pipes shall be legibly and durably marked with letters of minimum height 3mm. The marking shall be reproduced at intervals of not more than 1m. The following information shall be marked on the pipe. a) b) c) d) e)

The manufacturer’s name or registered trademark. The type number and designation ‘PE’ in the form “TYPE 30PE” as appropriate. The class of pipe in the form ‘CLASS IRRIG’. The nominal inside diameter and wall thickness. Identification of place of manufacture. The manufacture’s code is acceptable.

Polyethylene pipes shall be fixed intact to the ground using heat resistant stakes at every 10 metres and an automatic end flush valve shall be installed at the end of the line. When poly pipe is laid continuously in a loop there should be two stakes at the corners in order to keep the pipe fixed intact to the ground. The maximum length of the pipe to one side shall be based on manufacturers’ recommendation


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Section 02732

Pipelines

All fittings for drip lines shall be insert type manufactured from black Polypropylene and all fittings should be secured by plastic ratchet clips. The pipe for sprayers and quick coupling valve connections shall be as per BS 1972-67 class C. The fittings for the above pipes should be compression quick joint type with minimum 12 bar nominal pressure rating.

3.1.4 Glass Reinf orced Plast ic Pipes (GRP) 2

Stiffness (N/m ) Pipe Diameter (mm)

6 m cover between Final Ground level and Invert

> 6 m cover between Final gro und level and Invert

150 200 250

-

300 350 450

10,000

600 700

5,000

800 900 1000 Pumping Main

10,000

A. Products shall be capable of withstanding a strain of 1% over 60 years without failure or cracking when tested in accordance with the strain corrosion type test requirements specified herein. B. Manufacturers shall provide corporate guarantee for performance of 60 years C. Only material, approved by the Department, shall be used. D. The Contractor shall submit, for Engineer’s approval, the manufacturer’s name, technical literature and latest tests pertinent to the proposed resin. E. Resins shall be compatible to the used glass and the silica sand filler. F. The procedure, medium and acceptance criteria for testing the above resins shall be approved by the Engineer prior to commencing any test. G. Resin shall have a high diffusion resistance against aqueous chemicals that may diffuse through the liner. H. All resins shall be stored properly in cool conditions below 20°C. Date of manufacture, manufacturer, type of resin, shelf life, etc. shall be clearly written on each container. I. Storage, handling, application shall be strictly in accordance with manufacturer’s instructions. J. Resins from different manufacturers shall not be mixed. K. All glass types shall have a surface treatment compatible with the resin. Glass reinforcement shall comply with DIN 61855 and these specification. L. All surface of GRP pipes coming contact with concrete shall be protected by using, e.g. (500 gauge PE-sheet or 1.5mm thick self-adhesive membrane) wrapping material. M. Manufacturer’s mandatory current instructions are to be followed.

3.1.5 Agg regate Filler A. Aggregates shall be a well graded silica sand filler type ranging from 0.25mm to 1mm as per DIN 1689/1, free from impurities, aluminum hydroxide, aluminum silicate, calcium carbonate powder and other susceptible materials complying with the following table:


Page 139 of 589

Section 02732

No 1

Pipelines

Description Quartz Content (%)

Remarks ≥95

Hexagonal Crystal 2

Petrography forms (Quartz)

Crystalline Cryptocrystalline masses

3

Color

Colorless or light color

4

Transparency

Transparent

5

Cleavage

Absent

6

Mohs scale

7 (scratching glass easily but can not be scratched by knife)

7

Moisture Content (%)

< 0.5, DIN 18121, Part 2

8

Grading

0.25mm to 1.0mm (well graded)

B. Testing frequency for the properties of silica sand fillers is one set to every batch. C. The silica sand in the structure wall (S3) shall be saturated and embedded in the resin and shall be applied to the matrix to ensure a uniform thickness of the structural section of the wall. D. The use of silica sand fillers is not allowed in the inner liner (S1) and sealing layer (S2). E. The amount of silica sand filler in the structure of the pipes shall be dictated by the structural design, but shall not exceed 40%.

3.1.6 Concrete Pipes A. Reinforced Concrete Pipes and fittings with PVC / HDPE liner: To BS 5911: Part 100 class ’H’ or ASTM C76M, class IV or equivalent class to DIN 4032 / DIN 4035 shall comply as detailed below. a. RC-Pipes and Fitti ngs shall be designed to allow maximum allowable permissible crack width of 0.2mm over a 30cm continuous length. b. Cement MSRPC to be to ASTM C150 Type II. c. Aggregates to comply with specification. d. Reinforcement: to comply with specification. e. Admixtures as specified, subject to Engineer’s approval. Use admixtures in accordance with the manufacturer’s recommendations. f. Water : to comply with specification. g. Coating (outside) as specified. h. Membrane at Joints: The exterior surface of joints shall be sealed by a flexible, 1.50mm thick self-adhesive bituminous membrane (30 cm wide) to prevent entering of cement slurry. i. Liner : Entire interior of pipe shall be lined with PVC-Liner with T-Locks or HDPE Liner with Conical Studs / T-Locks.

3.1.7 Accessories 3.1.8 Joints A. Unless otherwise specified the joints shall be the socket spigot type and designed to withstand internal test pressure and prevent the infiltration of groundwater. B. Pipes shall be capable of withstanding "draw" of 13mm over and above the initial jointing allowance. C. The Contractor shall ensure that joints withstand the tests specified herein including vacuum tests and shall submit reports of all tests executed. D. Overlaps in PVC or HDPE type liners shall be welded over joints after the pipeline is back-filled, the groundwater table has been restored to its original level and the joint has proved to be watertight. E. Joints shall be capable to withstand and be water tight at a deflection of: a. Not less than 1 ½ degrees in any direction for pipes ≤DN 600 b. Not less than ½ degree in any direction for pipes > DN 600 F. Provide the spigot and socket flexible joints with annular space between the pipe and socket. Seal the annular space with an approved flexible membrane immediately upon completion of a satisfactory initial hydraulic test and prior to concreting or backfilling but not prior to testing. G. All connections to fittings and appurtenances as valves, TEE’s etc. shall be flanged. All joints shall be capable of withstanding the various tests specified for the appropriate class of pipe.


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Section 02732

Pipelines

H. Flanged pipe joints must incorporate an annular gasket at the joints and these gaskets must cover the full face of the flange with holes cut in them corresponding to the bolt-holes in the flanges.

3.1.9 Seal Gaskets / Rings A. Flexible type joints on spigot and socket pipes shall be sealed with EPDM rubber ring. B. Ensure that joint gasket and joint ring are suitable for use in the prevailing climate, soil and groundwater. C. Ensure that all rubber seal rings / gaskets are embossed with permanent badging inscribing relevant standard, diameter, manufacturer’s name, type and date of manufacture. Permissible Limits as per Hardness Range

Properties Class Dimensions Hardness (Shore A) Tensile Strength Elongation at Break

50

60

70

-

-

-

-

50 ± 5

60 ± 5

70 ± 5

ISO 48

9 Mpa (min.)

9 Mpa min

9 Mpa min.

ISO 37

375% min

300% min

200% min

o

12% max.

12% max.

15% max.

o

20% max.

20% max.

20% max.

Compression set @ 23 C, 7days Compression set @ 70 C, 1 day Spliced Joint 100% Stretch for 60 seconds o

Water absorption, 7days @ 70 C o

Stress relaxation, 7 days @ 23 C Ozone resistance After accelerated aging (ISO 188)

Hardness Change Tensile %age Elongation %age

Base polymer identification

Testing

Standard

(Shore A)

Frequencies N/A Each Delivery

ISO 815

4 times / year Each Delivery

No visual separation

-

+8 / -1 %

ISO 1817

4 times / year

ISO 3384

1 time / year

14% max.

15% max.

No cracking

No cracking

16% max. No cracking

ISO 1431-1

+8 / -5 - 20 % +10 / -30% Ethylene propylene type

ISO 48 ISO 37 -

3.1.10Lub ricant A. Lubricant agent for the pipe and other connections where the rubber seal rings are involved shall be odorless, soft paste like soap and meet the following requirements: No

Item

1

Made out

2

Free from other substances toxic

3

Health

4

Solubility in water

Remarks Vegetable oils type but free from fish, waste, seal animal marine oils and resins Free from arsenic, lead, copper Free from poisonous materials, non toxic, non caustic Complete soluble

Average change in mass or volume of rubber Max. +/- 2 % seal ring Visible Deterioration of rubber seal ring None Retained tensile strength of rubber seal ring 90% of original Retained hardness of rubber seal ring 90% of original Acidity / Alkalinity (pH) =7 to =9 Flash point Non-combustible

Long Term Test (As guideline 5 – ASTM D471) T°C = 50 +/- 2 Time = 670 hrs. 6 7

B. The soft soap shall not affect the rubber seal ring, pipe material and coating. C. The lubricant (i.e., Soft Soap) must be as per written recommendations of EPDM - Rubber Manufacturer, subject to the approval of the Engineer.

3.1.11Fittings A. GRP fittings shall conform to DIN 19 565, DIN 19 869 and BS 5480 molded or formed to suit pipe size and end design, in required tee, bends, elbows, clean-outs, reducers, traps and other configurations.


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Section 02732

Pipelines

3.1.12Marker Tapes A. Where instructed by the Engineer all trenches for pipe lines during backfilling, shall be marked with a high quality acid and alkali resistant yellow polyethylene tape of minimum 150mm width placed 300mm below finished surface. B. Tapes shall be marked in Arabic and English at 2m intervals as instructed by the Engineer. C. Tapes shall have a minimum strength of 125kg/cm in the longitudinal direction and 105kg/cm transversely with an elongation factor in the longitudinal direction of 350 percent. D. The words and background color shall remain legible and color fast in soil conditions pH >11

3.1.13Geo-textil e Filter Fabric for Granular Pipe Bed and Surround A. Geo-textile fabric of approved size and dimensions or as directed by the Engineer shall be provided. B. Geo-textile fabric shall be procured from an approved reputed manufacturer, tested and suitably certified, and placed on the prepared formation level as shown on drawings or as instructed by the Engineer. C. Material shall be supplied in rolls wound on a suitable disposable paper tube. Each roll shall be accompanied by a certificate from the manufacturer indicating the date and place of manufacture, a confirmation that the material has been manufactured and tested in accordance with the Specifications and a list of tests and results of such tests. At the discretion of the Engineer random tests shall be carried out by a laboratory approved by the Engineer in order to verify the certification provided. D. Geo-textile fabric shall consist of non-woven, needle and mechanically bonded, UV stabilized, Polypropylene. It shall be chemically resistant to commonly encountered chemicals and its physical properties shall comply with the following requirements: App li cati on

Wrapping Filter

Granular

Between Sub-base and Sub-grade

Sloping Embankment Beneath Rip Rap

Properti es Weight (minimum) 2 Thickness (under 2 kN/m ) Opening Size Grab Tensile Strength CBR Puncture Resistance Weight (minimum) 2 Thickness (under 2 kN/m ) Opening Size Grab Tensile Strength CBR Puncture Resistance Weight (minimum) Thickness Opening Size 090w Grab Tensile Strength CBR Puncture Resistance

Unit 2

g/m mm mm N N 2 g/m mm mm N N 2 g/m mm mm N N

Value 130 0.90 - 1.40 0.08 – 0.10 > 400 >1400 >230 0.9 - 2.30 0.09 – 0.10 >1000 >2500 >280 1.20 – 3.00 < 0.10 > 1200 > 3000

Standards EN 965 or ASTM D 5261 ASTM D 5199 or EN 964-1 EN ISO 12956 or ASTM D 4751 ASTM D 4632 BS 6906 – 4 or EN ISO 12236 EN 965 or ASTM D 5261 ASTM D 5199 or EN 964-1 EN ISO 12956 or ASTM D 4751 ASTM D 4632 BS 6906 – 4 or EN ISO 12236 EN 965 or ASTM D 5261 ASTM D 5199 or EN 964-1 EN ISO 12956 or ASTM D 4751 ASTM D 4632 BS 6906 – 4 or EN ISO 12236

E. Securing pins for geo-textile shall be nails with a washer suitably dimensioned to secure fastening of geo-textile and to prevent slipping. F. Overlaps at joints shall be 50cm wide. G. The formation level, to receive the fabric, shall be smooth, compacted, free from obstructions, depressions and true to line and level. Fabric shall be laid / fixed loosely. Damaged or displaced fabric shall be replaced.

3.1.14Manufacture 3.1.15 PVC-u Pro duc ts A. Supply pipes in straight lengths of not greater than 6m excluding the depth of any socket. B. Determine the nominal pipe wall thickness from the table in ISO 4065. C. Comply with the limits specified in ISO 3606 when measuring the nominal outside diameters and wall thickness in accordance with ISO 3126. D. Ensure that all pipes including cut lengths and all fittings before dispatch from the pipe manufacturer's works are indelibly marked as follows: Contract 106 , Volume II

Page 142 of 589

Section 02732

a. b. c. d. e. f. g. h.

Pipelines

The letters PVC-u. The manufacturer's name initials or identification mark. The nominal external diameter in millimeters. The pressure classification in bars. The date of manufacture A stamp to show that they meet the inspection requirements and hydraulic tests at the point of manufacture. A unique number shall be visible on the external face of the pipe. The number shall appear on all documents related to the consignment of the pipe test certificates and submissions. The manufacturing Standard.

3.1.16 Drainpipes A. Slotted drainpipes shall be fabricated from basic PVC-u. B. Class 16 shall be used up to OD 400 mm. and for pipes OD 450 and OD 500 mm. minimum wall thickness shall be 20 mm and 23 mm respectively.. C. Slots shall be cleanly cut. o D. Slotting of pipes shall be in rows, cut in the upper 180 section of pipe barrel. E. Where more than one row of slots are provided, slots shall be staggered. F. Drainpipes shall be laid in approved naturally rounded gravel material 20mm single size as shown in the drawings. G. The slots shall be spaced and located that the vertical loading strength of pipes is not less than 90% of the minimum vertical loading strength specified for non-drain PVC-u pipes. H. Gravel shall be surrounded by approved geotextile filter fabric as specified. I. Slots dimensions and arrangement shall comply with the following table: OD (mm) Slot

Length (mm) Width (mm)

No. slots / m No. of rows

110

160

225

250

280

315

355

400

450

500

40 5 12 2

55 5 12 2

80 5 12 2

90 5 12 2

100 5 12 2

80 5 18 3

90 5 18 3

100 5 18 3

105 5 18 3

120 5 18 3

3.1.17 GRP - Products 3.1.18Manufacturi ng Process A. Pipes shall be fabricated by employing an approved process utilizing a rotating mould/mandrel and equipment that accurately controls dosing and placing of resins, glass and aggregates in a uniform and consistent manner. B. Pipes, joints and fittings shall be designed for a minimum working life of 60 years and shall be able to withstand the testing, working pressures and service medium specified. The liner shall have a minimum thickness of 1.5mm and the total wall thickness shall be sufficient to withstand the loads and pressures encountered on site. The length of pipes shall be 3.0m for pipelines in filled areas and at sites where replacement of subsoil is required.

Filament Winding Process A. Glass fiber reinforcement, consisting of continuous fibrous glass strand roving or roving tape, shall be impregnated with thermosetting resin and wound onto the outside of a rotating mandrel in a predetermined pattern under controlled tension. Two methods, namely the Dual Helical Filament Winding and the Drostholm process, are at present in use. B. The glass shall be well saturated with liquid resin or pre-impregnated with partially cured resin. The composite structure may contain silica sand. Section of Wall

Inner Liner (S1)

Sealing (S2) Contract 106 , Volume II

Layer

Descript ion Resin Glass Silica Sand Thickness Resin Glass Silica Sand

Dual Helical Winding & Drostholm Process Vinyl Ester C-Veil None = 1.5 mm Vinyl Ester E glass None Page 143 of 589

Section 02732

Pipelines

Structural (S3)

Thickness Resin Glass Silica Sand Thickness Resin Thickness

Wall

Protective Outer Layer (S4)

= 2.5 mm Vinyl Ester or Isophthalic or Unsaturated Polyester Resin E glass < 40% as per structural analysis Vinyl Ester Minimum 0.5 mm Required (No pigments are allowed) (If exposed outside) As specified

UV Protection Pipe Surround

Centrifugal Casting Process A. Ingredients (resin, glass and silica sand) are fed into a rotating mould followed by spinning at high speed. B. Resin in the inner liner (S1) and sealing layer (S2) shall be Vinyl Ester. C. Chopped (cut) textile ECR* or E-glass roving in conjunction with silica sand filler and resin as specified in DIN 61 855 Part 1 shall be used as reinforcement in the structural wall (S3). D. Minimum requirements are shown on the following table: Section of Wall

Inner Liner (S1)

Sealing (S2)

Layer

Structural Wall (S3)

Protective Outer Layer (S4)

Descrip tion

Centrif ugal Process

Resin

Vinyl Ester

Glass (if used)

C or Advantex

Silica Sand

None

Thickness

≥ 1.5mm

Resin

Vinyl Ester

Glass

E glass

Silica Sand

None

Thickness Resin

≥ 2.5mm

Glass

Advantex / E

Silica Sand

Maximum 40%

Thickness

To be refined by structural analysis

Resin

Vinyl Ester

Sand

As per manufacturer

Thickness

≥ 0.5mm

Isophthalic /Vinyl Ester / Unsaturated polyester resins

UV Protection

Required (No pigments are allowed) (if installed outside)

Pipe surround

As specified

Installation

As per manufacturer's instructions

Remarks: (*) or approved equivalent

3.1.19Qualit y Control Tests Carry out the quality control tests listed below at the frequency stated. Records of all tests and inspections to be maintained by the manufacturer. Forward two copies of all test certificates and reports to the Engineer. Ensure that the raw materials are checked for compliance with the relevant Standard.

3.1.20 GRP produ cts 3.1.21 General A. Tests include long-term stiffness, deflection and creep, flexural test, hydrostatic pressure, corrosion resistance, longitudinal and hoop tensile strength and impact resistance. The external pressure resistance shall be determined in accordance with ASTM 2924. B. The results of type tests appropriate to the proposed products shall be used to determine the properties of pipes. Each type test shall have been carried out on representative samples of the pipes or fittings to be used. If alterations are proposed to the method of manufacture and pipe material or pipe design, the manufacturer shall carry out all the required type tests to the satisfaction of the Engineer. Contract 106 , Volume II

Page 144 of 589

Section 02732

Pipelines

C. Quality control tests shall be carried out on raw materials (e.g., resins, aggregates, glass) as well as on laminate specimens, and shall include, but not be limited to visual inspection, checking of dimensions, pressure tests etc. No 1

2

Test

Standard ASTM D 2563 /

Visual Inspection

DIN 19565 (*) ASTM D 3567 /

Dimensional Check

DIN 19565 (*)

Frequency 100%

Remarks Acceptance Level – II (Table 1), ends shall be sealed with 2 layers Vinyl Ester Resin Make a series of at least four readings,

100%

approximately equally spaced and within the accuracy of 5%

3

Water Absorption

ASTM D 570

1%

4

Barcol Hardness

ASTM D 2583

100%

5

Loss On Ignition

ASTM D 2584

4%

Liner, structural wall and overall

1%

Acceptance Range – Table: 2

ASTM D 2990 / D 1599

1%

For pressure pipes only

ASTM D 4161

1%

Initial 6

Longitudinal

Unit

Tensile Strength by Strip or Beam

7

Hoop Tensile Strength

8

Joint Tightness

BS 5480, Appendix A or B / DIN 16869, Part II (*)

Part 1, Table: 2 – 18 Min. 35 and/or 90% of resin manufacturers declared value

Test shall be conducted in straight, misaligned and in shear loading conditions

10% for gravity 9

Hydrostatic Pressure

BS 5480, Appendix K

100% for pressure pipelines

Initial Specific Stiffness and 10

Resistance Damage

to

Structural

under

Ring

BS 5480, Appendix H, Method B

4%

Deflection 11

Impact Resistance

12

Creep

13

External Pressure

14

Strain Corrosion

BS 5480, Appendix J

1%

DIN 16869

1%

ASTM D 2924

1 / Six Months

-

One set / 3 Years or

Controlled at temperature of 40°C for minimum

at the change of

one set of tests consisting of 18 testing

ASTM D 3681

raw material source 15

Hydrostatic Design Basis

ASTM D 2992, Procedure B

Specific Ring Stiffness and 16

Creep Factor Under Ring

Chemical

Resistance

(Alkaline Environment)

specimens. Controlled at temperature of 40°C for minimum one set of tests consisting of 18 testing specimens. Controlled at temperature of 40°C for minimum

BS 5480, Appendix L

Deflection (Creep) 17

All type of pipes

one set of tests consisting of 18 testing specimens. Controlled at temperature of 40°C for minimum

ASTM D 3262

one set of tests consisting of 18 testing specimens under pH 12.

Remarks: (*) Centrifugal Cast

3.1.22 Chemical Resistanc e Test (Strain Corros ion) A. Strain Corrosion tests for determining the chemical resistant properties of fiberglass pipe in a deflected condition shall be carried out in accordance with the appropriate standards. B. The procedure, medium and acceptance criteria for testing of GRP products shall be approved by the Engineer prior to commencement of tests. C. Tests shall be conducted in compliance with applicable and acceptable standards and the failure strain applicable at 60 years shall be established. The value shall not be ≥ 1%.

3.1.23 Hydraulic Test A. Each pipe shall be subjected to a hydraulic pressure test. The pipe shall be acceptable if, after the test pressure has been applied for 5 minutes, no leakage or sweating of the barrel occurs. B. For gravity pipelines a pressure of 1.5 bar shall be applied and for pressure pipes 1.5 times the nominal pressure. In addition to the test above for every thirtieth pressure pipe and every oneContract 106 , Volume II

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hundredth gravity pipe the testing period shall be increased to 4 hours. The batch of pipes shall be accepted, if no leakage or sweating of pipe occurred. C. Each fitting shall be subjected to an internal low-pressure air test at the manufacturer’s works prior to delivery. The test pressure shall be 0.1 bar applied for minimum period of 5 minutes without signs of leakage or distress. Fittings of mitered construction shall be manufactured from tested pipes only.

3.1.24 Dimensions A. An optical scale comparator with minimum 7 magnification having reticule graduation with a 0.13 divisions shall be used for the measurements of the wall thickness and liner thickness of products. B. A circumferential vernier wrap tape having an accuracy of +/- 0.4mm or a micrometer caliper with an accuracy of +/- 0.25% shall be used for the determination of average outer diameter (OD) of products. C. The length shall be measured with a steel tape or gauge having graduations of 1mm or less. D. The wall thickness, length, diameter and square ness of pipe ends shall be measured for each pipe and fitting. The dimensions shall not deviate from the tolerances specified.

3.1.25 Stiffness A. At least one pipe out of each batch of 30 number of pipes (or less) shall be tested to determine the initial specific stiffness. B. In addition, each test specimen shall be deflected to amounts according to its nominal stiffness. At the lower deflection there shall be no indication of structural damage as evidenced by inter laminar separation, separation of the liner or coating (if incorporated) from the structural wall, tensile failure of the glass fiber reinforcement, fracture or buckling of the pipe wall. a. Specimens from pipes of 10,000 N/m², nominal initial stiffness shall be based on: 1. Min. 7% (Liner not to crack criteria) to DN = 200mm 2. Min. 9% (Liner not to crack criteria) to DN > 200mm 3. Min. 12% (Structural wall not to crack criteria) to all DN b. Specimens from pipes of 5,000 N/m², nominal initial stiffness shall be based on: 1. Min. 9% (Liner not to crack criteria) to DN =200mm 2. Min.12% (Liner not to crack criteria) to DN > 200mm 3. Min. 20% (Structural wall not to crack criteria) to all DN c. All %ages deflection stated above are of the diameter (DN).

3.1.26 Longitudinal Tensil e Strengt h A. Longitudinal tensile strength of pipes shall be carried out as specified in the appropriate standard. Tests shall be carried out on one pipe out of 100 No's produced for each diameter and class

3.1.27 Barcol Hardness A. A minimum of one pipe for every 30 pipes manufactured shall undergo a Barcol hardness test in accordance with BS 4549: Part 1: Appendix A. B. A minimum of one pipe of each class and diameter of pipe shall be tested. C. The sample pipe shall also withstand a commercial acetone test on the internal portion of the laminate.

3.1.28 Los s on Igni tion A. A minimum of one pipe for every 30 pipes manufactured shall be tested in accordance with EN 60 (Glass Reinforced Plastics: determination of the loss on ignition) or ASTM D 2584 “Standard Method of Test for Ignition Loss of Cured Reinforced Resins”.

3.1.29 Joint Tests A. A minimum of two pipes out of 100 pipes shall be joined and tested subject to the following: a. The test pressure shall be as specified under hydraulic test b. An external test pressure of 1.0 bar (gauge) shall be applied to two sections of pipe assembled with a deflected joint to check the water-tightness of the joint. 0 c. The deflection during the joint test shall be 1.5 for DN =600 and 0.5° for DN >600.


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3.1.30Visual Inspecti on A. Each pipe and fitting shall be subjected to a complete visual inspection before shipment and after off loading at site.

3.1.31Burs t Test on Pressure Pipelines A. For pressure pipes a Burst Test shall be carried out in accordance with BS 5480 to determine the initial circumferential tensile strength of the pipe.

3.1.32 PVC-u Pro duc ts 3.1.33 Vicat Softening Point 0

A. Ensure that the deformation temperature of each tested sample is not lower than 79 C, when two random samples taken from the pipe are tested in accordance with ISO 2507.

3.1.34 Impact Resistance A. Ensure that the pipe sample when tested to ISO 3127, pipe samples have a true impact rate (TIR) below 10% at a confidence level of 90%.

3.1.35 Heat Reversion A. Ensure that at no position around the pipe, the length changes by more than 5% when three samples of each pipe size are tested to ISO 2505. Samples shall not show faults such as cracks, cavities or blisters during or after the tests.

3.1.36 Hydraulic Test 0

A. Test specimens of each pipe size in accordance with ISO 1167, three specimens at 20 C and a 0 further three specimens at 60 . Ensure that samples of pipe will sustain the following without failure o

2

Test Temperature ( C)

Minimum time for failures, hours

Induced Stress N/mm

20

1

42

60

1,000

10

3.1.37 Effect of Sulp huric Ac id A. Test in accordance with ISO 3473. Each pipe size to meet the required characteristics contained therein.

3.1.38 Resistance to Acetone A. Test in accordance with ISO 3472 specimens of pipe of each pipe size to meet the required characteristics contained therein.

3.1.39 Joint Tests A. Two jointed pipes of each pipe size to be tested in accordance with the requirements of Section 6.5 of ASTM D3262 but applying the following parameters in substation. a. Use a positive test pressure of 6 meters water head. b. Conduct the negative pressure test to determine the integrity of the joint against infiltration. Apply an external test pressure of 6 meters water head to two sections of pipe assembled with a misaligned joint. 0 c. Maintain 1.5 deflection during the misaligned joint tests. d. Perform a program of testing to demonstrate that the pipe joints continue to comply with the type tests

3.1.40 Fittings A. The Engineer may require fittings to undergo similar type of tests to those specified above. Carry out such tests in accordance with the appropriate ISO standard. Use fittings of similar quality to those of the pipes being tested. Contract 106 , Volume II

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3.1.41 Superficial Appearance A. Ensure that the internal and external surfaces of every pipe are visually inspected both before shipment and after off loading at site and that they are free from defects.

3.1.42Impact Resist ance A. Perform a program of testing to ensure that the pipe to complies with the type tests.

3.1.43Heat Reversio n A. Test at least one specimen during every 8 hours production run from each machine. Test in accordance with ISO 2505. Ensure that the length does not change by more that 5% at any point around the sample. The tested samples should not show faults, such as cracks, cavities or blisters.

3.1.44Hydraulic Test A. Test at least one specimen during every 8-hour production run from each machine to comply with 0 the requirements of the type test at 20 C.

3.1.45In Case of Test Failur e A. In the event that the pipe fails any of the tests outlined above, repeat the relevant test on further 10 pipes of that class and diameter as follows: a. Repeat the test on the 5 No. pipes produced immediately before and 5 No. pipes produced immediately after the failed pipe. b. If any of the ten pipes fail, cease the fabrication of pipes of that class and diameter. The suitability of manufactured pipes for the proposed installation will be determined and the Engineer reserves the right to reject all the pipes of that class and diameter. If the pipes are rejected, the Contractor shall replace the pipe at his own expense.

3.1.46Concrete Pipes and Fitti ngs 3.1.47General A. Do not make field joint to the liner until the lined pipe has been backfilled and pipe tests have been completed. Where groundwater is encountered, do not make any field joint until pumping of the ground water has been discontinued and no visible leakage is evident at the joint. Ensure that the liners at joints are free from foreign materials. Ensure that the liners at joints are clean and dry before joints are made. B. Ensure that any hot material is not in contact with the liner. C. Do not apply coating of any kind over any joint, corner, or welding strip, except where non-skid coating is applied to liner surfaces. D. Do not apply adhesive to the surfaces of pipe joints, or the liner or the joint strips. E. Ensure that the surface is clean to permit visual inspection and spark testing. Physically test all welds with a nondestructive probing method. Test installed liner using a hole detector set at 20,000 volts. Properly repair and retest all areas of liner failing to meet the field test. F. Test each transverse welding strip, which extends to a lower edge of the liner. Extend the welding strips below the liner providing a tab. Apply a 4.5kg pull normal to the face of the pipe by means of a spring balance. Ensure that the liner adjoining the welding strip is held against the concrete during application of the force. Maintain the 4.5kg pull if the weld failure develops, until no further separation occurs. Retest defective welds after repairs have been made. Trim neatly tabs after the welding strip has passed inspection. Provide all test equipment required in the manner recommended by the manufacturer and as described above. The personnel provided to perform the testing should be qualified.

3.1.48PVC Liner A. PVC liner shall be a combination of materials of high molecular weight polyvinyl chloride granules, pigments, and plasticisers specially compounded to retain flexibility in manufacturing the liner and in all joint, corner and welding strips. B. Polyvinyl chloride resin constituting at least 99% by weight of the resin shall be used in the formulation. Copolymer resins are not permitted. Contract 106 , Volume II

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C. Material for welding / joint strips, patches etc. shall be the same as PVC-Lining. D. Conductive copper wire shall be installed at each joint welding. E. PVC-liner and accessories shall: a. Be impermeable to gases and liquids and resistant to bacteria or fungous growth b. Have good impact resistance, be flexible c. Have an elongation sufficient to bridge up to 6mm settling cracks without damage to the lining d. Be permanently and physically attached to the concrete by locking extensions embedded in the concrete (e.g. T-locks) e. Have a minimum thickness of 1.65mm and be capable of being repaired at any time during the life of the pipeline f. Withstand a pull-off test of at least 17KN/m applied perpendicularly at the surface for 1 minute 2 g. Be capable of withstanding a 1.05kg/cm back hydrostatic pressure applied to the undersurface of the lining without losing anchorage and without rupture and leakage h. Have the physical properties indicated in the following table: Physical Properti es of PVC Liner Property

Initial

2

Tensile Strength kN/m

After 112 days exposure in chemical solut ions

15 (Min.)

Elongation at break

14 (Min)

200% (Min)

Shore Durometer, Type D: 10 – Sec

200% (Min)

Inst. 50 - 60 35 – 50

Weight changes

± 5

maximum with respect to initial test result

± 1.5%

maximum

3.1.49HDPE – Liner A. The lining shall be from HDPE (High Density Polyethylene) type material backed-up with integrated type conical studs or T-Locks. B. The raw materials shall be virgin type and the resin used shall be min. 99% to the resin incorporated in the formulation. C. All welding / joint strips, patches etc. materials shall be the same as HDPE-Lining. D. Conductive copper wire shall be installed at each joint welding. E. HDPE-liner and accessories shall be: a. Impermeable to gases and liquids and nonconductive to bacteria or fungous growth b. Flexible, resistant to impact c. Able to bridge up to 6mm settling cracks without damage d. Permanently attached to the concrete by locking extensions embedded in the concrete 2 e. Capable of withstanding a 1.05kg/cm back hydrostatic pressure applied to the undersurface of the lining without losing anchorage and without rupture and leakage f. Have a minimum thickness of 1.65mm and be capable of being repaired at any time during the life of the pipeline g. Have the physical properties indicated in the following table: Physical Properti es of HDPE liner sheets Property

Initial 2

After 112 days exposure in chemical soluti ons

Tensile Strength KN/m

22 (Min.)

20 (Min), (ASTM D638-95)

Elongation at break

600% (Min)

600% (Min), (ASTM D638-95)

Shore Durometer, Type D: 10 – Sec

Inst. 50 - 60 35 – 50

Weight changes

± 5

maximum with respect to initial test result, (ASTM D2240) ± 1.0%

maximum

Density – gr/cm3

0.920 (Min)

0.920 to 0.925, (ASTM D792)

Puncture Resistance – N

345 (Min)

325 (Min)

Water Absorption

< 0.1%, (ASTM D570)

N/A

Porosity

No pinholes, (Spark Test)

No pinholes


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3.1.50Agg regate Materials 3.1.51Submittals A. Submit 4.5kg samples of each type of material to testing laboratory in airtight containers. B. Submit names and addresses of suppliers for imported materials, together with a description of their activity, their stocking levels and their staff, both technical and support.

3.1.52Qualit y Ass urance A. Perform Work in accordance with Abu Dhabi Municipality and Works Department standards. Maintain one copy on site.

3.1.53Source Quality Contro l A. Perform testing and analysis of aggregates in accordance with these specifications. B. If tests indicate materials do not meet specified requirements, change material or material source and retest. C. Provide materials of each type from same source throughout the Work.

3.1.54Stockpi ling A. B. C. D.

Stockpile materials at place of concrete production. Stockpile in sufficient quantities to meet Project schedule and requirements. Separate different sized materials with dividers or stockpile apart to prevent mixing. Direct surface water away from stockpile site so as to prevent erosion or deterioration of materials.

3.1.55Qualit y Control A. The crushing strength of concrete pipes shall not be less than those specified in BS 5911, ASTM C76M, ASTM C39, DIN 4032 and DIN 4035 for the respective classes of pipes shown on the drawings. B. Use other methods of testing as required in accordance with BS 1881 [C497M]. C. Core concrete specimens shall be taken from RC-Pipe and the following tests shall be performed. a. Water permeability b. Rapid Chloride Penetration (RCP) + Chloride penetration profile. c. Chloride and Sulphate d. Strength (7 and 28 days). D. PVC / HDPE liner for concrete pipes and fittings: a. The Engineer may sample a specimen for each type of sheet or strip at any time during production or in the field prior to final acceptance. Assistance shall be provided in taking the samples. The specimens shall be tested to the following requirements: 1. Liners shall be tested for holes, using an approved electrical holes detector at a minimum of 20,000 volts. Repair holes in sheets and retest prior to shipments. 2. All welds shall be physically tested by a non-destructive probing method. E. Tensile test shall be done on specimens in accordance with ASTM D412 using DIE B for PVCLiner and ASTM 638-95 for HDPE Liner. Use weight change test on specimens of 25mm x 75mm in size and of specified sheet thickness. The specimens shall be conditioned to a constant o o temperature of 43 C after submersion in the following solutions for a period of 112 days at 25 C. At 28-day intervals, remove the specimens and record weight change from each of the chemical solutions. Chemical Solution

Concentration

Sulfuric Acid Sodium Hydroxide Ammonium Hydroxide

20% * 5% 5% *

Chemical Solution

Concentration

Sodium Hydroxide

1% *

Nitric Acid

1% *

Ferric Chloride

1%

Chemical Solution

Concentration

Soap Detergent

0.1% (linear

alkyl

benzyl sulfonate or gas) Bacteriological less than

BOD

not

0.1% 700mg/l

Remark: (*) Volumetric percentages of concentrated C.P. grade reagents


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F. If any specimen fails to meet the 112-day physical property requirement before completion of the 112day exposure, the material will be subject to rejection by the Engineer. G. If such samples of sheet or strips fail the specified test. Such failed material shall be rejected and removed from project or manufacturers storage yard. Replace such failed pipe with pipe that meets the specified requirements including any pipe that may be tested in its final position and backfilled at no addition cost to the Department. H. The concrete pipes shall be free from fracture, large or deep cracks and surface roughness. The planes of the ends of the pipe shall be perpendicular to their longitudinal axis. I. Carry out inspection procedures and tests in accordance with BS 5911 [ASTM C361M]. J. Test specimens taken from welded joints shall be without cracks or separation and must be tested in tension after flexing. Each specimen shall withstand a minimum 60kg/25mm of weld, or the 2 product of 140kg/cm times the minimum thickness in centimeters of the material adjoining the weld, whichever is greater. K. Inspected concrete pipes shall be subject to the following action by the Engineer: a. Rejection for any of the following reasons: 1. Failure to pass the hydrostatic test 2. Transverse reinforcing steel found to be in excess of 6mm out of specified position after the pipe is moulded 3. Unauthorized application of any wash coat of cement or grout 4. Any crack showing two visible lines of separation for a continuous length of 60cm or more, or an interrupted length of 90cm or more anywhere in evidence, both inside and outside except where such cracks occur during the external loading test. b. Repairable for any of the following reasons: 1. Exposure of any wires, and positioning spacers or chairs used to hold the reinforcement cage in position, or steel reinforcement in any surface of the pipe 2. Any shattering or flaking of concrete at cracks 3. Honeycombing on the exterior surfaces of the pipe exceeding 6mm in depth unless pointed with mortar or other approved material 4. Any crack having a width of 0.25mm or more throughout a continuous length of 30cm more 5. Any crack extending through the wall of the pipe and having a length in excess of the wall thickness 6. When required by the Engineer, fill with cement grout any crack, which is 0.25mm wide or wider and is not a cause for rejection. Use neat cement grout composed of cement mixed with water to fluid consistency for filling the cracks. c. Accepted as is, subject to cost deduction: 1. A deficiency in the specified wall thickness of the pipe larger than permissible. The deficiencies in wall thickness permitted herein do not apply to gasket contact surfaces. Submit the tolerances of such contact surfaces for approval by the Engineer. 2. A variation from the specified internal diameter in excess of 1 percent of interior surfaces, which have been reworked after placing of the concrete. The variation in internal diameter permitted herein does not apply to gasket contact surface. Submit the tolerances of such contact surfaces for approval by the Engineer.

4

Execution 4.1.1 Excavation

A. B. C. D.

In hard substrata remove loose material and prepare formation to receive bedding. Hand trim the last 15cm above formation level to required elevations. Correct over break with lean concrete class B5. Allow in rates to check the formation’s bearing capacity under the pipeline and/or structures to comply with drawings/structural calculation as per the Department/Engineer instructions. E. Ensure that the formation of excavations for pipelines are firm, free from water, even, true to grade, free of stones, and other protrusions and compacted to a minimum of 95% Proctor before placing of pipe bedding.


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4.1.2 Bedding & Surrou nd 4.1.3 General A. Where concrete surround or Low Strength Surround [LSS] to pipes is specified or instructed, prefabricated concrete blocks shall be placed on the compacted formation. Spacing between supports shall be close enough to ensure the straightness of the pipe barrel. A thin layer of soft padding shall be provided between supports and pipe barrel to prevent damage to pipes or coating. B. After laying the pipe the surround shall be carefully placed and worked under the pipes ensuring that pipe barrels are supported evenly. It shall then be brought up care being taken to prevent floating of pipes. C. Hydraulic tests of pipelines shall be carried out before placing concrete surround. Adequate measures shall be taken to prevent dislocation of pipes during testing. D. The thickness of the surround shall be = 200mm or = OD/4 whichever is greater measured from the outer surface of the pipe. E. The Engineer may require tests to be carried out at pipe formation if exceptionally poor ground conditions are encountered to assist in determining whether the native soil is stable or not. Where directed by the Engineer, over excavate the trench and backfill with either concrete B-5 or suitable approved granular material. F. Place the granular material over the full width of the bottom of the trench to the level of the underside of the pipe. Compact the granular material as specified in layers not exceeding 150mm up to 300mm above the crown of the pipe. Ensure that the depressions for the joints are completely filled and that the bedding material is well compacted under the haunches of the pipe over the full length of the pipeline. Ensure and maintain that the minimum degree of compaction as specified for bedding material is achieved over its whole depth range. Ensure that in all cases the degree of compaction is such that the pipe deflection does not exceed the limits specified herein. Comply with the Engineer‘s requirement for testing to be carried out on the bedding to determine the degree of compaction being achieved. G. If the Contractor is consistently unable to achieve the required degree of compaction or proves unable to keep pipe deflections to within the acceptable limit, the Contractor shall change his method of compaction or use a better class bedding material.

4.1.4 Aggregate Bedding 4.1.5

Concr ete Pipes

A. Aggregates for bedding to pipes shall consist of gravel or broken stone and shall be suitable "all in" ballast or stone. B. For pipes up to 1200mm nominal internal diameter the material shall be graded 20mm to 5mm all passing 20mm and not more than 20% passing 5mm sieves to BS410. C. For pipes above 1200mm nominal diameter the material shall be graded 37.5mm to 5mm all passing 37.5mm not more than 45% passing 20mm and not more than 20% passing 5mm sieves to BS410. D. The minimum thickness of granular material beneath the pipeline shall be to the following depth below the underside of the socket or coupling: a. ≥200 mm or ≥ OD/4 b. In exceptional circumstances the Engineer may permit the use of excavated material instead of aggregate bedding. Such permission may at any time be withdrawn and the Contractor shall provide material to the standards given above at no extra cost to the Department.

4.1.6

GRP and other Plastic Pipes

A. Aggregates for bedding and surround to GRP and other plastic pipes shall be a single sized natural rounded aggregate, nominal size 10mm. The bedding material shall be compacted to 95% Proctor density. B. The Thickness of the surround shall be = 200mm or = OD/4 whichever is greater measured from outer surfaces of the pipes. C. Prior to placement of the bedding material for the formation and sides of the trench shall be lined with an approved geo-textile filter fabric in accordance with the Specifications. Once the bedding material is placed around the pipe, the filter fabric shall be folded over the top of the bedding material and shall have a minimum overlap of 500mm. Contract 106 , Volume II

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D. The geo-textile filter fabric shall prevent migration of the native soil into the bedding material and vice versa. The geo-textile fabric shall form a continuous barrier to prevent migration and each joint shall be overlapped by at least 500mm.

4.1.7 Concrete Surround 4.1.8

Concr ete B15

A. Concrete shall be suitably protected and cured. B. Backfilling shall take place after the concrete has attained sufficient strength and after obtaining the Engineer’s approval. C. Outer dimensions of concrete surround shall be ≥ OD/2 + OD or ≥ OD + 0.30 m whichever is greater. D. Concrete surround shall be provided at all road crossings where the cover above pipes is less than 2.50 m for the total length between manholes and where instructed by the Engineer or shown on drawings. E. A self-adhesive membrane shall be provided at pipe joints to prevent cement slurry from entering the gap between pipe barrel and socket. This sealing shall be carried out immediately on completion of a satisfactory initial hydraulic test prior to concreting but not prior to the test. F. Joint filler shall be placed at each pipe joint flush with the outer surfaces of the concrete surround. G. After sufficient hardening of concrete a protective cover of not less than 300mm compacted depth of selected backfill material shall be placed evenly and gently over the top of the concrete and evenly compacted by hand in layers of 150mm thickness measured before compaction. H. Where a concrete slab is specified to protect the pipelines, extend such protection to a minimum of 200mm on undisturbed ground on either side of the pipe trench. Use reinforced concrete class 'B35' for the slab as shown on the Drawings. I. Support pipes to be bedded on or cradled with concrete on pre-cast setting blocks class B35, the top face of each block being covered with a separation layer as specified. J. Provide concreting to the pipeline either as bed or bed and surround as shown on the Drawings. Use concrete Class B-5 along such lengths as shown on the Drawings and/or as instructed by the Engineer. Use sulphate-resisting cement for concrete bed and surround. K. Ensure that the pipe is prevented from floating or otherwise moving during concreting. L. When support of excavations is provided, place building paper against that support before concreting to facilitate withdrawal of the support. M. GRP pipes shall be wrapped with polyethylene sheets 500 gauge to prevent direct contact with concrete. N. In the case of pipes with flexible joints, place a strip of fiberboard or other material at each joint with a thickness of 20mm and to be approved by the Engineer in a vertical plane at the edge of the socket to interrupt the concrete. O. For specification of concrete Class 'B-5' refer to DIN standard No. 1045.

4.1.9

Low Strength Surrou nd (LSS)

A. Instead of concrete surround, as specified before, a cemented Low Strength Surround may be used for GRP-pipes and other thin-walled flexible pipes, subject to the approval of the Engineer. LSS shall be a flowable mix, having a mortar like consistency conforming to the following criteria and shall be chemically compatible with the pipe material and surrounding environment: a. Stable volume b. Maximum density c. Minimum bleed d. No segregation e. Suitable for placing by concrete pump 2 f. Low strength, recommended 0.25 to 1.5 N/mm g. Easy to cut or excavate B. The LSS - mix shall have a low content of sulphate resisting cement, aggregates shall be = 5.0mm, admixtures promoting stable air contents and reduced mix water levels shall be used. C. In general LSS - mix shall be cast against the undisturbed trench walls. Where the trench wall is supported by shoring/struts and the like its width shall be = 200mm or = OD/4 (whichever is greater).


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4.1.10Installati on 4.1.11General A. Transport, store, handle and lay pipes according to the manufacturer's instructions and specification as approved by the Engineer. B. Ensure that the dewatering arrangements are properly working at all times. Prevent infiltration of groundwater into the permanent work. C. Lay pipes from the downstream end to upstream end with the socket end at the upstream end of each pipe. D. Lay pipes after placing manhole base. E. Lay pipe to slope gradients noted on drawings respectively on technical data, do not displace, misalign or damage pipe when compacting. F. Ensure that all products are sound and clean before laying. When pipe laying is not in progress, ensure that the pipe ends are at all times with watertight plugs or caps. The plugs or cap shall only be removed for the purposes of making a connection of the pipe end or testing the pipeline. The plugs or cap shall be replaced immediately on completion of the test. G. Joints shall be cleaned and lubricated, rubber seal shall be inserted in the groove of the socket end. Use a metal feeler to check that the rubber gasket is correctly located. H. Supply of pipes and fittings shall only proceed after the Engineer’s approval of the products, test results etc. I. Remove from site any rejected pipe. Ensure that they are not incorporated in the permanent works. J. Provide and maintain relevant tools recommended by the manufacturer. Ensure that a sufficient numbers of each tool are available in order that the work is never held up for the need of such tool. K. Cutting of pipes shall be done by an approved method, using appropriate machine. Cuts shall be flat, smooth and cut square ( Δ) to the pipe axis conforming to the following requirements: Nomin al Size Range DN200 - DN350 DN400 - DN700 DN800 - DN1400 DN1600 - DN2000

(mm) 3 4.5 8 10

L. Cut ends of GRP pipes shall be fully sealed with a continuous coating of two layers Vinyl Ester M. Hydraulic tests of pipes shall be carried out before placing the surround. The Contractor shall prevent the dislocation of pipes by adequate measures approved by the Engineer. N. Provide an approved independent laboratory to carry out tests to determine the in-situ density of the pipe bedding material as instructed by the Engineer. O. Unless otherwise indicated in the design drawings, form cut-off walls as specified. P. Adopt a suitable method of controlling the alignment of a pipeline installed in a tunnel heading or duct to the approval of the Engineer.

4.1.12Techni cal Expert A. Provide qualification details of the manufacturer's technical expert to be assigned to the Contract. The technical expert shall have expertise, experience and skills necessary for advising and monitoring all aspects of transport, storage, handling and installation of pipes as appropriate. B. The technical expert shall provide comprehensive technical assistance to the Contractor throughout the Contract and regularly monitor the Contractor's activities and report on shortcomings. C. The Contractor shall provide the Engineer and the Department copies of all instructions advice or reports given by the manufacturer's technical expert to him. The Technical Expert shall immediately inform the Engineer and the Department of any omission, variations and detractions from the approved handling and installation specification. D. The Contractor shall include in any agreement / sub-contract with suppliers, specialists etc. a clause specifying the above.

4.1.13Laying Pipes in Ducts A. Wrap GRP pipes installed in ducts with an approved material. B. The pipe shall be adequately supported.


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C. The space between pipe barrel and duct wall shall be filled with concrete and cement grout or with an approved low-pressure non-shrink cement grout for the complete length between working shafts. D. Where the clearance between: a. The outer surface of the pipe barrel and duct is less than 150 mm b. The crown of the pipe and the soffit of the duct is less than 300 mm c. The pipe and duct is in any respect insufficient to permit filling with concrete and cement grout Completely fill the space around the pipe with a low pressure, low strength, and non-shrink cement grout. E. Place concrete B5 to a level 150 mm below the duct’s soffit. Concrete made with an approved all-in aggregate will be permitted for this purpose. Place the concrete filling against a shuttered face and in lengths to be approved by the Engineer. Apply pressure grout to refusal to the 150mm space between the top of the concrete filling and the soffit of the duct. F. Where there is sufficient space around the pipe, place an initial Class 'B-5' concrete surround to a limit of 150 mm above the crown of the pipe. Take a deflection measurement after this concrete surround has set. G. Where the concrete filling is placed in one operation, take deflection measurements after the concrete has set and prior to pressure grouting at the crown of the tunnel heading or duct. H. Where low pressure low strength grout is used to completely fill a tunnel heading or duct, take deflection measurements once the grout has set. I. Check the deflections of every pipe laid in a tunnel heading or duct. Take deflection measurements at each pipe end at points 0.1m and 1.5m away from the joint and at 3.0m intervals. For pipe lengths of less than 3.0m, measure the deflection at each end at 100 mm away from the joint and at the mid-point.

4.1.14Cut – o ff Walls A. Unless otherwise directed by the Engineer a 30cm thick cut – off wall in SRC concrete B15 or solid c+s blockwall shall be constructed to prevent the bedding acting as a sub-soil drain between manhole wall and undisturbed trench wall. B. The walls shall be extended from the manhole base and keyed 15cm into the native soil. C. Top of the cut-off wall shall be 30cm above granular surround across the full cross section of the granular bedding, Cut-off walls shall be constructed at locations shown in the drawings as follows: a. Two numbers at manholes without side inlets b. Three numbers at manholes with one side inlet c. Four numbers at manholes with two side inlets. D. Costs for cut-off walls shall be included in the rates for trench excavation and pipe laying.

4.1.15Thrust Bloc ks A. Thrust blocks shall be constructed in concrete B35 at bends and junction on pressure pipelines to the dimensions shown on the Drawings or instructed by the Engineer. B. Concrete shall be cast against undisturbed trench-walls. Any over break between thrust block and trench wall shall be filled with concrete B15. C. No pressure is to be applied to thrust blocks until the concrete has attained its strength.

4.1.16Pipes in Crossi ngs wit h Walls o f Stru ctures 4.1.17Installatio n b efore c asting of concrete A. Pipes and pipe specials through concrete walls and floors shall, as far as possible, be built in during construction. B. Full co-operation is required between the civil work contractor and the M&E contractor to ensure proper positioning of pipe crossings / fittings. C. Locate the pipes exactly in the positions shown in the Drawings. D. Ensure that the pipes and fittings are true to line and level and fully in contact with compacted concrete at all points.

4.1.18Box Outs A. Box outs for pipe crossings shall be constructed as shown on drawings and/or as instructed by the Engineer. Contract 106 , Volume II

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B. The soffit shall be inclined to ensure a complete grouting over the entire width of wall. C. If not otherwise instructed or shown on drawings the sides of the box outs shall have a tapered central annular recess to provide a positive key. D. The concrete surface shall be thoroughly cleaned and roughened before grouting. E. For grouting pre-mixed non-shrink rheoplastic cement grout mix shall be used. F. Steel waterstops, if installed, shall be thoroughly cleaned from rust and other detrimental material immediately before grouting. G. Pipe connection to structures shall be by special sleeves as shown on drawings. H. Surfaces of PVC-u/GRP in contact with concrete structures shall be sanded to provide a good connection. I. The working space below the pipe connection to the structure shall filled with concrete class B5.

4.1.19Watertig ht System A. Due to the high salinity of the groundwater, infiltration into the pipelines must be avoided. B. All components of the scheme e.g. pipeline, manholes, chambers, plugs caps etc. shall be watertight. C. All open pipe ends shall be plugged and sealed immediately after the pipes have been laid and shall remain sealed until connections are made or pipes are tested. This applies especially to circumstances when pipe laying will be interrupted e.g. during work breaks etc. D. 14 days after suspension of operation of the dewatering system the Engineer will inspect joints in waterproofing systems. Sealing of joints may only commence with the Engineer’s written approval.

4.1.20Field Qualit y Contro l 4.1.21Mirror Test A. All gravity lines shall be inspected visually. A. Inspection test for level alignment and freedom from obstructions shall be carried out by means of a torch and mirror or by a laser beam. B. The Contractor shall provide and maintain on site for the Engineer’s use an Oval shaped mirrors 285mm x 150mm complete with telescopic handle (full extended length = 5.0m) and explosion proof hand torches with 100mm diameter reflector having 90m range complete with rechargeable battery.

4.1.22Hydros tatic Testi ng of Pipeline 4.1.23 General A. Submit for the Engineer's approval details of the proposed methods and program for testing including details of test equipment. B. Preparation of pipeline for testing shall be timed in such a manner that testing during the early morning hours or late afternoon hours is possible. Water tests of pipeline shall be carried out in lengths between manholes or chambers or such lengths as the Engineer may direct. C. Trenches shall be kept free from water and pipe ends and joints shall be exposed to enable inspection. D. Arrange for all tests to be witnessed by the Engineer. E. Test results shall be recorded on approved test data sheets, countersigned by the Contractor and the Engineer and copies to be provided for the Department and the Engineer. F. Prior to the final test the Contractor may undertake preliminary tests to satisfy himself as to the quality of the works carried out. G. Filling of pipeline shall start at the lower end. During the initial period water shall be added to maintain the pressure head in order to allow for absorption of water and the displacement of trapped air from the system. The final test may commence two hours after the pipeline has been filled. H. Provide all things necessary for carrying out testing, re-testing, cleaning and allow in the rates for the costs of labour, equipment (e.g. pumps, gauges, piped connections, stop ends etc.), temporary works and testing media (potable water). I. Ensure that pipeline is properly completed and supported before being put under test except as hereinafter detailed.


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a.

In addition to any tests of individual joints or other interim tests that may be specified elsewhere, submit all parts of the pipeline to a final test. b. Notwithstanding the foregoing, carry out at any stage of construction other tests that the Engineer considers desirable to check materials and workmanship on the pipeline. c. Ensure that the obligations to perform successful tests under the Contract are achieved. J. Pressure gauges: a. Shall have a diameter of 15cm b. Shall be placed in such a way that reading is facilitated c. The scale shall be such that the test pressure is 75% of the gauge’s range d. Shall be located at the upper end of the section to be tested K. Use potable water for testing and pipeline cleaning. L. Test the pipeline in lengths between manholes or valve pits or such shorter lengths as the Engineer may direct or permit. M. Use properly designed fittings for the purpose of temporarily closing the openings in pipeline to be tested. Use fittings adequately strutted to withstand the pressure specified. N. Any defect found should be made good and the pipeline shall be re-tested at the expense of the Contractor until acceptable test results are achieved.

4.1.24 Pressure Pipelines A. Divide pressure pipelines into sections not exceeding 500m in length. B. Test each section separately. C. Before pressure testing is started, re-check the pipes and the valves for cleanliness, and re-check the operation of all valves. Cap off the "open" ends of the pipeline (or sections thereof) with blank flanges or cap ends additionally secured where necessary with temporary struts and wedges. Complete all thrust blocks and fasten securely all pipe straps and other devices intended to prevent the movement of pipes. D. Apply test pressure to the entire pipeline or section being tested to either the design test pressure specified in the drawings or 1.5 times the working pressure. Immediately prior to commissioning, complete the pipeline and retest the entire pipe main. E. No testing will be permitted until seven days have elapsed after the thrust blocks and other holding down works have been completed. F. Fill each pipeline or section with water or air as applicable. G. Filling of pressure pipeline shall proceed at the following rate: Filling Rate for Pressure Test DN

H. I. J. K.

L. M. N. O. P.

l/sec

DN

l/sec

DN

l/sec

150 1.0 300 3.0 500 9.0 200 1.5 400 6.0 600 13.5 250 2.5 450 7.5 700 16.5 Raise the pressure in the pipeline by pumping water or air until the site test pressure is attained in the lowest part of the section. Maintain at this level by further pumping until it is steady for a period of not less than 1 hour. Monitor the pipeline over a period of 1 hour without further pressurization. At the end of this period, measure the reduced pressure in the pipeline, the original test pressure restored by pumping and the loss measured by drawing off water or air from the pipeline until the pressure has fallen to match the reduced pressure previously noted. Ensure that the loss does not exceed 0.02 liter per mm diameter per kilometer per 24 hours for each bar of head applied. If the pipeline fails the test, locate the faults, repair and retest the pipeline until it passes. Visually inspect all exposed pipe, fittings, valves and joints during the tests. Ensure that all valves in the pipeline are satisfactorily operating under working pressure and that the pipelines have been finally cleaned out as specified. Do not test pipes against closed valves.

4.1.25 Gravity Pipelines B. For gravity pipelines laid in steep gradients, test sections may be reduced in order to remain within the limits of test pressure specified herein. C. Gravity pipelines shall be subjected to an internal pressure equivalent to the depth of pipe plus 1m measured from the invert level. Contract 106 , Volume II

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D. The minimum pressure shall be equivalent to 5m depth and the maximum pressure shall be equivalent to 15m depth. E. After the pressure has been applied continuously for one hour the pipeline will be inspected. No pipeline will be accepted if leakage is detected at joints or through the barrel of the pipeline. Moist or “sweat” surfaces are considered a leakage. Lines DN600 A. Test all non-pressure pipelines up to and including 600mm nominal internal diameter after completion of concrete or granular bedding up to the soffit of the pipeline. Clear the bedding of pipe joints to allow visual inspection for leaks. Ensure that the trench is kept dry. B. Apply water lower end of the pipes at stages to ensure removal of trapped air from the system. The minimum required head for testing of either depth to invert plus 1.0m (at lower end of pipe), or 5.0m, whichever is the greater. C. After filling the pipe, maintain the water head continuously over a period of 60 minutes then the pipe joints shall be inspected. D. No pipeline will be accepted if leakage is defected at joints or through the barrel of the pipeline. E. Moist or sweat surfaces are considered a leakage. Lin es > DN600 A. The non-pressure pipelines over DN 600mm nominal internal diameter shall be checked against leakage by visual inspection from inside, after backfilling and at least 7 days from removing the dewatering system and restoring ground water level to it’s original level. B. Both ends of pipeline shall be kept dry until finishing the visual inspection.

4.1.26Deflection Measurement s 4.1.27 PVC-u Pipes A. After a line of PVC-u pipes has been installed, hydrostatically tested, and the trench backfilled, and the dewatering removed, draw a pig or ball through the pipeline, so sized that it will not pass any point in the pipeline which is deflected by 3%. a. If the test indicate that the deflection may exceed the permitted value, replace the pipe or the pipes. Remove from site any pipe or pipes which fail the deflection checks. Do not incorporate in the permanent works. b. Apply the deflection checks on all replaced pipes. Carry out deflection checks also on adjacent pipes for 50m either side of the removed pipes.

4.1.28 GRP – Pipes A. Obtain satisfactory initial deflection test results for sections of pipeline laid between manholes: a. Use a suitable mechanized device to the approval of the Engineer for gauging pipe deflections. Maintain devices for gauging pipe deflections in good working order. Submit calibration certificates before every period of use b. For pipes of less than 600mm diameter: Diametric dimensional measurement of the pipe, both vertically and horizontally shall be made and recorded. Each deflection measurement taken along the length of the pipeline shall be identified and recorded. Provide a continuous print out or a visual display of the measurements on a remote monitor. The device shall be calibrated before each pipe length is tested. c. For pipes of 600mm diameter and greater: Measure deflection by physical entry into the pipes. Use a regularly calibrated telescopic spring loaded graduated rod to measure percentage of deflections in each diameter. Provide a suitable trolley to facilitate access into the pipe. Record all measurements. B. Measure the horizontal and vertical deflections as follows: a. For pipe length greater than 3.0m 1. at each end of line at points 100mm away from the joint 2. 1.5m away from the joint and at 3. 3.0m intervals thereafter. b. For pipe lengths of less than 3.0m 1. at each end at a point 100mm away from the joint 2. at the mid-point. c. For GRP pipes installed with granular bed and surround, take measurements on at least three separate intervals as follows:


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1.

d. e.

f. g. h.

i.

Test I: After the pipe surround material has been placed and compacted to 150mm above the pipe crown. Do not proceed with further pipe laying/backfilling until this test has been satisfactorily completed 2. Test II: On completion of all backfill material up to ground level but before the dewatering is removed. Take this measurement within one day of the completion of backfilling 3. Test III: Immediately prior to the issue of a Provisional Acceptance Certificate For GRP pipes with concrete surround one deflection test shall be carried out immediately after placing concrete surround, preferably before hardening of concrete For pipes exhibiting any negative vertical deflection in the vertical in Test (I) and pipes exhibiting any deflection in excess of 2% in Test (II) or 4% in Test (III), expose the pipe and replace and re-compact the surrounding bedding material If the deflection exceeds 7% replace the pipe Rejected / replaced pipes must be taken away from Site Deflection of pipes exposed for re-compaction or replaced for other reasons shall be remeasured as specified before. Carry out deflection checks on adjacent pipes for 50m either side of the re-compacted or replacement pipes Tabulate the results of the deflection measurements. Submit copies of the results to the Engineer immediately after each set of measurements has been taken.

4.1.29Protectio n of Finish ed Work Protect pipe and aggregate cover from damage or displacement during backfilling operation.

5

Connections To Existing System

A. Before carrying out any work on the existing system the Contractor shall obtain written permission from the Operating Authority. B. Prior to start of works the Contractor shall submit for the Engineer’s approval a detailed working program and method statement. C. The Contractor shall also propose and adopt a method, to be approved by the Engineer, to monitor the ground water level over the full length of the existing pipelines. D. Upon commencing work the Contractor shall excavate to locate the point of connection, remove the plug or cap (if provided) and start laying and jointing pipes from the manhole. E. The Contractor shall take adequate precautions to ensure that no constructional debris from his working area enters any existing manhole or chamber or pipe. F. The Contractor shall take adequate precautions to ensure continued support to existing installations. G. Dewatering shall not result in the flow of water along the pipe zone material. H. Before commencing any dewatering works in the vicinity the Contractor shall undertake a deflection survey and CCTV survey of the existing pipeline from the point of connection to the next upstream and downstream manhole. He shall repeat the deflection survey and CCTV survey on completion of the connection and removal of the dewatering installation and at the end of the maintenance period. The deflection surveys shall measure vertical and horizontal pipe deflections at 2m intervals and at each side of a joint. Should the Contractor's method of working cause a change in the deflection of the existing pipeline or adversely affect the pipeline in any way, then he will be required to reinstate it at his own cost to a condition acceptable to the Engineer. I. The Conditions of the pipeline should be identified before any connection work locally is carried out. J. Certain manholes are located within recently improved paved areas. It is the responsibility of the Contractor to seek the necessary permissions for his proposed method of working for the connections to these manholes.

6

Continuit y of Flow

A. The construction of the new works may necessitate the replacement of existing pipelines or manholes. B. The Contractor shall provide temporary facilities to ensure the continuity of flow service, until the works have been completed, commissioned and taken over by the Operating Authority. C. The Contractor shall be deemed to have included all the necessary costs for the required temporary works in his rates. D. The Contractor shall not be entitled to any additional costs or extension of time arising from these temporary works.


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Section 02732

7

Pipelines

Subsurface Drainage 7.1.1 General A. Should the Soils Investigation Report indicate poor subsoil drainage conditions, it will be necessary to install a subsurface drainage system. The purpose of the subsurface drainage is to improve percolation of water, and to maintain a non-saline water table at a level that provides desirable plant growth conditions, increases the usability of areas for recreation, prevents structural damage and drains remove only excess water. B. The subsurface drainage system shall comprise a network of slotted collector pipes and un-slotted transporter pipes to be connected to centralized soak-aways. The pipe lines shall be constructed of the materials and to the form of construction specified, and to the lines and levels shown on the drawing, unless otherwise approved by the Engineer: C. Soak-aways shall be as indicated in detail drawings. Locate soak-aways at low points in green areas as directed by the Engineer. D. Also refer to respective Section of the Contract Documents for subsoil drainage and storm water systems.

7.1.2 Collector Pipes A. Collector pipes shall be slotted PVC-u pipes conforming to ISO 161/1 class 16. The slots shall be machine cut at the manufacturer’s works and shall be arranged in two longitudinal rows. The rows shall have 90 degree radial separation. The slots shall be staggered with a pitch of 150mm. The minimum gross area of slots per unit length of pipe shall be as given below: Nominal Diameter (mm)

Slot Area ( mm2)

110 160 200 250

1000 1720 2200 2720

B. Joints between pipes shall be of a type that presents no obstruction to drain-cleaning equipment, which employs a self-intruding, high pressure hose, working from manhole.

7.1.3 Transporter Pipes A. Transporter pipes shall be un-slotted PVC-u pipes conforming to ISO 161/1 class 16.

7.1.4 Depth and Spacing Of Laterals A. The depth and spacing of drainage lines depends on the texture of the soil to be drained. Sandy soils permit more rapid movement of water than do heavy clay soils, and therefore lines may spaced farther apart and deeper in sandy soils than in clay soils. If drains are spaced too far apart, the central portion between lines will remain poorly drained. Typical Depths and Spacing of Drainage Texture

Spacing (m)

Depth (m)

Clay, Clay loam

9 – 20

0.75 – 1.00

Silt loam

18 – 30

1.00 – 1.20


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Sandy loam

30 – 90

Organic soils

24 – 60

1.10 – 1.40 1.10

– 1.40

7.1.5 Filters and Envelopes A. Filters are permeable materials, typically non-woven fabric, but may include sand and gravel, placed around the drainage pipe or envelope to restrict migration of non-colloidal particles from the surrounding soils.

7.1.6 Drainage Coefficient A. The drainage coefficient is the depth of water expressed in millimeters (mm) which must be removed in twenty four (24) hours to drain any area satisfactorily. For porous sandy soils with flat topography, the approximate drainage coefficient is 7.6 mm.

END OF SECTION


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Appendix 1

Municipality Guideline for Road Cutting

Appendix 1, Municipality Guideline fo r Road Cutting 1

Backfilli ng Of Trenches & Excavations In Roads, Parkin g And Sidewalks 1.1.1 Trenches and Excavation in Large Dimensio ns

Trenches and Excavations in Asphalted road/tiled areas under the control of Abu Dhabi Municipality shall be backfilled as soon as practicable after the services works have been approved. The following methods of Backfilling shall be adopted.

1.1.2 Backfi ll between Concrete Surrou nd for Pipe & Pavement Level The Backfilling between top of surrounding concrete for pipes and finished pavement level shall consist of three main items. The details and descriptions of these three items are as follows: A. Formation of Embankment B. Formation of Sub-grade C. Reinstatement of specified thickness of road Construction

1.1.3 Formation of Embankment The depth exceeding 50 cm below specified thickness of Road Construction shall be considered as Embankment. Excavated material found suitable shall be used for embankment fill, if not, the material shall be obtained from borrow pits in Al Wathba or Sweihan areas after approval form the Representative Engineer of Abu Dhabi Municipality's Road Section. The acceptance of the quality of the material shall be subjected to the approval of the Central Eng. Labs. of Abu Dhabi Municipality. The borrowed material shall conform to the following Specifications.

1.1.4 Embank ment Fill Material Sieve Analys is

Percent Passing

No. 40 (0.425 mm) No. 200 (0.075 mm) Max. dry density Opt. Moisture Content Plasticity Index CBR Value at 90% Compaction

50 Max. 25 Max. 1.80 g/cc (min.) 17% (max.) 6 (max.) 10 (min.)

Required soaked value corresponding to 90% of the maximum dry density shall be equal to or greater than (10) percent when determined by ASTM Standard Method D-18836-61 at optimum moisture content applying 10, 25, 56 blows on three different samples. The samples shall be soaked for a period of four days in water and tested immediately afterwards.

1.1.5 Placin g and Compacti on Backfilling of the embankment shall be formed in uniform horizontal layers not exceeding compacted thickness of 30 cm for the full width of the trench. Each layer shall be watered, mixed and compacted thoroughly to obtain minimum 90% compaction of the relevant max. dry density of the material.

1.1.6 Compaction Tests Each layer shall be checked by Abu Dhabi Municipality Central Engineering Laboratories according to AASHTO (T191) determination of density in place by sand cone method. Required numbers of the density tests shall depend upon the area and dimensions of the trench.


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1.1.7 Formation of Sub-Grade The Sub-grade thickness of 50 cm shall be laid between top of embankment and specified thickness of road construction. This item of backfilling shall consist of granular material having minimum 25% soaked CBR Value at 95% compaction of max. dry density. Required soaked CBR value shall be determined by ASTM Standard Method D-18836-61 at optimum moisture content applying 10, 25, 56 blows on three different samples. The samples shall be soaked for a period of four days in water and tested immediately afterwards. Borrow pits of granular materials are located in Al Wathba and Sweihan areas. Contractor shall be able to start laying sub-grade after having approval from representative Engineer of Abu Dhabi Municipality Roads Section. The granular material shall fulfill the following specifications.

2

Sub-Grade Granular Material 2.1.1 Sieve Analysis Sieve ASTM 1" 3/4" 3/8" No. 4 No. 10 No. 40 No. 200

% Passing 100 80-100 70-100 50-90 40-80 20-60 5-20

Maximum dry density Optimum moisture content Plasticity Index CBR Value

1.85 g/cc (min.) 15% (max.) 6 (max.) Min. 25% at 90% compaction

2.1.2

Placing & Compactio n

The sub-grade shall be laid in two compacted layers of 25 cm each. Material for each layer shall be watered with the rate of optimum Moisture Content, mixed and compacted thoroughly with roller or small pneumatic compactor to obtain 95% compaction of the relevant max. dry density. The surface of the sub-grade shall be smooth, shaped in accordance with the project elevations and a tolerance of +2 cm in all directions.

2.1.3 Compaction Test Each layer of sub-grade shall be checked and approved, by Abu Dhabi Municipality Central Engineer Laboratories according to AASHTO (T-191) determination of density in place by sand cone method. The Numbers of density tests to be carried out shall depend upon the area and dimensions of the trench.

3

Reins tatement Of Thickness Of Road

For backfilling purpose existing thickness of layers and type of materials shall be adopted. The specified thickness of road construction shall consist of the following items. A. Sub-grade (15 – 30 cm) according to existing structure OR B. Filter Material (Provisional) 30 cm C. Geo-textile fabric (Provisional) a. Sub base (15 – 25 cm) b. Bituminous prime coat c. Aspahltic concrete base course d. Bituminous tack coat e. Asphaltic concrete wearing course

3.1.1 Sub-Grade (15 – 30 cm ) The layer of sub-grade shall be constructed in accordance with the specifications. Contract 106 , Volume II

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Appendix 1


3.1.2 Filter Material (30 cm) Provisional The filter material shall be crushed aggregate from Abu Dhabi. This material shall be laid in lifts of not less than 15 cm compacted until the foundation is stabilized and no settlement will occur. The total thickness of the layer shall not be less than 30 cm. Only after inspection and approval of the representative Roads Engineer laying of Geo-textile fabric and sub-base may be allowed. The filter material shall consist of crushed aggregate (5 cm to 2 cm size) as per specification of Town Roads Section.

3.1.3 Geo-Textile Fabric (Provi sional) Wherever in existing road construction geo-textile fabric will be found, the same type of item shall be laid over the filter material complying with the following requirements. The geo-textile fabric furnished by the Contractor shall be of an approved grade suitable for placement and shall confirm to the following specifications.

3.1.4 CBR TEST Av. Piston force (DIN 54307) Elongation Calculated Av. Tensile Strength Elongation Load at 20% Elongation

1900 N 50% 18 kN/m 78% 6.8 kN/m

3.1.5 Fall Concrete Test Hole Diameter

19 mm

3.1.6 Pun cture Resistance o

110 cone 6 mm dia

500 N

3.1.7 Grab Test (DIN 55858) Length Tensile Strength Elongation

Length Diagonal 810 N/25 mm 70%

850 N/mm 80%

3.1.8 Strip Test (DIN 53857) Tensile Strength Elongation

11 kN/m 60%

12 kN/m 60%

3.1.9 Plain Strain Test Tensile Strength (ASTM D111)

270 N

3.1.10Water Permeabili ty Permeability Flow at 10 cm water column

10 x 10* cm/sec. 2 10 L/Sec/m

3.1.11Pore Sine d 50% d 90%

40 unilyon 55 micron

Weight (DIN 53854) Thick ness (DIN 53855)

230 G/m 12 mm

Roll size Geo-textile finish


2

Supplied in 100m long rolls 5m or 5.4m wide Nuddled and thermic bonded pre-compressed

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Appendix 1


3.1.12Materi al Polypropylene (PP) / Mx(CH2-CH-CH3) 3.1.13 Life A. In normal geo-technic conditions unaffected by acids, alkalis bacteria humidity and decay must be protected against direct sunlight. B. The geo-textile fabric shall be a woven or non woven fabric consisting only of a long chain polymetic filaments or yarn formed into a suitable network such that the filaments or yarn retain their relative position to each other. C. The fabric shall be inert to commonly encountered chemical properties of the in-situ soil and water. Installation shall comply with the following requirements unless otherwise directed by the Engineer. D. The surface to receive the geo-textile fabric shall be prepared by spreading sand to a relatively smooth condition free of obstruction, depressions and debris. E. The geo-textile fabric shall not be laid in a stretched condition, but shall be laid loosely with the long dimension parallel to the centerline of the pavement. F. In the event the width of the proposed area for fabric requires more than one panel of fabric, the panel shall be overlapped a minimum of 15% of the panel width. G. To prevent slippage of the overlapping fabric, the area of overlap shall be stabilized as approved by the Engineer with pins, anchor, blocks or aggregate piles. H. In the event construction machinery is used to place the fabric, the working platform for the machinery shall be the soil and not the previously laid fabric. I. The damaged or displaced fabric during installation or during placement by overlaying aggregate material or working machinery shall be replaced at the contractors expense.

3.1.14Granular Sub-Base (15-25cm) 3.1.15 Materi al The granular sub-base material shall be a mixture of Abu Dhabi/Buraimi Wadi gravels and soil from Swaihan or Wathba borrow pit with the proportions of 80% and 20% respectively.

3.1.16Grading The grading of the mix shall conform to the following limits:

ASTM Sieve

Percent Pass in g

2½" 3/4" 3/8" No.4 No.10 No.40 No.200

100 80 - 100 60 - 90 45 - 72 30 - 54 10 - 34 5 - 12

3.1.17Physic al Properties The physical properties of the mix shall be as follows: Max. dry density Liquid limit Plasticity Index Sand Equivalent Loss by abrasion

2.07 g/cc (minimum) 25% (max.) 6% (max.) 25% (min.) 40 maximum

The soaked CBR Value of the mix shall not be less than 60% corresponding to 100% of the relevant max. dry density when determined by ASTM standard method D-18836-61 applying 10, 25, 56 blows on three different samples. The samples shall be soaked for period of four days in water and tested immediately afterwards.


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Appendix 1


3.1.18Placin g And Compacti on Mixing of the material from two different sources shall be carried out by motor graders in open place. Water at the rate of + 1% from optimum moisture content may be added during mixing operation. The premixed material shall be laid over the smooth surface of sub-grade in the trench. Sub-base more than 20 cm in thickness shall be laid in two layers. The layers of sub-base shall be thoroughly compacted to obtain 100% compaction of the relevant max. dry density. The surface of the sub-base shall be smooth, shaped in accordance with the project elevations with a tolerance of + 1 cm in all directions.

3.1.19Compaction Tests The acceptance of sub-base layer shall be subjected to the approval of Central Engineering Laboratories after carrying out the density tests in place by sand cone method (AASTTO T-191). Required numbers of the density test shall depend upon the area and the dimensions of the trench.

3.1.20Bituminous Prime Coat The liquid asphalt for use as prime coat shall be medium curing out back asphalt MC2 conforming to table No. 1 of the specification. The applicable specification for prime coat shall be to AASTO Standard (M82-75). The rate of application of prime coat shall not be less than 0.7 liter per square meter and not more than 1.50 liter per square meter.

3.1.21Asphaltic Concrete Base Course (10 Cm) 3.1.22General Bituminous base course shall be laid over compacted sub-base treated with bituminous prime coat (medium curing type). The material used shall consist of fine and coarse mineral aggregate and mineral filler uniformly mixed with hot asphaltic cement.

3.1.23Materi als Mineral aggregate for use in base course shall be black crushed aggregate obtained from crushing naturally occurring stone from the Wadis in Abu Dhabi. All aggregate shall have crushed faces.

3.1.24Coarse Aggregate Coarse aggregate shall be crushed stone from the Wadi in Abu Dhabi and be generally spherical or cubical in shape. The flakiness and elongation particles in any grading group shall not exceed 20.

3.1.25Fine Agg regate Fine aggregate for use shall conform to AASHTO M29-70. The aggregate shall consist of natural sand or of sand prepared from stone or gravel or combination thereof. It shall consist of hard, tough grains, free from injurious amounts of clay, loam or other deleterious substances. Sand for the Asphaltic Concrete base course shall consist of crushed and natural screened sand. Use of dune sand or desert sand shall not be permitted. The grading of fine aggregate from any one source shall be made upon representative samples of fine aggregate from such sources are proposed for use. Fine aggregate having a variation in fineness modules greater than +0.25 from the fineness modules of the representative sample may be rejected. The grading requirements shall conform Table 1, AASHTO Specification for fine aggregate for bituminous paving mixtures - M29-70 providing the resulting mixture meets the stability value (Marshall) as specified.

3.1.26Filler Mineral filler shall consist of finely divided mineral matter such as rock dust, slag dust, hydrated lime or hydraulic cement. It shall be free from organic impurities, and at the time of use, shall be sufficiently dry to flow freely and shall be essentially free from agglomerations. The material used shall conform to AASHTO M17-77. Contract 106 , Volume II

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3.1.27Bit umen Bitumen shall be of penetration grade 60-70.

3.1.28Combined Gradatio n The gradation of the combined mineral aggregates for bituminous base course shall be as follows: Sieve Sizes Square Opening 1½" (38.1 mm) 1" (25.4 mm) 3/4" (19.0 mm) 3/8" (9.51 mm) No. 4 No. 8 No. 10 (2.00 mm) No. 20 (0.84 mm) No. 30 No. 40 (0.42 mm) No. 50 No. 100 No. 200 (0.074 mm)

% Passing By Weight 100 90 -100 70 - 90 55 - 75 45 - 62 35 - 50 ------19 - 30 13 - 23 13 - 23 7 - 15 3-8

3.1.29Properties of Mix The asphaltic concrete mix shall conform to the following requirement: Marshall stability minimum Kg. 850 Flow mm Stiffness ratio Kg/mm minimum 300 Percentage voids total mix Voids filled Bitumen content (60 - 70) by weight of mix

2-5 3-6 35 - 75 4.0% - 5.0%

3.1.30Job Mix The Contractor shall submit his job mix design to the Engineer at least 30 days in advance of commencing the particular works. Details regarding source, properties and test results of all mineral aggregates filler, asphaltic cement shall be submitted together with a single definite percentage of aggregate passing each required sieve size, a single definite temperature at which the mixtures are to be emptied from the mixer, a range of temperature at which the mixtures are to be delivered on site, all of which shall fall within the acceptable limits of mix specification.

3.1.31Sampling All mixtures delivered on site shall conform to agreed job mix design. The Engineer shall collect as many samples of material and mixtures both for Laboratory and on site as he considers necessary for tests purposes. No time or date limit shall apply to sampling of mixtures. The Engineer may if he considers it necessary change job mix if results obtained from collected samples give unsatisfactory results. No claim for delay shall be entertained should the work be stopped due to unsatisfactory material on site. Any change in material source or characteristics shall be notified to the Engineer. In such event a new job mix shall be prepared and approved before the use of new or changed material is authorized.

3.1.32Constr uct ion Requir ement The mix shall be laid as asphalt finisher to line and level as required. The mix shall be placed on the road at a temperature not less than 150o C. The Engineer may stop laying and compaction of asphalt if he considers the prevailing wind and resulting sand storm is injurious to the asphalt. No claim shall be entertained as a result of this action. During the laying of asphalt and until the completion of


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compaction no standing plant shall be allowed on the road surface. Minimum allowable thickness after compaction shall be 8 cm.

3.1.33Degree Of Compaction The layer of Asphaltic Concrete Base Course shall be thoroughly compacted to obtain a minimum 98% of maximum marshall density of mix.

3.1.34Surface Toleranc e The surface tolerance of a compacted layer when measured with a four meter straight edge shall not exceed + 5 mm in any direction. the surface shall be declared unacceptable if more than 10% of gross area exceeds the allowable tolerance.

3.1.35Bituminous Tack Coat A. The tack coat shall be liquid asphalt rapid curing type RC-2 or as directed by the Engineer and conforming to table No. 1 of the specification. B. The specification for tack coat shall be to a AASHTO designation M81 - 75. C. The rate of application of tack coat shall not be less than 0.3 liter per square meter and not more than 0.6 liter per square meter.

3.1.36Asphaltic Concrete Wearing Course A. Asphaltic Concreting Wearing Course shall be laid on newly laid base course. B. Wearing Course shall be laid and compacted on either regulated surface or Base course which had been treated with RC-2. C. Physical requirement of mineral aggregates, filler, bitumen, job mix, method of sampling, trial strip and degree of compaction shall be as specification for bituminous base course. D. Sand for the Asphaltic Concrete Wearing Course shall consist of crushed and natural screened sand. Dune sand or desert sand shall not be allowed.

3.1.37Combined Gradatio n The gradation of the combined mineral aggregates for asphaltic Wearing Course shall be according to ASTM C136-46 and conform to the following grading limits: Sieve Sizes Square Opening

% Passing by Weight

3/4" (19.00 mm) 1/2" (12.7 mm) 3/8" (9.51 mm) No. 4 (4.76 mm) No. 10 (2.00 mm) No. 20 (0.800 mm) No. 40 (0.42 mm) No. 200 (0.074 mm)

93 - 100 ------64 - 77 48 - 61 31 - 42 17 - 25 4- 8

3.1.38Properties of Mix The asphaltic concrete shall conform to the following mix design parameters: Marshall Stability Minimum Kg. Percentage asphaltic cement (60-70) by weight of 5 - 6 Flow mm Stiffness ratio Kg/mm (Minimum) Percentage voids total Mix Voids Filled

100 kg 2-5 350 2-5 70 - 85

3.1.39Surface Toleranc e The level of the compacted finished surface of the individual layer shall fall within the following maximum variation when measured with a four meter straight edge in any direction. Contract 106 , Volume II

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Regulating course Wearing Course

+ 3 mm + 3 mm

The surface shall be declared unacceptable if more than 10% of gross area exceeds the allowable tolerance.

3.1.40Degree of Compaction The Asphaltic Concrete Wearing Course shall be thoroughly compacted to obtain minimum 98% of relevant maximum marshall density of the mix.

4

Backfill ing Of Excavation & Trench es In Paved/Tiled Car Parki ng

The Method for backfilling of excavation and trenches in tiled Car Parking shall be the same as one for asphalted roads up to the layer of sub-base. Interlocking blocks shall be laid over a layer of crushed black sand over sub-base layer in conforming to the grades thickness and typical section of the existing car parking.

4.1.1 General Pre-cast Interlocking Concrete Tiles are designed to form a structural element and the surfacing of pavements having the unit-to-unit joints filled so as to develop frictional interlock. Interlocking concrete blocks shall be colored pre-cast paving blocks from approved manufacturers. Their thickness shall be of 6 cm for sidewalks and footpaths and 8 cm for vehicular areas. This recommended specification is the result of incorporation the results of our latest experimental findings into existing specification.

4.1.2 Material 4.1.3 Cement The cement to be used in the manufacture of paving blocks shall be sulphate resisting Portland cement Type-V in accordance with ASTM C150.

4.1.4 Aggregates The aggregates to be used in the manufacture of the paving blocks shall be from crushed rocks and from approved sources, conforming to the requirements of BS 882. The sand shall be washed and free from deleterious substances. The aggregate shall not contain harmful material such as coal, mica, shale or similar laminated materials, which causes strength deterioration. In addition, the aggregates shall meet the following requirements. Permissible Limit No

Properties

Test Method Course Aggregates

Fine Aggregates

BS 812

BS 882

BS 882

ASTM C142

Max 3% Colour less to yellow Max 0.5% Max 2%

1

Particle Size Distribution

2

Clay Silt & Dust

3

Organic matter content, finely distributed matter expansive Solids

4

Water Absorption

ASTM C128

MAX. 1% Colour less to yellow Max 0.5% Max 2%

5

Specific Gravity

ASTM C127

Min. 2.6

Min 2.6

6

Shell Content

BS 812

Max 10%

Max 10%

7

Flakiness Index

DIN 4226

Max 25%

-

8

Elongation Index

DIN 4226

Max 25%

-

9

Soundness (MgSO4) 5 cycles

ASTM C88

Max 5%

Max 5%

10

Sulphate Content (SO 3)

DIN 4226

Max 0.3%

Max 0.3%

11

Chloride Content (Cl)

DIN 4226

Max 0.04%

Max 0.04%


DIN 4226

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12

Aggregate Crushing Value

13

Los Angeles Abrasion

BS 812

Max 25%

-

AASHTO T96

Max 25%

-

4.1.5 Water The water to be used in mixing and curing the pre-cast concrete blocks shall be of drinking quality, clean and free from injurious substances of sewage, oil, acids, strong alkalis, vegetable matter, clay and other such substances harmful to be finished product.

4.1.6 Pigment Pigment to be used in manufacturing of pre-cast concrete interlocking blocks shall be in the form of dry, soft powder and shall not contain chemical compounds capable of affecting adversely the setting and development of strength of the cement and other properties of the finished products shall be compatible with other admixtures used in the same mix.

4.1.7 Design Mix COMBINED GRADING Dia. Limi t* (% Passing) 8.00 100 4.75 72-82 2.36 41-61 1.18 25-46 0.60 16-31 0.30 8-17 0.15 3-8 0.075 0-3 *Notes: a) Smooth, non-gap graded curve is expected. b) Central tendency should be attempted.

4.1.8 Cement Contents 3

420 Kg/m - 430 Kg/m

3

4.1.9 Water Cement (W/C) Ratio 0.40 - 0.42

4.1.10Pigment Content 0% (By mass of cement) ≤1

4.1.11Physic al & Mechanic al Properties The physical and mechanical properties of the inter locking concrete blocks shall conform to the following requirements:


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Property & Permissible Limi t 3

1 2 3 4

5

6

Average Bulk Density (T/m ): ≥ 2.375 (min. 48 hrs immersion) 3 Minimum Bulk Density (T/m ) = 2.330 (min. 48 hrs. immersion) Average Bulk / Apparent Density Ratio ≥ 0.88 (min. 48 hrs. immersion) Minimum Bulk / Apparent Density Ratio = 0.8788 (min. 48 hrs. immersion) Average Water Absorption (%) ≤ 5% (min. 48 hrs. immersion) Maximum Water Absorption (%) = 5.5% (min. 48 hrs. immersion) 2 Average Compressive Strength ≥5 2 MN/m (min. 48 hrs. immersion) 2 Minimum Compressive Strength = 47 MN/m (min. 48 hrs. immersion) (DIN 18-501) The abrasion resistance of the interlocking pre-cast concrete blocks, when tested as per ASTM C418 shall not have volume loss greater than 15 cu.cm per 50 sq.cm and the average thickness loss shall not exceed 3 mm. Average Flexural Strength ≥ 5 N/ sq.mm (Dry) Minimum Flexural Strength = 4.5 N/sq.mm (Dry) (NEN 700 = Netherland’s Standards) Note: At least 4 out of 5 of all tested specimen shall pass the average criteria for all upper physical and mechanical properties.

4.1.12Abrasi on Resis tance Test The abrasion resistance of the interlocking pre-cast concrete blocks, when tested as per ASTM C418 shall not have volume loss greater than 15 cu cm per 50 sq cm and the average thickness loss shall not exceed 3 mm.

4.1.13Flexur al Streng th A. Average flexural strength ≤5 N/ sq mm (Dry) B. Minimum flexural strength = 4.5 N/sq mm (NEN 700 = Netherland's Standards) Note: At least 4 out of 5 of all tested specimens should pass the average criteria for all upper physical and mechanical properties.

4.1.14Dimensional Toleranc e Length or width of unit shall not differ by more = 1.6 mm from designated dimensions. Height of unit shall not differ by more than = 3.2 from the specified standard dimensions.

4.1.15Quality Contro l Assurance The Quality Control Assurance Program following covering sampling and testing is an integral part of this Specification. Full compliance with the said program is required.

4.1.16Plant Inspecti on and Approval A. Prior to approval of a supplier to produce pre-cast pavers the supplier's facilities will be inspected by the Engineer. B. The plant inspection will cover all aspects of the administration, operation, personnel resources, manufacturing method, quality control procedures, condition of plant, component materials, the curing/storage facilities and labeling/identification procedures for the pre-cast pedestrian and vehicular pavers. C. Based on this inspection the Engineer will notify the Contractor of any improvements that are necessary before provisional approval of the plant will be issued. In the event improvements are outstanding, a follow-up inspection will be made by the Engineer before the plant is considered for approval to produce pavers. D. During the actual production of pavers the Engineer will periodically inspect the plant to ensure continued compliance with the provisional approval.


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4.1.17Manufacturer's Plant, Produc tion & Testin g Q A Procedures A. All pavers shall be produced strictly in accordance with the requirements of the Specifications. The plant, materials, equipment and method of manufacture shall be provisionally approved by the Engineer prior to actual production of the pavers. B. Pavers shall be manufactured using the materials and proportions approved at the time of provisional approval of the facility. No variation of the mix proportions will be allowed unless authorized in writing by the Engineer. Each production batch (approximately 400 units) shall have clearly ink stamped with indelible ink on one of the side faces of each paver the manufacturer's name or logo for identification purposes. Also, each batch shall have affixed a label giving the batch identification number the date of casting and the date of removal from the curing chamber. C. Pavers shall be clearly identified by fixing a tag to each and every bundle/batch indelibly marked with the name of Abu Dhabi Municipality on one side of the label and the Contract Number and Contractor's name on the other side. D. The manufacturer shall provide, install and operate a permanent material laboratory at the site of manufacturing of the pavers fully equipped and staffed with qualified Quality Control manpower to undertake all tests as required and necessary to assure compliance with the Specifications and these procedure. The aforesaid test laboratory shall perform independent random testing of the pavers at the manufacturer's site. All test results shall be kept on file and provided to Government representatives. The Abu Dhabi Municipality's consultants shall have the right and shall be allowed to use the test laboratory.

4.1.18In-House Quality Ass urance Testi ng Procedures From every day of production specimens will be selected at random by designated manufacturer's Quality Control Personnel and subjected to the following tests: Dimensional Tolerance: Water Absorption: Bulk Density: Apparent Density: Compressive Strength: Flexural Strength:

10 Units 10 Units 10 Units 10 Units 5 Units 5 Units

For the first four tests the very same units should be used then split half for compressive and half for flexural strength tests. Test procedure should be in accordance with the relevant test specifications. Sampling should exclude the best 20% and be uniformly distributed within the remaining 80% based on visual inspection.

4.1.19Testi ng & Reporting The daily test reports shall be submitted to the Municipality and Consultant for appropriate paver batches, pallets or bundled groups delivered to the site.

5

Independent Quality Ass urance Testin g Procedures

On at least a bi-weekly basis representative of the independent testing company approved by the Government of Abu Dhabi shall inspect the production facility and report on the following: A. B. C. D. E.

Aggregate mix proportions Cement content of mix Water cement ratios Color weight per mix Curing facilities and procedures

Samples shall be taken by the Independent Testing Company. The samples shall be tested by the Independent Testing Company for testing as follows: Dimensional Tolerance: Water Absorption: Contract 106 , Volume II

15 Units 15 Units Page 346 of 589

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Bulk Density: Apparent Density: Compressive Strength: Flexural Strength: Abrasion Test:

15 Units 15 Units 5 Units 5 Units 5 Units

For the first four tests the very same units should be used. Then they should be split into three groups of 5 each for the remaining three mechanical tests. Test procedures should be in accordance to the relevant test standards designated in the specifications. Sampling should be uniformly covering a range excluding the best 20% as decided by visual inspection. A report shall be issued to the Manufacturer, Municipality, Consultant and Contractor covering each inspection.

6

Contractors Quality Assur ance Testing Procedures

The Contractor should carry out a quality assurance program on at least one month basis. Similar to that of the manufacturers in-house program under close supervision of the engineer as frequently as required. Samples can be removed after placement as well if any doubts arise. There will be no limit of testing to satisfy the engineer's and department requirements.

7

Certi fication s Of Suppliers Of Materials

In addition to the above all suppliers of materials used in the manufacture of the pavers shall provide the following certifications for all deliveries to the manufacturer: A. Certification of the supplier that the materials delivered meet the applicable Specifications. A minimum of one certification shall be required covering all deliveries made during a 24 hours period. B. Latest and current certification of tests conducted by an approved Independent Company on materials at the supplier's source. Such certifications shall confirm that materials at the supplier source are compliant with the Specifications and that testing by the Independent Testing Company is being carried out on at least a monthly basis. C. Originals or certified copies of these certifications shall be provided to the Municipality, Consultant and Contractor on a monthly basis. It is the responsibility of the manufacturer to obtain the certifications from the materials suppliers and distribute as indicated herein.

8

Requi rements Of On-Site Deliv ery

A. The receipts for pavers delivered for use on all Government Contracts must state the name of the Contractor, Contract Number and the identification number of each batch/bundle delivered to the site. B. Each delivery shall also be accompanied by copies of the In-house Certification and reports on the testing relevant to the batches delivered. Originals or certified copies of these documents must be transmitted to the Consultant responsible for supervision of construction for the Government, on delivery of pavers to the site. C. No pavers shall be laid on site until the Consultant receives and approves the aforesaid documentation. D. The Consultant shall be notified 24 hours in advance of pending paver deliveries. No truck shall be off-loaded until inspected by the Consultant. At the Consultant's option, test samples may be taken from the load truck and immediately checked for compressive and flexture strength at the site lab, prior to permission to off-load. At the Consultant discretion, truck loads, may be rejected based on visual and immediate test observations. Approval by the Consultant to offload the pavers does not otherwise approve the pavers pending results of the manufacture, independent and site laboratory testing and proper performance handling and installation.

9

Construc tion Details 9.1.1 Laying Course

A. The laying course shall consist of sand with a particle size of 0-4 mm (3/16") containing not more than 3% silt plus clay by weight. The sand shall be obtained from a single source, allowed to drain before use and shall be covered with suitable sheeting to minimize moisture changes.


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B. The laying course shall be laid to a compacted depth of 50 mm. During laying the sand shall be uniform in moisture content and shall be carefully screeded to form a smooth compacted surface to receive the paving blocks. C. The profile of the laying course before compaction shall be similar to that of the finished surface. The maximum deviation from the design levels shall be 0.5 mm. D. The edge restraints to the paved area shall be laid in advance of the laying course.

9.1.2 Surface A. The paving blocks shall be laid on the sand laying course in such manner as not to disturb the blocks already laid. Each block shall be placed firmly against its neighbor so that they fit closely together. The joints between blocks shall not exceed 3 mm. B. Where blocks do not fit the edge restraints or other obstructions such as manholes or up-stands the gaps shall be filled using cut blocks. C. Blocks shall preferably be cut using a mechanical block splitter. D. Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall be checked after laying the first three rows of blocks and thereafter at regular intervals. If joints begin to open, the blocks shall be knocked together using a hide mallet. 2 E. After each 20m , or such area that has been agreed with the Engineer, has been laid the blocks shall be compacted to the required levels using a plate vibrator. 2 F. The Plate vibrator shall have a plate area of 0.20 to 0.35 m and have a compaction force of 1224 kN. Two passes of the plate vibrator shall be made in each direction i.e. 90o to each other. Fine dry sand with a particle size of 0 – 3 mm, shall then be brushed over the paving, filling of joints, and a further pass of the plate vibrator made in each direction. G. No paving shall be left un-compacted overnight except for the 1 m strip at the temporarily unrestrained edge. On completion, the finished surface level shall be within 5 mm of the design level and the maximum deviation within the compacted surface measured by a 3 m straight edge shall not exceed 3 mm. The level of any two adjacent blocks shall not differ by more than 2 mm. Any areas of paving which do not comply with these tolerances shall be removed, the sand laying course adjusted and the paving blocks, re-laid to the correct levels.

10 Backfill ing Of Excavation & Trench es In Side Walks 10.1.1Areas With Interloc king Tiles 10.1.2 Areas With Bu rnt Clay Tiles The method of backfilling the excavation and trenches in sidewalks shall be the same as for the asphalted roads up to the layer of sub-base (Clause 1.3.2). Burnt clays tiles shall be laid on a setting bed of cement mortar over the sub-base layer conforming to the lines, grade, thickness and typical cross section of the existing sidewalks.

10.1.3 Materi al Burnt (Kiln fired), extruded clay tile, natural red, unglazed, with (544 Nos.) square riffles on face surface, with ribbed underside. Colored throughout. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Dimensions Density Water Absorption Per ASTM C373: Bending Resistance Scratch Hardness Coefficient Of Thermal Expansion Modulus Of Rupture Per ASTM C674: Modulus Of Elasticity, Per ASTM C624: Wear Resistance Per ASTM C501: Chemical Resistance Per ASTM C650:

240 X 115 X 13 Mm 2200-2500 Kg/Cu Cm 1.5 -2.0% 2 30.88N/Sq Mm or approx. 308.8 KP/cm 6-7 Hardness According To Moh's Scale 4.0 X 10-6 45 - 50 Mpa 50 Gpa 15 - 20 No Visible Change

10.1.4Constr uct ion Details Laying and constructing sidewalks tiles shall be in accordance with the following procedure:


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A. Sidewalk tiles shall be as indicated on the construction Drawings and specified herein. Color of ceramic tiles shall be permanent, stain resistant and shall be red/brown and of slight color variation in the range of color, evenly distributed and as approved by the Engineer. The Contractor shall submit three samples of each range of color of tile for selection and approval of the Engineer before fabrication of tiles. B. Unless otherwise determined by the Engineer, quarry tiles shall be 240 mm by 115 mm thick. All edges shall be sharp and true. Where required, tiles shall be cut with approved power saws. Edges shall be smooth cut with a carborundum stone. Tiles with jagged or flaked edges shall not be installed. C. Leveling of natural ground surface shall be done according to the proposed grades and slopes. Objectionable material and unsuitable soil shall be removed from the site. D. A layer of selected material for sub-base shall be laid and compacted conforming to the requirements of sub-base for the pavement. E. A concrete slab of Class 'C' shall be placed and an expansion joint of pieces of bituminous preformed joint filler, 1 cm thick, conforming to AASHTO M33 and in accordance with the instructions of the Engineer will be placed every 5 meters. F. Sidewalk tiles shall be placed on a setting bed of mortar consisting of one part cement to three parts sand. G. Pointing and grouting mortar shall be dry grout mixture consisting of one part Portland cement and two parts fine sand with liquid latex additive used as a gauging liquid or as per supplier recommendations. H. Tile shall be laid symmetrically starting at centers of areas and finishing with equally cut rows on the sides. I. Placing of sidewalk tiles shall be carried out in lengths not exceeding 5 meters separated by expansion joints of pieces of bituminous preformed joint filler, 1 cm thick, confirming to AASHTO M33 and in accordance with the instructions of Engineer.

11 Reins tatement Of Curb Stones This work shall consist of the reinstatement of upstanding and flush curb stones in accordance with the following specifications and in conforming with the lines, grades and typical section shown on the attached drawings.

11.1.1Curbs For upstanding curbs elements may be pre-cast or cast in place from concrete produced in a fully automatic batching plant, while flush curbs shall be always cast in place. The curbs shall be prepared with a concrete mix containing 400 Kg/cum of sulphate resisting cement to AASHTO M-85 specifications. The mix shall conform the following gradations. ASTM Sieve 3/4" 1/2" 3/8" No. 4 No. 8 No. 15 No. 30 No. 50 No. 200

% Passing by Weigh t 100 76 - 100 60 - 80 40 - 60 22 - 42 12 - 32 7 - 23 4 - 15 2 - 10

The 28 days comprehensive strength of the concrete determined on cubes specimens shall not be less than 335 Kg/sq cm, and not less than 70% of this figure after 7 days.

11.1.2Dimens ion s Upstanding curbs shall be formed by homogenous elements 60 cm. long where required to be laid in straight lines but may be reduced to 30 cm long where required to be laid in curves.


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11.1.3Bedding & Back ing to Upstandin g Curbs Concrete class 'C' shall be used for bedding and backing of upstanding curbs. The concrete mix shall contain 220 Kg. Sulphate resisting cement per cubic meter to give a minimum cube strength of 130 Kg/sq cm after 28 days. This item shall be carried out in accordance with the lines, grades and typical sections shown on the attached drawings.

12 Reins tatement Of Pavement Markin g This work shall consist of painted traffic marking and road paint lines in accordance with the attached drawing or as established by the representative engineer from Road Section of Abu Dhabi Municipality. The pavement marking material shall be thermoplastic paint


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12.1.1Medium & Rapid-Curing L iqui d As phalts - Bitum inou s Surface Coarse

Specification Designation

AASHO

ASTM

MC -

MC -

MC -

MC -

MC -

MC -

Test

Test

0

1

2

3

4

5

General Requirements

RC - 0

Method

Flash Point (Open Tag) C

T 79

D 7310

Furol Viscosity at 82.2 Deg. C, Seconds

26,7

26,7

26,7

26,7

+

+

+

+

-

-

-

-

-

-

-

-

100-

250-

200

500

-

-

125-

300-

250

600

65,6

65,6

65,6

+

+

+

+

+

+

-

-

-

-

-

-

-

-

-

-

100-

250-

200

500

-

-

-

-

-

-

125-

300-

250

600

-

-

-

-

15 +

15+

-

-

-

-

75-

D 88

seconds

RC - 5

56,6

150

Furol Viscosity at 60 Deg. C,

RC - 4

37,8

Seconds T 72

RC - 3

37,3

75-

seconds

RC - 2

The material shall be free from water



RC - 1

150 -

-

-

-

75150

-

75150

Distillation: Distillate (percent of total distillate to 360 Deg. C) to 196 Deg. C to 225 Deg. C to 265 Deg. C

T 78

D402

to 316 Deg. C

25 -

20 -

10 -

5-

0

0

55 +

50 +

40 +

25 +

8+

-

40-

25-

15-

70

65

55

5-40

30 -

20 -

75 +

70 +

65 +

55 +

40 +

25 +

75-

70-

60-

55-

60-

20-

82

80

87

85

90

75

90 +

80 +

87 +

83 +

80 +

70 +

50 +

60 +

67 +

73 +

78 +

82 +

50 +

60 +

67 +

73 +

78 +

82 +

120-

120-

120-

120-

120-

120-

80-

80-

80-

80-

80-

80-

300

300

300

300

300

300

120

120

120

120

120

120

100

100

100

100

100

100

100

100

100

100

100

100

+

+

+

+

+

+

+

+

+

+

+

+

99,5

99,5

99,5

99,5

99,5

99,5

89,5

89,5

89,5

89,5

89,5

89,5

+

+

+

+

+

+

+

+

+

+

+

+

Residue from distillation to 380 Deg. C volume percent, by difference Test

on

residue

from

distillation: Penetration 25 Deg. C 100 gr. 5 sec. Ductility

25

Deg.

C

*

centimeter Solubility

in

carbon

tetrachloride percent

* **

T49

D5

T51

D 113

T44**

D 4**

If penetration of residue is more than 200 and its ductility at 25 Deg. C is less than 100, the material will be acceptable if its ductility at 15, 6 Deg. C is 100. Except that carbon tetrachloride is used instead of carbon disulphide as solvent Method No. 1 in AASHO T44 Procedure No. 1 is ASTM Method D4.

END OF SECTION


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Section 03100

Concrete Formwork

Section 03100, Concrete Formwork 1

Perform ance Requi rements

A. The formwork shall be sufficiently rigid and must be designed so that concrete slab, walls, and other members will be of correct dimensions, shape, alignment, elevation, and position and within tolerances as specified. B. Design Formwork to safely support all vertical and lateral loads that might be applied until such load can be supported by the concrete structure. C. All exposed corners shall be chamfered 15x15mm, In case of tanking provided to the concrete surfaces the sharp corners shall be chamfered 20x20mm and rounded to a radius of 50mm.

2

Submittals 2.1.1 General

A. Contractor shall submit the following but not limited to: a. Vertical load (Dead load and Live load) b. Lateral pressure of concrete c. Unit stress d. Safety factors for accessories e. Method of concrete placement f. Height and rate of pour g. Thickness of member h. Placing temperature i. Concrete slump and density j. Wind load k. Impact load.

2.1.2 Design Calculations Sheet A. Design calculations shall include: a. All major design values and loading conditions 3 b. Assumed value of live and dead loads; dead load of concrete = 2800 kg/m , live load = 75 2 kg/m , horizontal force = 1/100 of vertical loads c. The compressive strength of the concrete for formwork removal and for application of construction loads; wind load; impact load; rate of placement, temperature, height and drop of concrete; weight of moving equipment operated on formwork; camber diagrams d. Structural stability calculations.

2.1.3 Workin g Drawings A. Working Drawings shall include the following: a. Details of the individual panel b. Anchors, form ties, shores, lateral bracing, and horizontal lacing c. Field adjustment of forms and tolerance d. Water-stops, keyways, and inserts e. Working scaffolds and runways f. Weep-holes, cleaning holes and vibratory holes when required g. Detailed size, location, and dimension of tendon conduit in post tensioned concrete structures h. Construction joints, contraction joints, and expansion joints to conform to design drawings i. Sequence of concrete placement and minimum elapsed time between adjacent placements j. Notes to formwork erector showing size and location of conduits and pipes embedded in concrete k. Special provisions such as safety, fire, drainage, and protection from debris at water crossing l. Procedures, sequence, and criteria for removal of forms, shores, and re-shores.

2.1.4 Job Mock -Up A. Provide Mock-ups to the requirements as specified.


Page 352 of 589

Section 03100

Concrete Formwork

B. Construct a job mock-up of formwork to a reasonable size include items such as reinforcement, accessories, expansion and control joints, stiffeners, bracings, penetrations through concrete, and obtain Engineer’s approval prior to commencement of related work; columns, slabs, girders and beams, walls, and staircases. C. Upon approval by the Engineer, the job mock-up may remain as part of the finished work.

3

Quality Assu rance

A. The design and the erection of the formwork is the responsibility of the contractor. B. Contractor shall design formwork to the correct dimensions, shape, alignment, elevation, and position. C. Immediately before casting concrete the forms shall be wetted from both sides taking care that surplus water is drained before concreting commences. D. Form joints and corners shall be watertight.

4

Fabri cated Metal Form Materials

A. In accordance to manufacturer’s design and instructions and Engineer’s approval.

5

Polyprop ylene Formwork Liner

A. To improve the surface finished to fair-faced concrete a polypropylene formwork liner shall be provided to the surfaces of formwork in contact with concrete, Material shall be: a. 100% Polypropylene b. Non-woven c. Thermally bonded / needled d. Sufficiently stiff to prevent wrinkling when remolding by hand e. Have sufficient pores permitting draining of water and air circulation f. Liner shall be stretched to provide even surfaces before fixing to the formwork g. Surfaces of formwork shall be used without formwork release agent h. Re-used formwork liner shall be cleaned and free from any stains oil, soil, cement slurry etc. B. Formwork liner shall be used for all B35 concrete works.

6

Formwork Accessor ies

A. Form Ties: Removable or snap-off type, galvanized metal or plastic, fix or adjustable length, factory -fabricated, cone ends if required by the drawings. B. Form Release Agent shall not be used. C. Corners: Filleted chamfered, rigid plastic or wood strip type on all exposed corners of finished concrete of columns, walls, and beams unless otherwise stated in the contract specification. D. Dovetail Anchor Slot: Galvanized steel, foam filled or non-filled, release tape sealed slots. E. Nails, Spikes, Lag Bolts, Through Bolts, Anchorages: Sized as required, of sufficient strength and character to maintain formwork in place while placing concrete. F. Form Anchor shall be factory-fabricated metal. Select form anchors in accordance with the manufacturers publish design data and test information.

6.1.1 Waterstops A. Preformed water-stop shall be manufactured from elastomeric material (chloroprene – neoprene or equal and approved) and shall be resistant to aging, oxygen, irradiation, with ultra violet light, water, temperature, oil, grease, and chemicals. B. All construction joints and movement joints in water retaining structure must incorporate waterstops. C. For site jointing heat welding (butt joint) use apparatus provided by the water-stop manufacturer. D. Minimum width for surface type water-stop is 230mm with a minimum of two flange integral ribs (watafoil section) incorporated with brass eyeletted reinforcement. E. All water-stop intersections and joints must be factory made. F. Side form Spacer shall be factory-fabricated or job-site fabricated, cement mortar No. 1 with plastic coated tie wire. G. Fabricate movement joints water-stop into the longest practical units at the supplier’s works. Ensure that the fabricated water-stop is continuous throughout the structure below highest water level. H. Water-stop shall have the following characteristics: Contract 106 , Volume II

Page 353 of 589

Section 03100

No

7

Concrete Formwork

Item / Property

1 2

Tensile Strength Elongation (Ultimate)

3

Hardness Shore – A15

4 5 6 7

Ozone Resistance Eyelet Reinforcement Water stop Width Section

Test Method

Requir ements

ASTM D 638 or DIN 53504 or BS 2782 (@ 25 °C) ASTM D 2240 or BS 2782 (@ 25 °C) ASTM D 1149 -

Min. 13.50 N/mm² Min. 300 % Min. 70 No Failure Brass Min. 230mm Heavy Duty

Execution 7.1.1 Erection - Formwork

A. Verify lines, levels and centers before proceeding with formwork. Ensure that dimensions agree with drawings. B. Erect formwork, shoring and bracing to achieve design requirements. C. Provide bracing to ensure stability of formwork. Shore or strengthen formwork subject to overstressing by construction loads. D. Arrange and assemble formwork to permit dismantling and stripping. Do not damage concrete during stripping. Permit removal of remaining principal shores. E. Align joints and make watertight. Keep form joints to a minimum. F. Obtain approval before framing openings in structural members, which are not indicated on Drawings. G. Provide fillet and chamfer strips on external exposed corners of beams, joists columns and slabs. H. Coordinate this section with other sections of work, which require attachment of components to formwork. I. Formwork placed after reinforcement shall have sufficient concrete cover over reinforcement before proceeding. J. Maintain safe working condition for workmen and public during erection. K. Provide top formwork to concrete faces where the slope exceeds 1 in 2.5. L. Provide a uniform pattern of joint lines to face of concrete when erecting forms. M. Provide a uniform joint with a batter of approved dimension for non-vertical joints to give a straight and neat joint line. N. Do not use form supports, which result in holes or tie-wires extended through the full width of a member. O. Where part of a metal tie remains embedded in concrete, it shall not have less cover than reinforcement. Fill holes with special material approved by the Engineer. P. Position chamfer molding strips on exposed corners. Q. Do not apply form release agent when using Polypropylene formwork liner.

7.1.2 Form Cleaning A. Clean forms as erection proceeds, to remove foreign matter within forms. B. Flush with water or use compressed air to remove remaining foreign matter. Ensure that water and debris drain to exterior through clean-out ports.

7.1.3 Formwork Tolerances A. Subject to the following permissible tolerances the concrete works shall be executed true to dimensions, shapes, positions and levels: a. Levels and Position: Top of blinding layer ±0 -10mm, top of slabs and beams 4mm when checked with a 2m straight edge. b. Plumb Alignment on Appearance: The plumb alignment for walls and columns shall not exceed +/- 0.1% and the vertical surfaces of walls shall be smooth and flush, with differences on the surface not exceeding 2mm when measured with a 2m straight-edge. The difference in surfaces of exposed slabs shall not exceed +/- 3mm when measured with the 4m straightedge. The dimensions may vary between 0mm and +10mm without being rejected.


Page 354 of 589

Section 03100

Concrete Formwork

7.1.4 Field Qualit y Control A. Inspect erected formwork, shoring, and bracing to ensure that work is in accordance with formwork design, and that supports, fastenings, wedges, ties, and items are secure. B. Do not reuse damaged wood formwork for concrete surfaces to be exposed to view. Do not patch formwork. C. The Contractor shall give written notice to the Engineer at least 24 hours ahead of time-scheduled time for placing reinforcement for inspection.

7.1.5 Form Removal A. Do not remove forms or bracing until concrete has gained sufficient strength to carry its own weight and imposed loads. Loosen forms carefully. Do not wedge pry bars, hammers, or tools against finish concrete surfaces scheduled for exposure to view. B. Store removed forms in manner that surfaces to be in contact with fresh concrete will not be damaged. Discard damaged forms. C. Do not remove formwork without prior approval from the Engineer. D. No claim for delay of work will be considered if the Engineer requires to delay the removal of the formwork for a period of time not exceeding 28 day on account of the weather or other reasons such as a transference of loading on the newly completed work that might occur on the removal of any timbers or supports struts wailings or soldiers. E. Minimum timing prior removal of formwork shall be as per the following table: Removal of formwork to:

Minimum period prior to Removal

Slab and beam sides walls and unloaded columns

3 Day

Slab and beam soffits props left in position

7 Days

Removal of props to slab and beam soffits

14 Days

END OF SECTION


Page 355 of 589

Section 03200

Concrete Reinforcement

Secti Section on 0320 03200, 0, Conc Conc rete Reinf Reinforc orcement ement 1

Submittals

A. The following following shall shall be submitted submitted by the the Contractor: Contractor: a. Manufacturer’ certificate of compliance for each shipment of steel bars, certify representative samples have been tested and the tests comply with the requirement herein specified b. Certified copies of mill test report of reinforcement materials analysis c. Layout of the individual panels, panels, plans and sections, bar sizes, spacing, splicing, locations, location of construction joints, and control joints, quantities of reinforcing steel and wire fabric, bending and cutting schedules, supporting and spacing devices, and notes to reinforcement erector showing size and location of the embedded conduits, pipes and sleeves d. A proposal for cleaning reinforcement from any any deleterious material material before the work is carried out e. Details of tie wires and spacers f. If welding to be carried out: 1. Detail of the workmanship and the welding connection between reinforcing bars for proposed joints when specifically instructed by the Engineer. 2. Welders' Certificates certifying welders employed on the Work. Verify welders Certificates with recognized Authority.

2

Deliv Deliv ery, ery, Storage, And Protection Protect ion

A. Transport, Transport, handle, handle, store, store, and protect protect as specified. specified. B. Provide strong-back or multiple multiple supports when lifting bundles to prevent from sags in the bundle. C. Provide tags for all bundles of reinforcement; include bar schedule and bar mark reference after bending. D. Store and cover reinforcement bars on site in protected racks above ground.

3

Reinforcement 2

A. Un-coated Un-coated deformed deformed steel steel bars shall shall have have a yield yield stress of 460 N/mm as per BS 4449. B. Locate reinforcing splices not indicated on drawings, drawings, at point of minimum stress. Review location of splices with Engineer. C. Bend all reinforcement bars cold to the forms and the dimensions shown on the drawings and in accordance with DIN 1045. Ensure that the minimum bending radius 'r' for bar diameter is four times the bar diameter and in hot-rolled and cold worked high yield steel, not less than 6 times the bar diameter, unless otherwise noted. D. Tie wires shall be 1.6mm min. black annealed annealed mild steel to ASTM A496. E. The grade of concrete for spacers shall be higher than the pour concrete.

4

Examination

A. Notify the Engineer at least 24 hours ahead of scheduled scheduled time for concreting concreting to enable inspection of reinforcement.

5

Placement

A. Place, support support and and secure secure reinforcemen reinforcementt against against displacemen displacement. t. B. Accommodate placement of formed openings. C. Maintain concrete cover around reinforcement as specified. Concrete Cover to Reinfo Reinfo rcement

Minimum Cover

External against earth-faces, internally internall y in liquid retaining structures

50mm.

External in a tidal environment, in or under water

75mm.

Internal work in non-liquid retaining structure Walls, beams and columns Slab reinforcement Distance between parallel bars


50mm main steel. 40mm ≤25mm to all bars, Ǿ of the largest bar

Page 356 of 589

Section 03200

Concrete Reinforcement

D. Turn ends of tie wires into the main body of the concrete. Do not allow tie wire to project toward the surface. E. Place chairs, bolsters, or bar supports between parallel layer of reinforcing steel for slabs provided with more than two layers. F. Place concrete spacers spacers under reinforced bars to separate layers of reinforcement from concrete blinding or formwork. G. Maintain a minimum distance of 300mm for main wire and 150mm for transverse wire when mesh reinforcement is laid adjacent to other sections of reinforcement or when lapped. H. Do not use shapes of reinforced bars not shown on the drawings I. Notify the Engineer prior to any cutting, bending and fixing of of the reinforcement. J. Provide adequate scaffolding system to ensure that being walked upon during the placing of concrete or other operation does not displace the reinforcement.

5.1.1 Cleaning A. Clean reinforcem reinforcement ent before before work is carried carried out. B. Ensure that reinforcing bars are kept free from oil, grease, grease, tar, paint, loose rust, concrete droppings, salt contamination, and other deleterious material. C. Immediately after placing concrete and before concrete is hardened clean carefully contaminated reinforcement bars with wire brush.

END OF SECTION


Page 357 of 589

Section 03300

Concrete, Mortar & Cementitious Material

Secti Section on 0330 03300, 0, Conc Conc rete, Mor Mortar tar & Cementit Cementit iou s Material 1

Desig Desig n Requi Requi rements

A. Design a mix for each each class class of concrete concrete as specified specified for use in in the works. works. B. Produce a workable concrete that will when handled, handled, transported, pumped and compacted at the site will set within 90 minutes without segregation and excessive bleeding. C. Where waterproof concrete is required, the Contractor shall take full responsibility for ensuring that such construction is completely waterproof. Any leaks appearing during the construction and maintenance period of the Contract shall be completely repaired by the Contractor at his own expense.

2

Submittals

A. Submit details details of of the proposed proposed ready mix mix supplier. supplier. Include Include the following: following: a. Name and location of supplier and and his plant plant b. Management structure at plant c. Description of production, and quality control management practiced d. Description of plant, equipment equipment and production rate per per hour hour e. Description of maintenance management practiced f. Identify technical team and their qualifications and experience g. Number of delivery vehicles and their rated capacities h. Description of in-plant testing facilities. B. Submit details of on-site management plan and capabilities for receiving, pumping, placing, compacting, sampling and curing concrete. Include the following: a. Identify concrete crew, their skills, experience and training received b. Equipment and materials to be available on site before any concreting operation c. The organisation plan for utilising equipment, materials and men to ensure that the concreting operation runs smoothly without errors and in a timely fashion d. The arrangement for sampling, making of cubes, curing, transport and testing of cubes e. The quality control plan for ensuring that the concrete placed attains the strength, durability and finish specified. C. Submittal for mix design for each class of concrete concrete to be used shall include the following: a. Name of supplier and identity of plant b. List of itemized raw materials, their sources, trade names (if any) and detailed recent test reports, their proportionate quantities based on a yield of 1 cubic meter. The fresh concrete properties (slump temperature, air content, and wet density). The cured concrete properties (compressive strength, ASTM C1202 (RCP) and water permeability as per DIN 1048 – All at (7and 28 days), apparent density and chloride content. D. Calculate and include the various ratios and other details to include w/c ratio, fine to coarse aggregate ratio, combined grading of aggregates, paste to aggregate ratio by volume. E. Submit names, locations and services provided provided by sub-contractor regarding testing, supply of flaked ice, chilled water, technological support and know how or other materials used in concrete production or placement. F. All submittals related to this section shall be approved by the Engineer only in combination with the results of the trial mix and placement in accordance with this section provided they are all to his satisfaction. G. Analogy table comparing comparing the proposal proposal versus the Contract Specifications shall be submitted as per the following guide Format / Table:


Page 358 of 589

Section 03300


Form: Comparison of Specifications and Submittal (To (To be filled by Conc rete Batchi Batchi ng Plant and verified by Contractor ) GENERAL Department Consultant Contractor Concrete Producer Date of Submission

No

Item

Contract No Location of Plant Plant No Unique Mix No Submittal No.

Specifications

Ac ti on

Submittal Proposal

Name, Sign atur e and Date

Results of Trials / Tests Tests

Remarks

Remarks Remark s

Prepared Prepared by Plant: Checked by Contractor: Remarks: Remarks :


Page 359 of 589

Section 03300

3


Quality Quality Assu rance

A. Perform Work Work in accordan accordance ce with submitted submitted and approved approved manageme management nt and quality plan. B. Maintain one copy of of each document clearly displayed on site. Make it mandatory for all staff on site to receive a copy of the approved management and quality plan and for them to read and understand it. C. Plant appraisal and trail shall be performed periodically during Contract period.

4

Qualific ation s Ready-Mix Ready-Mix Concrete Concr ete Supplier Suppl ier

A. The proposed proposed ready-mix plant must be an off-site commercial commercial plant properly staffed staffed and equipped equipped to consistently produce the classes of concrete to be used to the standards achieved at the trial and placement. B. The ready-mix plant must have a modern fully automated computerized plant wet batching plant. C. A batch-system computer printed non-simulated delivery ticket must accompany each each load delivered to site and shall include the following: a. Serial number and date and vehicle number b. Identification of supplier and batching plant, Name of purchaser and destination site c. Project designation d. Class of concrete e. Itemized list of raw materials, their sources, trade names names (if any) and weights or volumes used in each batch and their variances f. Number of batches in the load g. Weight and volume of concrete delivered h. Time of loading, departure and discharge i. Mixing time for each batch at the plant j. Results of properties properties measured measured at at plant and at site. D. The ready mix plant shall have a flaked icemaker. E. Plant must be equipped with a water chiller of sufficient capacity capable of maintaining the water o temperature in the water storage tank to below 6 C during hot weather. F. Well-trained qualified personnel must operate the ready-mix plant. G. A sufficient number of well-maintained concrete mixing trucks must be provided to maintain a continuous delivery of the required amount of concrete to the job site without delay or hindrance. H. A fully equipped testing laboratory operated by experienced and qualified qualified personnel must exist exist at the plant. The testing laboratory shall meet the current requirements stipulated by the department. I. The plant must have the capability to stock sufficient raw materials to meet the peak demands of concrete supply to the works. J. Delivery agitator trucks shall not carry separately any liquid admixtures admixtures when delivering concrete to the site. K. A second supplier supplier that meets all the requirements must be proposed in the event that the primary supplier becomes incapacitated. L. Water, liquid admixture or other additives additives shall not be added to the concrete after wet concrete concrete has been loaded into agitator trucks. M. Dry concrete ingredients shall not not be loaded into the truck at any time. N. At the end of the project the plant shall provide all data on CD for all concrete delivered to each respective site. O. The ready mix plant must be able to print delivery note, load summary and and non-simulated printout showing target and actual of all batched ingredients (See following tables as guideline).


Page 360 of 589

Section 03300


ABU DHABI MUNICIPALITIES AND AGRICULTURE DEPARTMENT PUBLIC GA RDENS DIRECTORATE FORM: DELIVERY NOTE COMPANY LOGO / ADDRESS (ENGLISH)

COMPANY LOGO / ADDRESS (ARABIC)

DELIVERY NOTE Serial Number: Date:

o

Log ID No:

Plant No: Location: Customer: Delivery Destination: Unique Mix No.:

Mixer No:

Order No:

Class Strength:

Ambient Shade Temp. ( C): Driver: Driver No: Contract / Project: Project ID.: Required Slump @ Site (mm):

Truck No:

Free W/C :

Target Mean Strength: Qty. Ordered 3 m Time (HRS)

Qty. Delivered 3 m Plant Checks Slump (mm)

Temp. °C

Technical Manager – Name and Mob. Tel.:

Qty. This Load 3 m Cubes Ref.

Time (HRS)

Time Start Placing:

Loading Time* Arrival Time: (HRS) (HRS) Site Checks Slump (mm)

Time Placing:

Temp. °C

Finish

Cubes Ref.

Aggregate check:

Received, Checked & Accepted by Contractor - Name and Signature: Plant’ QC – inspector Name and Signature:

Remarks:

Verified by ADM / Consultant’s Inspector Name and Signature:

* Loading Time = The time the water is added to the first batch. Contract 106 , Volume II

Page 361 of 589

Section 03300


AB U DHABI MUNICIPAL ITIES AND AGRICULTURE DEPARTMENT PUBLIC GARDENS DIRECTORATE Form: Computer Controlled Batch Plant Printout – Load Summary COMPANY LOGO / ADDRESS (ENGLISH) (ARABIC)

COMPANY LOGO / ADDRESS

Serial Number: Contract:

Contractor:

Start Batching Time:

Printing Date:

End of Batching Time:

Batching No.:

Printing Time: Batched Quantity:

LOG ID NO: Number Batches:

Batched Volume:

of

LOAD SUMMARY PRINTOUT Material

DS

Approved Design 3 1m (SSD) Kg

Required Kg

Batched Kg

% Variation

Aggregate Absorption %

Total Moisture %

Adjusted Water Kg

[A]

5mm

[B]

10mm

[C]

20mm

[D]

Cement [E] Admix. [F] Admix. [G] Additive [I] Water Ice

Remarks: 1. “Non-simulated Printout” wording to be printed automatically in all batches 2. Target W/C, Actual W/C to be printed herein and / or to be printed in the Form “Individual Batch Printout” 3. All abbreviations (e.g., A, B, C etc.) shall be defined separately in the delivery note / printout 4. Enter water temperature at pan mixer inlet 5. Enter no. of batches making up the load 6. Enter mixing time for each batch of concrete


Page 362 of 589

Section 03300


AB U DHABI MUNICIPAL ITIES AND AGRICULTURE DEPARTMENT PUBLIC GARDENS DIRECTORATE Form: Computer Controlled Batch Plant Printout – Individual COMPANY LOGO / ADDRESS (ENGLISH)

COMPANY LOGO / ADDRESS (ARABIC)

Serial Number: Contract:

Contractor:

Printing Date:

Start Batching Time:

End of Batching Time:

Batching No.:

Printing Time: Batched Quantity:

LOG ID NO:

Batched Volume:

No. of Batches:

Individual Batch Printout Material

DS

Approved Design 3 1m (SSD) Kg

Required Kg

Batched Kg

% Variation

Aggregate Absorption %

Total Moisture %

Adjusted Water Kg

[A]

5mm

[B]

10mm

[C]

20mm

[D]

Cement [E] Admix. [F] Admix. [G] Additive [I] Water Ice

Remarks: 1. “Non-simulated Printout” wording to be printed automatically in all batches 2. Target W / C, actual W/C to be printed herein and / or to be printed in the Form “Load Summary Printout” 3. All abbreviations (e.g., A, B, C etc.) shall be defined separately in the delivery note / printout 4. Enter water temperature at pan mixer inlet 5. Enter no. of batches making up the load 6. Enter mixing time for each batch of concrete

4.1.1 Batching Accuracy No 1 2 3 4 5 6

Ingredients Coarse Aggregates: 10mm and 20mm Fine Aggregates: 5mm, Dune Sand Cement Water Ice Liquid Admixture


Individu al Batch (%)

Load Summary (%)

+/- 2

+/- 1

+/- 1 +/- 3

Page 363 of 589

Section 03300

5


Storage Of Cement

A. Store and protect cement from deterioration and contamination. B. Store in dust controlled dry waterproofed silos. C. Provide separate labeled and white painted or shaded cement silos for each consignment of cement. Do not mix different types of cement consignments.

6

Aggregates

A. Store in purpose built shaded or covered bins or bunkers with an impermeable sloping substrate. B. Prevent intermixing from adjacent aggregate piles of a different size. C. Prevent contamination of aggregates.

7

Admixtures

A. Store in waterproof closed container fitted with a stirrer or circulating pump.

8

Water

A. The water used for mixing or curing concrete and washing the aggregates shall be clean and free from injurious amounts of oil, acid, alkali, salts, organic matter or other deleterious substances. B. Chemical water analysis shall be made before using a certain water source and test certificates from an independent laboratory shall be submitted for the Engineer’s approval. C. When comparative tests are made with distilled water of known quality, any indications of unsoundness, marked change in time of set, or reduction of more than 10% in mortar strength shall be sufficient cause for the rejection of the water under test.

9

Mix Desig n

A. Before commencing any concrete work, the Contractor shall design the mixes for the concrete, which he proposes to incorporate in the Permanent Works. Each mix shall be designed to produce the required class of concrete having a characteristic strength not less than the appropriate value specified. Each design shall fulfill the following requirements: a. The combined grading of coarse and fine aggregate shall be continuous b. The proportions and properties of the mix shall be within the limits set out for the various classes and types of concrete described in these Specifications. Should approved dune sand be used its proportion should not exceed 12% of the mix for non-washed fine aggregates and 15% for the washed aggregates. c. The water/cement ratio shall be consistent with attaining the average strength but without the ratio exceeding the specified maximum. The aggregate/cement ratio shall be suitable to achieve the minimum workability consistent with proper compaction by the methods specified. d. When submitting his proposals for design mixes to the Engineer, the Contractor shall provide, in addition to details of his cement, aggregates and water details of: 1. The proportions, in which the dry materials are to be mixed, including the aggregate/cement ratio, cement per cubic meter of compacted concrete and the sieve analysis of the individual and combined aggregates 2. The moisture content of the aggregates and the calculated value for their absorbed water 3. The water cement ratio proposed 4. The workability of the mix and the range in which it is to be maintained 5. The 28-day individual and average strength of the six cubes 6. The individual and average densities of the six cubes 7. The dates on which the cubes were made and tested. B. The mix designs shall be submitted as per the following guide Format / Table:


Page 364 of 589

Section 03300


ABU DHABI MUNICIPALITIES AND AGRICULTURE DEPARTMENT PUBLIC GA RDENS DIRECTORATE

Form: Concr ete Mix Design Summary General Consultant

Concrete Supplier

Contract No

Location of Plant

Date of Submission

Plant No

Contractor

Unique Mix No

Mix Parameters Strength Class

Enter Achieved Previous Mean Results (If available)

Design Strength (N/mm²)

Compressive Strength (BS EN 1230-3: 2002) @ 28 Days (N/mm²)

Target Mean Strength @ 28 Days (N/mm²)

RCP (ASTM C1202) @ 28 Days (Coulombs)

Slump @ Plant (mm)

Permeability (DIN 1048) @ 28 Days (mm)

Slump @ Placement (mm)

Water Absorption (BS EN 1097-6 : 2000) @ 28 Days (%)

3

Wet Density (kg/m )

Bleeding (ASTM C232) (%)

3

Dry Density (kg/m )

Aggregate Drying Shrinkage BS EN 1367-4 : 1998) (%) 3

Mix Design Proportions for one m of Concrete (SSD based) Ingredient

Type

Source

Weight (Kg)

Cement

Mineral Additives (GGBS, Fly Ash, Micro Silica)

Coarse Aggregates (20mm, 10mm)

Fine Aggregates (5mm, Dune Sand)

Liquid Admixtures Free Water Other Additives / Admixtures

Aggregate Breakdown

Calculated Ratio

20mm (%)

Fineness Modulus

10mm (%)

Paste Volume Fraction

5mm (%)

Free Water / Cement Ratio

Dune Sand (%) Total Fine Passing 0.075mm (%) Contract 106 , Volume II

Page 365 of 589

Section 03300


Sieve (% Passing) Combined Aggregates Sieve Size (mm)

20mm

10mm

5mm

Fine Aggregates Dune Sand

Comb. (%)

Limits (%)

Sieve Size (mm)

5mm

Dune Sand

Comb. (%)

Limits (%)

20 14 10

10

5

5

2.36

2.36

1.18

1.18

0.600

0.600

0.300

0.300

0.150

0.150

0.075

0.075

Envelope / Graph (show min . and max. limits) Combined Grading

Fine Aggregates Grading

Remarks: 1. Attach test certificates to support summary data. 2. Attach statistical analysis and data for proposed concrete mix designs 3. Where there are no existing statistical data, estimated population target mean shall be assigned. 4. The Minimum Estimated Target Mean shall be set at 5 N/mm² below the 28 Days trial mix strength and no cubes shall fall 10 N/mm² below the trial mix strength. 5. After filling of all boxes of this form by the Ready Mix Plant, the same shall be duly checked and signed by all concerned parties mentioned below. Batching Plant

Contractor

Consultant

Name of Company Name of Person Position Signature Date Remarks:


Page 366 of 589

Section 03300


9.1.1 Concrete Trial Mix and Placement A. Following the Engineer’s approval of the mix designs, the Contractor shall prepare trial mixes of each class of concrete in the presence of the Engineer. B. Prior to the trial mix and placement the Engineer shall satisfy himself by inspection and audit that the ready mix plant and Contractor is capable, ready well equipped and experienced or trained to conduct the successful production and placement of concrete. C. A trial mix and placement shall be conducted to test and prove the ability of the contractor to source concrete to the desired quality and his ability to place, compact and cure the concrete to achieve the desired properties of strength, permeability, finish and workmanship. D. Sieve analysis, absorption and moisture content determination shall be made on the aggregates. The batches of concrete shall be mixed as specified herein and tested. E. The Contractor shall allow sufficient time in his program for designing and making trial mixes and testing. If during the course of the works the concrete fails to comply with the specified requirements, or the source of aggregate or cement should differ from those with which the preliminary design mixes were carried out, the Engineer will instruct the Contractor to prepare further design mixes, which will be tested in accordance with the specified procedure. F. At least two cubic meter of concrete for each class proposed for use shall be manufactured, sampled, tested, delivered, pumped, placed, compacted and cured into a dummy construction at the site following the details, methods and plans submitted. G. The dummy construction shall be designed as: a. For coring samples at 7 and 28 days b. A surface for trial and demonstrative application of coatings, laminates and other treatments or finishing to be used in the works. c. Fresh concrete shall be sampled be molded and cured for testing at 7 and 28 days to the following schedule: No. of Cubes

Tested for

150mm

3

7 day cube compressive strength & density

150mm

3

28 day cube compressive strength & density

150mm

3

7 day cube for water permeability (DIN 1048)

3

150mm

3


1

150mm

3

7 day ASTM C 1202 (RCP)* + chloride & sulfate profile (Cl 3.10F)

1

150mm

3

28 day ASTM C 1202 (RCP)* + chloride & sulfate profile (Cl 3.10F)

3 3 3

3

1 150mm Spare *RCP = Rapid Chloride Penetration d.

At 7 day and 28 days 150mm cylinder cores shall be extracted from the dummy placement and tested for: No. of Cores

Tested for

3

7 day compressive strength + density

3

28 day compressive strength + density

3


3


1

7 day ASTM C 1202 + chloride & sulfate profile (Cl 3.10F)

1

28 day ASTM C 1202 + chloride & sulfate profile (Cl 3.10F)

10 Concrete Materials A. Mixing on Site shall only be permitted for small quantities and for non-structural concrete e.g. grouting around pipes.

10.1.1Cement A. Cement shall be obtained from Emirates Cement Factory and shall be delivered cool and ready for use. Contract 106 , Volume II

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B. Use Ordinary Portland cement throughout the works unless otherwise stated in these Specifications or Drawings or site discoveries shall cause the Engineer to direct the use of alternative cement at the Contractors own cost. C. The maximum value of Tri-calcium Aluminates C3 A shall not exceed 8% for MSRPC / Type II, but it shall be not more than 5% for SRPC / Type V. D. The acid soluble alkali of cement shall not exceed 0.6% by weight of the cement. E. Cement shall be MSRPC-type II for reinforced concrete and SRC for plain concrete.

10.1.2Agg regates A. Aggregates shall not have the potential to cause alkali-silicate or alkali-carbonate reactions or other damaging chemical reaction between aggregate and alkalis. The Contractor shall carry out the tests to ensure that the aggregate-cement additives mixture is free of potentially damaging reactions. B. Aggregates shall be initially assessed for reactivity in accordance with ASTM C289 and C1260 and if potential activity is shown, then tests in accordance with ASTM C227 and C586 shall be conducted. C. Fine and coarse Aggregates: Use DIN 4226 & BS812 Part 100 in conjunction comply with the requirements as specified and the following: a. The fine aggregate ( ≤ 5mm) shall be crushed type having hard, strong durable particles and shall come from an approved source. It shall be clean and free from salt or organic matter. Dune sand if used shall consist of siliceous natural sand. b. Coarse aggregate (e.g., 10 / 20mm) shall consist of crushed gravel, or other approved inert materials of similar characteristics and shall be clean, hard and sound. No material of a shelly nature shall be used. D. Aggregates shall be screened and washed. Each type and grading of aggregate shall be stored separately in bins. Bins shall be provided with sloped concrete flooring ensuring adequate drainage. E. The combined aggregate should be as coarse grained and densely graded as possible. The maximum particle size shall be so chosen as to be compatible with mixing, handling, placing and working the concrete and its size shall not exceed one third of the smallest dimension of the component to be concreted. With closely spaced reinforcements or small concrete cover, the greater part of the aggregate shall consist of particles smaller than the distance between adjacent bars and between the bars and formwork. Maximum size of coarse aggregates in all cases shall be 25mm. F. The concrete shall contain a certain quantity of ultra fine particles in order to be properly workable and to achieve a close texture. Additional ultra fine material, if any, shall consist of natural or artificial mineral substances comprising, as far as possible, a mixture of different sized particles, which do not soften and impair the durability of the concrete. An adequate content of ultra fine material is especially important in concrete, which has to be conveyed long distances or, in concrete for thin-walled densely reinforced components and in waterproof concrete. G. After approval by the Engineer, the whole of the aggregate supplied for use on the Works shall be obtained from the approved sources and the quality and grading shall be maintained consistent and equal in all respects to the samples submitted. H. Should it become necessary to change the source of supply for any of the materials, fresh tests shall be made to determine the proportions of the materials to be used and adequate steps shall be taken to maintain the required standard of the materials. Sieve tests shall be carried out when the first delivery is effected and thereafter at intervals as directed by the Engineer.


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10.1.3Aggr egate Tests, Compli ance Requirements and Frequencies No 1

2

Description

Test Methods BS 812 / EN ASTM / DIN

Grading

Part - 103 (wet)

Material Finer Than 0.075 mm

Part - 103 (wet) Part 103 (wet)

a.

Natural / Crushed Gravel

b.

Crushed rock

Permissi ble Limit s Fine Coars e

Frequency

Table 4 of

Table 3 of

BS 882

BS 882

DIN 4226

Max. 3%

Max. 1%

Ditto

DIN 4226

Max. 7%

Max. 1%

Ditto

Daily See note 1

3

Clay Lumps & Friable Particles

C142

Max. 1%

Max. 1%

Ditto

4

Light Weight Pieces

C123

Max. 0.5%

Max. 0.5%

Ditto

5

Organic Impurities

C40

Note – 4

N/A

1 / 6 Months

6

Water Absorption

C128 / C127

max 2.3%

max 2%

1 / Week

Min. 2.6

Min. 2.6

1 / Month

Min. 2.6

Min. 2.6

EN 1097-5

Specific Gravity (Apparent) 7

a.

Fine ≤5 mm

b.

Coarse ( e.g., 10mm / 20 mm)

C127 C128

Shell content in aggregate

8

a.

Coarser than 10mm

EN 933-7

None

None

b.

5mm to 10mm

EN 933-7

None

None

c.

2.36mm to 5mm

None

None

d.

Finer than 2.36mm

None

None

e.

Hollow shells

None

None

C131/C535 EN 933-7

1 / 3 Months

Particle shape 9

1 / Month

a.

Flakiness Index

Part - 105.1

b.

Elongation Index

c.

Elongation/ Flakiness Factor

DIN 4226

N/A

Max 25%

Part - 105.2

N/A

Max 25%

Note - 2

N/A

Note – 2

Acid Soluble Chlorides 10

11

a.

*MSRPC (TYPE II) Reinforced

b.

*SRPC (TYPE V) Plain Concrete

Acid Soluble Sulfates

1 / Month BS 4027 / BS 812,

C150

Appendix C EN 1744-1 / BS

DIN 4226

Max. 0.03%

Max. 0.02%

Max. 0.03%

Max. 0.02%

Max 0.3%

Max 0.3%

Soundness 12

1 / Month

812, Part 118

a.

MgSO4( 5 cycles)

b.

Na2SO4

1/ 3 Months EN 1367-2

C88

Max 10%

Max. 10%

C88

Max 10%

Max. 10%

Mechanical Strength 13

1 / Month

a.

10% Fines Value

EN 1097-2

Min. 100 KN

b.

Impact Value

EN 1097-2

Max. 30%

c.

Los Angeles Abrasion

C131/ C535

14

Drying shrinkage

EN 1367-4

15

Moisture content

EN 1097-5

Max. 30% Max 0.05%

1 / 6 Months

C566

2 / Day

Potential Reactivity 16

17

a.

Aggregates, Chemical Method

b.

Cement-aggregate Combination

Petrographic Examination

C289 C227/C1260

Part 104

C33 C295

Innocuous 6

Innocuous

month 6

month 1 / 6 Months

expansion

expansion

max. 0.10%

max. 0.10% 1 / year or for

N/A

N/A

each

aggregate source

Remarks: 1. An approved independent laboratory shall carry out all tests at least once every three months. Unless the stipulated frequency is greater than 3 months in which case the independent laboratory test shall be conducted at exactly the stipulated frequency. Submittals for approval shall include


new

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2. 3. 4. 5. 6.


these independent test laboratories, where the Engineer deems the ready-mix laboratory unfit for test; he shall direct that test shall be conducted by an approved independent laboratory. Not more than 5% particles shall have (w : b :l) ratios greater than 1:2:3 (flaky) and 1:1:3 (elongate) when 100g of sand is inspected under the microscope (w : b : l = width : breadth : length). Aggregates may initially be assessed for its reactivity and if potential reactivity is indicated, then the mortar bar test shall be carried out. Color of supernatant liquid shall be lighter than standard color solution. *MSRPC = Moderate Sulphate Resistant Portland Cement. *SRPC = Sulphate Resistant Portland Cement.


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10.1.4Concrete Classi fic ation, Mix Design, Frequenci es and Material No

Item

Class of Concrete Reinforced

Un-reinforced

Structure / MH Units MH

1

Units

(e.g.,

(e.g., Reducing /

Typical Applications

In filling soft areas and

In lieu of backfilling, pipe

over break, blinding etc.

surround etc.

Circular Base, Shaft), Cover Slab), Columns, Pipe Surround etc. Slabs, Beams etc.

2 3

4

Strength Class

B35

B15

7 Days (150mm)

32

17

6

Strength (N/mm²)

28 Days (150mm)

42

21

9

Target

7 Days (150mm)

42

25

15

28 Days (150mm)

53

32

19

Design

Mean

Mean

Strength (N/mm²)

B5

Cement Type 5

MSRPC / Type II Min.

Content

Max.

SRPC / Type V

370 Kg/m

3

270

120

420 Kg/m

3

310

150

Max. 0.60

N/A

Age

Max. 3 months

Water Free Water / Cement Ratio

Max. 0.40

pH 6

7 < pH < 9

Chlorides

Max. 0.025%

Sulfates

Max. 0.035%

Alkali Carbonates & Bicarbonates

Max. 0.05%

TDS

Max. 0.02% 3

Green / Wet

+/- 40 Kg/m (As per unit weight determined during trials)

7

Density

8

Slump

9

Bleeding

10

Admixture

11

Max. Chlorides (Cl) by weight of Cement

Max. 0.30%

12

Max. Sulfates (SO3) by weight of Cement

Max 4%

13

Concrete Temperature at placement

14

Ambient Shed Temperature

15

Cement Temperature

16

17 18

Hardened

Min. 2400 Kg/m

3

N/A

N/A

100mm (+/- 25mm) (At Site) Max. 1 %

N/A

N/A

No content of CaCl 0.15%

Max. 30 °C Max. 40 °C and Falling

Individual

Max. 35mm

Permeability

Mean

Max. 25mm

(BS 1881 : Part 122) (30 min.) RCP (ASTM C 1202)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max. 75 °C when entering mixers

Water

Water Absorption

N/A

N/A

N/A

Max. 2.3 %

N/A

N/A

Max. 4000 Coulombs

N/A

N/A

Frequencies of Tests

19

Green

/

Wet

Concrete

3

3

Density

Once / 25 m or Part Thereof


Bleeding

At Trials as instructed by Engineer

Concrete Temperature

Each Load

Once / 50 m (Optional Indicative)

Shed Temperature

Each Load

Each Load (Optional Indicative)

Slump

Each Load


Combined Grading

3

Each Load 3

3



Air Entertainment Compressive

Once / Week 3

6 Cubes / Each 25m or Part Thereof

Density Water Permeability Hardened

RCP

Concrete

6 Cubes / 50 m

3

6 Cubes / Week

Each Compressive Test 3

6 Cubes / Each 25m or Part Thereof 3 Cubes / Small Pours - 50m

N/A

3

3

N/A

3 Cubes / Large Pours - 100m Or Part Thereof

Chloride (Cl) Profile on RCP-Samples Water Absorption


N/A 3

Identify aggregates

20

N/A

th

On every 5 set of RCP – Tests 3

3 Samples / 75 m or Part Thereof

N/A N/A

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Remarks: 1. RCP: Rapid Chloride Penetration. 2. The listed strength classes are relevant to cubes with the sizes of 150 mm. 3. Chloride (Cl) Profile test shall be conducted on core samples prior to and after RCP-Tests with full length of core. 4. In addition to the actual samples / cubes required for testing, spare cubes shall be taken by Contractor and / or as per discretion of Engineer at the site. 5. If any tests on hardened concrete fail, with Contractor’s expenses additional sampling and tests shall be conducted on either spare cubes or cores that to be recovered from the concerned unit with the discretion of Engineer. 6. With the discretion of Engineer, the frequencies in number of tests can be increased and Contractor shall carry out the tests at his expenses. 7. Strengths as per Grade and Concrete Strength Classes are to be considered as per the following table:

No

Grade

Strength Class

1

BI

B5

2 3

BI B II

B15 B35

Characteristic Strength (Min. Compressive Strength of each Cube) 200mm 5 N/mm² 15 N/mm² 35 N/mm²

150mm 6 N/mm² 16 N/mm² 37 N/mm²

Design Series Strength (Minimum Average Strength of Each Series of Cubes) 200mm 150mm 8 N/mm² 9 N/mm² 20 N/mm² 21 N/mm² 40 N/mm² 42 N/mm²

Target Mean Series Strength 200mm 18 N/mm² 30 N/mm² 52 N/mm²

150mm 19 N/mm² 32 N/mm² 53 N/mm²

8.

The Minimum Estimated Target Mean shall be set at 5N/mm² below the 28 Days trial mix strength and no cubes shall fall 10 N/mm² below the trial mix strength. 9. Concrete is graded into strength classes B5 to B35 on the basis of its compressive strength determined from the cubes of 200mm at the age of 28 days. 10. If cubes with edges 150mm in length are used instead of cubes 200mm in length then the results obtained to be converted by means of relationship q u (200) = 0.95 x qu (150).

10.1.5Admi xtures A. Water reducing and retarding shall be in accordance with DIN 1045 section 6.3 and BS EN 480. a. Do not use additives containing chlorides. b. Use water reducing additives and retarding additives in accordance with the manufacturer's recommendation c. Conduct trial mixes in the presence of the Engineer and the manufacturer’s representative d. Notify the Engineer of limits of dosage for the various temperatures encountered during use e. Retarding additives shall not contain reducing sugar of more than 4% by weight of additives f. The concrete surfaces on removal of formwork shall be of an even texture. The surface shall be free from cellular deformations, micro-cracks or other textural defects. B. The following data shall be provided at the submittal stage: a. The generic chemical name(s) of the main active ingredient in the additive b. Chloride and alkali content c. Solids and water content (range) d. All information as required under BS EN 480-1,2,4,5,8,10,11,12 o o e. Dosage limit at 25 C and 30 C f. Any detrimental effects that may affect the performance or durability of the concrete.

10.1.6Accessories A. Bonding Agents shall be: a. Polymer emulsions (e.g. PVA Acrylic, latex) b. Solvent based 2 component epoxy - amide or epoxy amine c. Moisture curing epoxy d. Solvent free 2 component epoxy - amide or epoxy – amine e. Solvent free 2 component epoxy – Polysulphide


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f.


Water-based 2 component epoxy Polyamide or Polyamine Concrete Exposure Conditio ns

Rigid Bondi ng Agent Type

Flexible Bonding Agent Type

1

5

1,2,3,4,6

5

2,3,4,6

5

Exposed to permanent damp but not soaking wet.

2,3,4

5

Below ground level or under immersed situations.

4

5

Permanently dry area only - 1m above GL. Exposed to seasonal rain only. GL to 1 meter above ground level.

B. Vapor Retarded: 0.5mm thick clear polyethylene film type, for below grade application. C. Non-Shrink Grout: Premixed compound consisting of non-metallic aggregate, cement, water reducing and plasticising agents; capable of developing minimum compressive strength of 17MPa in 48 hours and 48MPa in 28 days.

10.1.7Joint Devic es and Filler Materials A. Joint Filler shall be: a. Preformed compressible cellular and resilient, non-brittle at ambient temperatures and all exposed conditions complying with ASTM D1751 b. Joint filler for use in potable water service reservoirs; use granulated cork bound with insoluble synthetic resin c. Joint filler for use in other structures including pavements, use granulated cork bound with bitumen. B. Joint Sealant shall be: a. Polysulphide elastomeric joint sealant, gun grade, > 99% solid content and non-staining o b. Resistant seal to weather, ozone, salt water, sulphates, heat >75 C, UV radiation and biodegradation and suitable for the climate and environmental conditions prevailing on Site c. All surfaces coming into contact with sealant and/or seal strips shall be prepared and primed as instructed by the manufacturer(s). Sagging, slumping, tackiness are not allowed. ShoreHardness A equal 25. 1. Primer and bond breaker shall be obtained from the same manufacturer as the sealer.

10.1.8Grouts & Mortars Type

Descripti on

Application

Properties

Grouts:

Cementitious

Blend dry cementitious material and the addition of water to produce a pourable fluid.

Epoxy / Chemical

Two or more chemical components which when mixed together produces a fluid consistency

Anchoring

Pre-measured, two pack, filled polyester / epoxy resin grouts


Grouting / filling voids, cavities, gaps, recesses, bedding to bearing plates and to fix foundation bolts (Not to vibration area) Bedding to bearing plates, crack repair grouting and to fix foundation bolts at vibration load area / rotating machinery zones or other equipment subject to dynamic loads Anchoring starter bars, dowels, tendons, anchoring bolts, ballustradings, etc.

Non-shrink, non-metallic, chloride free, compressive strength at 28days shall be min. 2 60N/mm

Non-shrink, resistance to repetitive dynamic loads, compressive strength at 7days 2 shall be min. 80N/mm Non-expansive, tolerant to wet or damp conditions, vibration resistant compressive strength at 1day 2 shall be min. 90N/mm

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Type

Descripti on

Application

Properties

Mortars:

Cementitious

Blend dry cementitious material and the addition of water to produce a highly consistent / trowellable.

Plastering works, high volume damage repairs and general high build structural repairs

Shrinkage controlled, compressive strength at 28days 2 shall be min. 50N/mm

Epoxy / Chemical

Two or more chemical components which when mixed together produces a trowellable consistency

Superficial repairs of epoxy coating substrates, filling pin holes , repairs to sealing surface cracks, minor repairs at vibratory zones, etc

Non-shrink, wide range of chemical resistance, resistance to abrasive and dynamic loads, compressive strength at 7days 2 shall be min. 70N/mm

Note: 1. Mixing, Placing, build up thickness and compaction shall be strictly accordance to the manufacturer’s recommendations. 2. The tables specify the selection of grout / mortar (but not limited to) verses applications.

11 Execution A. Verify that site conditions are as specified. B. Verify requirements for concrete cover over reinforcement. C. Verify that anchors, seats, plates, reinforcement and other items to be cast into concrete are accurately placed, positioned securely, and will not cause hardship in placing concrete. o D. Concreting shall not be carried out when the shade temperature is above 40 C. o E. The temperature of fresh concrete must not exceed 30 C.

11.1.1Preparation A. Prepare previously placed concrete (if any) by cleaning and chipping to remove all oil, laitance and clear substrate of loose fragments of rocks, earth, mud, timber, and other debris and standing water to the satisfaction of the Engineer. B. In locations where new concrete is doweled to existing work, drill holes in existing concrete, insert steel dowels and secure with approved non-shrink grout. C. Coordinate the placement of joint devices together with the erection of concrete formwork and placement of form accessories. D. Fix joint filler for movement joints to the required dimensions of the joint cross-section. Secure to resist movement by fresh concrete. Extend joint filler from bottom of slab to within 25mm. Provide a firm base for the joint sealer. Where the depth of joint between the concrete surface and the waterstop does not exceed 500mm, place filler in single depth sections.

11.1.2Concrete Castin g A. Provide Engineer with a minimum of 24 hours prior notice of the commencement of operations to enable appropriate inspections to be carried out. If concrete is not placed within 24 hours of the approval being given, make a fresh application for approval to concreting. Perform further inspections immediately prior to concreting to check that placement areas and surfaces are clean, formwork and reinforcement workmanship and formations are in compliance, all necessary equipment, tools and curing materials are at the placement area, staff have been properly trained and instructed. B. Do not place the concrete until the Engineer has inspected the surfaces upon which the concrete is to be placed, the formwork, the reinforcing steel work, the equipment, tools and curing materials and re-examined management and organizational matters relating to the placement. C. Ensure reinforcement, inserts, embedded parts, formed expansion and contraction joints cannot be disturbed during concrete placement. A competent steel fixer shall be in continuous attendance to adjust and correct the position of any reinforcement bars which may be displaced D. Concreting during hot weather shall follow the guidelines as set out in ACI 305R. Concrete shall 2 not be placed or continue to be placed if the surface evaporation of water exceeds 1kg/m /hr. If ordered by the Engineer because of better weather conditions, concreting shall be done at Contract 106 , Volume II

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E.

F.

G.

H.

I.


nighttime. In such case sufficient lighting shall be installed by the Contractor at no additional cost to the Department. Only the previously nominated approved and trained crew shall conduct the placement and in accordance with the approved plan, methods and manner in accordance with the approved submittals. Do not exceed 90 minutes for the concrete from the time of adding water to the time of final discharge. If concrete in any part of the placement begins to set before the entire placement has been completed, all placing operations shall halt immediately; the ends of the placement shall be suitably trimmed and stopped and curing shall be applied. Pour and compact concrete in horizontal layers not exceeding 0.30m and keep it at an even level throughout the Work. Do not allow concrete to slide or flow down sloping surfaces directly into its final position. Place concrete to its final position using previously approved means. Avoid separation of the constituent materials. Ensure that vibration shock or other perturbation are not transferred to the reinforcements, formwork and compacted concrete. Vibrators shall not be used to move concrete horizontally from one place to another. Do not allow the concrete to be dropped freely from a height greater than 1.5 meter. Use chutes, or conveyor belts designed to insure there is no segregation or loss of mortar. The use of long troughs chutes and pipes for conveying concrete from the mixer to the forms shall be permitted only on written authorization of the Engineer. Open troughs and chutes shall be metal lined. All chutes, troughs and pipes shall be kept clean and free from coatings of hardened concrete.

11.1.3Compaction A. All concrete shall be compacted by mechanical vibration. B. Vibrators shall be operated at frequencies of greater than 6,000 cycles/min. C. The radius of compaction shall be determined before concreting begins by immersing the activated poker into a sample of the fresh concrete and measuring the compacted radius. D. DIN 4235 - Internal Vibrators for Compacting Concrete - shall be observed. E. The poking shall be so organised that: a. It shall be performed on an imaginary grid with poking distances smaller than the measured compaction radius b. Poking points shall be followed sequentially along the poking distances on the imaginary grid. Random poking methods shall not be allowed c. Pokers must penetrate the fresh concrete lift and dip below the surfaces of compacted concrete beneath d. Pokers shall be dipped so that it descends and ascends vertically along the same coordinates into which it was immersed. Pokers shall not be dragged whilst it is still immersed in the concrete e. Activated pokers shall be laid to rest in fresh concrete f. The concrete must not be overworked nor must it be under worked. Dwell times of pokers in concrete shall be adjusted to achieve thorough compaction but not long enough to cause segregation g. The Engineer shall reject the placement if proper and thorough compaction has not been applied to all parts of the placement h. The Engineer shall immediately halt further placement, if any part of the placement begins to set before the entire placement has been completed. In such an event, the placement shall be cut back and stopped to an area of thorough compaction and the un-compacted concrete shall be removed immediately from the placement area i. When the laid concrete is not more than 3 hours old (calculated from the time of batching), the fresh concrete shall be placed without further preparation j. When the laid concrete is more than 3 hours old, the surface of the hardened concrete shall be roughened, wire brushed or sand blasted to expose the coarse aggregate without leaving loose particles at the surface. This surface shall be washed k. Before placing the new concrete, a thin layer of cement mortar shall be applied to the surface of the older concrete. The mortar shall consist of cement and sand mixed in the proportion of the concrete mix, but omitting the coarse aggregate. The fresh concrete shall be placed against the layer of mortar while it is still plastic l. When concreting has been interrupted before completion of the pour the surface of the concrete shall be cut away as directed by the Engineer and laitance removed. Contract 106 , Volume II

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11.1.4Finishing A. Concrete shall be compacted to the levels desired. Compacted concrete shall not be moved or displaced. B. The surface of the fresh concrete shall be finished using the appropriate tools and to the standards specified.

11.1.5Curing A. Curing shall be conducted as specified. B. Runs, honeycombing, segregation, voids and grout/matrix loss shall not occur. C. Provide shading for the placement area for minimum of 24 hrs before if likely to be directly exposed to the sun. 0 D. Ensure that the concrete is not more than 30 C immediately prior to placement and compaction. If o during any part of the compaction the concrete temperature rises above 30 C, further placement shall be halted. E. Maintain records of concrete placement, record of curing time and type. Record date, location, quantity, air temperature, and test samples taken. F. Place the Concrete continuously between the control joints and construction joints. When placing concrete against horizontal or inclined elements of water-stops, lift the water-stop and place concrete and compact it to a level slightly higher than the underside of the water-stop before releasing the water-stop to ensure complete compaction of the concrete around the water-stop. G. Do not have idle periods during a placement; do not permit cold joints to occur. H. Place floor slabs in checkerboard or saw cut pattern indicated. I. Saw cut joints within 24 hours after placing. Use 3/16inch thick blade and cut into 1/4 depth of slab thickness. J. Screed floors and slabs on grade level, maintaining surface flatness of maximum 6mm/3m.

11.1.6Adverse Weather Condit ions A. ACI 305 R guidelines shall be followed. B. Concrete placements shall not be organised or continued if the surface evaporation rate is likely to 2 exceed 1kg/m /hr. C. Do not mix or place concrete when the ambient shade temperature exceeds 40º C. D. Do not execute concreting if it rains or during sandstorms.

11.1.7Granolithic Floori ng A. Lay granolithic flooring using granolithic concrete. B. Lay granolithic flooring to a minimum thickness of 50mm and in accordance with the recommendations for unbounded construction contained in the Advisory Note "High-Strength Concrete Toppings for Floors, Including Granolithic" published by the U.K. Cement and Concrete Association. C. Form joints at maximum intervals of 4m unless otherwise shown on the Drawings. Provide joints of a simple butt type. D. Where granolithic skirting are shown on the drawings or ordered by the Engineer, form it using granolithic concrete. Run a concave fillet of 50mm radius at all junctions. Round the top edge of the skirting to a radius of 15mm.

11.1.8Separate Floor Toppings A. Prior to placing floor topping, roughen substrate concrete surface and remove deleterious material. Broom and vacuum clean. B. Place required dividers, edge strips, reinforcements and other items to be cast in. C. Apply bonding agent to substrate in accordance with the manufacturer's instructions. D. Place concrete floor toppings to required lines and levels. Place topping in checkerboard panels dimensions not to exceed 6m. E. Screed toppings level, maintaining surface flatness to a maximum 1:1000.


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11.1.9Concrete Blin ding A. Place a concrete blinding layer class B-15 immediately upon completion of formation level and compaction of sub soil where shown on the drawings or ordered by the Engineer, to prevent deterioration of the formation and to form a clean working surface for the structure. B. Minimum thickness of blinding layer is 50 mm unless otherwise shown on drawings or BoQ.

11.1.10

Field Quality Contro l

A. Field inspection and testing to the requirements of Quality Assurance. B. Sample and test concrete materials when instructed or when material source changes. C. Maintain records identifying casting locations in the form of documents and drawings with details of: a. batch number of concrete b. date of placement c. supporting documents of delivery tickets (non simulated print-out) d. name of concrete crew foreman e. Test results f. Number and size of compactors g. Weather data, start and finish times h. Record problems encountered. D. Take test cubes in sets at times and places as specified and/or the Engineer may direct unless otherwise stated and in any case not less than the rate specified in these specifications. E. Obtain concrete for these cubes from actual mixes for the work and prepare and test in accordance with DIN 1045, DIN 1048, ASTM C1202, BS1881:Part 103:1983 and 104:1983. F. The Contractor shall perform and record the tests as specified to ensure that the concrete delivered to the sites is in conformance to the approved mix design: G. The Engineer shall not be hindered from inspecting all facilities, documents, materials and equipment pertaining to the project and its operation at any time during the course of the work. All existing documents requested by the Engineer shall be made available immediately. Information requested by the Engineer shall be given within 24 hrs or as otherwise agreed. H. All works in connection with the tests specified and for making modifications to the mixes shall be at the Contractor's expense and after obtaining Engineer’s approval. I. All tests shall be done in the presence of Engineer’s representative, signed by all parties, and recorded. J. The following procedures shall be followed if the test results are not complying with specification: a. If a cube fails to produce the minimum specified strength or density when tested at 7 days. The Contractor shall immediately remove the structure of which the cube represent or await at his own risk the result of the 28 days test b. If the 28 days results also fail to attain the average strength specified, the Contractor may opt to test cores from the structural of which the cubes represent. The strength data from the cores shall be in line with the data obtained during the trail mix and placement c. The Contractor shall remove the structure of which the cubes and cores represent or execute such additional works or adopt such additional measures as the Engineer may direct at the Contractor’s expense. K. In certain cases the Engineer may so direct or the Contractor may with the prior approval of the Engineer obtain approved samples of the concrete from the structure by drilling or coring. After dressing the samples for testing, submit the samples to density compressive, permeability and RCP tests as specified in order to obtain further information. Correlation data between cube and cylinder strengths shall be extracted from the trial and placement results and such data shall be used in ascertaining or obtaining validity of results between placed concrete and cube samples. Should the Engineer refuse to sanction the coring of cured structures the Contractor shall not make any claim in consequence thereof. Do not allow samples dressed for testing to contain any reinforcement other than minor reinforcement in the plane parallel to the compressive faces. All costs caused by investigation of concrete quality shall be borne by the Contractor. L. Submit to the Engineer a copy of records for each sample cube taken and tested. M. The Contractor shall submit for the Engineer approval suitable repair materials for repairing cored area and for making good minor defects in concrete.


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Section 03300

11.1.11


Water Permeabili ty Test

A. Waterproof concrete shall be so dense (impermeable) that the greatest depth of water penetration on testing does not exceed the value shown below. Permeability tests shall be carried out on three slabs 200 x 200 x 120mm / cubes 150mm x 150mm x150mm having an age of ≥ 28 days but not exceeding 35 days. B. Concrete for permeability tests shall be sampled at the batching yard at least once per week when concrete is being cast. A sufficient number of moulds 200mm x 200mm x 120mm / cubes 150mm x 150mm x 150mm must be available on Site. Slabs / cubes shall be prepared as per DIN 1048. C. 24 hours after concreting, immediately after removing the forms, the surface to which the test pressure shall be applied shall be prepared as follows: a. A 10cm diameter circular area shall be roughened with a wire brush in the center of the slab. The remaining area, not to be exposed to pressure, shall be sealed to avoid leakage of water. Test slabs shall then be stored in water until the time of testing. b. The test pressure shall be applied vertical to casting surface of concrete via automatic operating pressure used as follows: 1. 1kg/cm² for 48 hours 2. 3kg/cm² for 24 hours 3. 7kg/cm² for 24 hours c. Drop of pressure shall be recorded at intervals of 4 hours and pressure shall be reinstated automatically by pressure vessel thereafter. Should leakage be observed on the surface of the slabs, the concrete from which samples have been taken is rejected unless additional tests show satisfactorily results. d. Immediately after the test the slab shall be split into the surface dried from surface water and the greatest penetration measured. The maximum value shall not exceed 35mm individually and the mean value of all three measures shall not exceed 25mm.

11.1.12

Water Tightness Test

11.1.13

Structures

A. On completion of casting reinforced concrete walls and bottom slabs. All water retaining structures shall be proved watertight by testing to the satisfaction of the Engineer. B. Testing shall be carried out before backfilling around the structures, before applying protective coating / tanking and before sealing joints in lining. C. Fill the structure under testing with clean potable water to a level 1.00m above existing groundwater table or 2.00m below floor level, whichever is higher. All openings below the water table shall be made watertight by suitable means and measures. D. The water table shall be maintained for 240 hours and monitor the outer faces of structures. E. If there is evidence of dampness on the outer faces of structure then the structure is deemed to have failed the test. F. Should the structures be deemed by the Engineer to have failed the test, the Contractor shall be responsible for and bear the expense for locating the source of leakage and for carrying out all necessary remedial works to make the structures watertight. G. The Contractor shall retest the structures and repeat all the procedures until the structures are proved watertight to the Engineer‘s satisfaction. All costs shall be beard by the Contractor.

11.1.14

Manhol es and Chambers

A. At the beginning of the Works and prior to construction of manholes the Contractor shall prepare at the pre-cast site 3 No sample manholes consisting of bottom part and shaft. The height of shaft shall be 2m in excess of the deepest manhole. B. After placing seal strips and joining pre-cast shaft with bottom part, but before laminating and applying protective tanking and joint sealant, the pipe openings shall be plugged watertight and the manhole shall be filled with clean potable water till the top of shaft. The water table shall be maintained for 240 hours. During this period a visual inspection of the joints shall be carried out. The manhole shall have passed the test if leaks are not visible. C. This test shall be repeated for every 50 No. manholes placed or part thereof. D. Should the test fail two manholes will be tested and so on. Failed manholes shall be repaired or replaced as determined by Engineer. E. Costs for tests, repairs or replacement shall be included in the rates for manholes. Contract 106 , Volume II

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Section 03300

11.1.15


Repair of Leaks

Repair of leaks in concrete shall be carried out by high-pressure injection of a low viscosity injection epoxy resin, which can be applied during ambient temperature and high humidity. The Contractor shall submit for the Engineer’s approval a detailed description of working method and material proposed for the repair works. All surfaces affected by the repair works shall be cleaned and made good after completion of repairs.

11.1.16

Loading of Struct ures

A. Do not apply load of any kind to any part of a concrete structure until the concrete has matured for at least 7 days and then only with the approval of the Engineer and after confirmation that the specified 7 day cube strengths have been met. B. Do not apply the full design load until a period of 28 days has elapsed after casting. C. Do not permit backfilling around any structure incorporating a ground or floor slab before that slab has been cast and properly cured for a period of 28 days. D. The structure shall not be subjected to any flooding, hydrostatic pressure or contamination until the concrete has been fully protected in accordance with these specifications.

11.1.17

Patching

A. The Engineer shall inspect the concrete immediately upon removal of forms. B. Patch imperfections as directed in accordance with the relevant standards. C. Do not treat any concrete surfaces until the Engineer has inspected the structure.

11.1.18

Defective Concrete

A. Defective Concrete shall be defined as one or more of the following: a. Not conforming to required levels, lines, details and elevations. b. Failure to attain the required concrete strength, permeability or finish. c. Non conforming due to improper placement or voids preparation of concrete formwork, insufficient cover, formwork liner, improper formwork joints, honey combing, segregation excessive voids, damaged to surface, exposed reinforcement, improperly placed snap on or cone ties, unsatisfactory surface of the performance of finishing work on the concrete. B. The discovery of defective concrete must be reported to the Engineer, immediately. Remedial work shall not be carried out without the prior agreement of the Engineer. A proposal to the method, nature and materials to be used in the repair of defective concrete shall be submitted to the Engineer. The Engineer has the right to instruct the removal of the structure in part or whole if he deems that the structure is irreparable or the proposed repair proposed is not consistent with restoring the fitness of the structure. C. The Engineer decision shall be final in all aspects related to the repair or demolition of defective concrete structures. D. The method proposed by the Contractor for dealing with shrinkage cracks, leaks, or other defective work shall have no adverse effect on the finished structure. Treatments of internal and external concrete surfaces of water tanks, etc. (coatings or toppings) do not relieve the Contractor of his obligations under the Contract. E. These treatments shall be considered as an additional step for waterproofing and/or resistance to chemical attack and shall be applied only after the structure has been proved watertight. Special attention shall be given to the elimination of cracking due to shrinkage of the concrete. In this connection consideration should be given to the curing of concrete.

11.1.19

Reinforcing Fibers

A. Where indicated on drawings, or specified or as instructed by the Engineer concrete reinforcing fibers shall be used in plain (not reinforced) structure mass concrete to reduce cracking. Application shall be strictly in accordance with the manufacturer’s instruction. B. The Contractor shall secure the services of an experienced, qualified technician, so certified from the manufacturer of the fibers, for initial start-up of concreting works. C. Together with his request for approval of material, the Contractor shall state the type of fiber proposed, amount of fiber required and references. D. Fibers shall be corrosion-, salt- and acid resistant; they shall have low absorption, thermal and electrical conductivity. The tensile strength shall be ≥ 0.56 kN/mm². The length of fibers shall be as Contract 106 , Volume II

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Section 03300


required to achieve rapidly disperse to a fiber ball free concrete, a non-cracked concrete and as specified by the manufacturer.

11.1.20

Sanding Surface of GRP / uPVC Ports / Sock ets

A. Ports / Sockets of Plastic Pipes installed during cast in-situ / pre-casting: a. Roughen the external surface with emery paper (min. No. 2) b. Apply one layer of compatible vinyl ester resin c. Spread 3mm silica sand on unset resin surface to attain enough roughness d. Allow full curing of resin prior to proceed with casting of concrete.

11.1.21

Construction Joints

A. Form construction joints as required in slabs and beams at the quarter point of the span and at right angles to the member except where otherwise approved by the Engineer. Where beams support slabs, construct both beams and slabs in one operation. B. In all cases, provide vertical stop-boards at the end of each section of work, which is to be concreted in one operation. Thoroughly compact concrete against these stop-boards. C. Construct construction joint panels consecutively where slabs, beams and walls incorporate. Where this is not possible, form a gap not exceeding 1.0m between adjacent panels. Do not concrete the gap until a minimum interval of 7 days has expired since the casting of the most recent adjacent panel. D. The size of bays for reinforced floors, walls and roofs shall not exceed 7.5m in both direction and 6m when un-reinforced or with nominal reinforcement. E. Provide construction joints of plain butt type or rebated type as directed or approved by the Engineer. F. Expose the aggregates at the construction joint of the freshly poured concrete over the full section to provide a sound irregular surface by means of water spray and light brushing or other means approved by the Engineer prior to placing new concrete against it. G. Thoroughly clean away all foreign matter, moisten the surface immediately before placing the new concrete. H. Provide water-stops to construction joints in water retaining structures. I. Ensure that all such construction joints are watertight and any joints which may leak or weep to be rectified to the Engineer's satisfaction. The water-stop bars to be fastened properly by special clips to avoid movement during casting concrete. Nails are not permitted. J. If during the course of the Contract it should become apparent that the Contractor's methods of forming construction joints are not proving effective, the Engineer may order the Contractor to execute at the Contractor's expense such preventative measures as the Engineer may consider necessary to ensure the water-tightness of construction joints in further work.

11.1.22

Movement Joints

A. Construct movement joints for expansion and contraction in accordance with the details and to the dimensions shown on the drawings or where otherwise ordered by the Engineer. B. Pay particular attention to the effect of climatic extremes on any material used in any movement joint. Submit for the approval of the Engineer your proposals for the proper handling and use of the said materials having due regard for any recommendations made by manufacturers. C. Incorporate water-stops into all expansion and contraction joints of structures, which retain liquid or any structures below water level. D. Do not use different types of water-stop material together in any complete installation. E. For horizontally placed surface type water-stop, use water-stop of an interposing sliding plate. F. Maintain water-stops carefully in the position shown on the drawings. Support the water-stop on accurately profiled stop boards to create rigid conditions. G. Fix the joint filler to the required dimensions of the joint cross section. Provide a firm base for the joint sealer. Where the depth of joint between the concrete surface and the water-stop does not exceed 500mm place filler in a single pieces. H. Carry out the sealing of movement joints only when adjacent concrete surfaces are perfectly dry. I. Clean the joint grooves, insert a bond breaker, and adequately prime and fill the groove with approved sealer strictly in accordance with the manufacturer’s instructions. J. Store the sealer in accordance with the manufacturer's instructions. Do not use sealer after its shelf life has elapsed. Contract 106 , Volume II

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Section 03300

11.1.23


Box-Outs and Sleeves

A. Request inspection of box-outs, ducts and sleeves by M&E Contractor one day before placing concrete B. Provide formed openings where required for items to be embedded or pass through concrete work, locate and set in place items which will be cast directly into concrete as shown on the drawing or instructed by the Engineer. C. Coordinate with work of other sections in forming and placing openings, slots, reglets, recesses, sleeves, bolts, anchors, other inserts, and components of other Work. D. A free flowing non-shrink grout, suitable for application at high ambient temperatures, shall be used. The material shall be obtained from manufacturer approved by the Engineer. E. Install accessories in accordance with manufacturer's instructions, straight, level, and plumb. Ensure items are not disturbed during concrete placement. The soffit of box-out shall be inclined to guarantee a complete grouting over the entire width of wall or slab to be grouted. F. Install water-stops in accordance with manufacturer's instructions continuous without displacing reinforcement. G. Provide temporary ports or openings in formwork where required to facilitate cleaning and inspection. Locate openings at bottom of forms to allow flushing water to drain. H. For box-out in water retaining structures (e.g., manholes excluded) a perforated flexible hose, especially designed to enable injection of sealing material at joints between the surface of box-out and concrete, as well as between the pipe barrel and concrete, shall be installed. Both ends of the hose shall be brought to the accessible surface of the wall and shall be plugged. After the grout has set, but not before 21 days after casting, water shall be injected into the hose and a pressure of ≥ 2 bar be applied and kept for 24 hours. Should water appear on the concrete surface cement slurry shall be injected with a pressure of 12 bar. Immediately after injection the hose shall be flushed out with clean potable water. After 48 hours the water test shall be repeated. If necessary the injection of cement slurry shall be repeated until satisfactory results are obtained. I. Close temporary openings with tight fitting panels, flush with inside face of forms, and neatly fitted so joints will not be apparent in exposed concrete surfaces. J. To ensure a proper surfaces at sleeves a special plug, providing chamfer 1.5 x 1.5cm at the outer rim of the sleeve shall be inserted into sleeve prior to closing formwork. Joints at the surface of plug shall be sealed by masking tape to prevent seepage of cement slurry. K. Do not allow form support ties, bolts and other devices to be embedded in the concrete with out prior approval from the Engineer. L. Ensure that the embedded portions of the ties in concrete have a minimum cover of that to the reinforcement.

END OF SECTION


Page 381 of 589

Section 03346

Concrete Floor Finishing

Section 03346, Concrete Floor Finishing 1

Submittals

A. Provide data on concrete hardener, sealer, and slip resistant treatment, compatibility’s, and limitations. B. Submit method statement. C. Maintenance Data: Provide data on maintenance renewal of applied coatings.

2

Mock-Up

A. Construct mockup area under conditions similar to those, which will exist during actual construction. B. Locate where directed by the Engineer. C. Mockup shall remain throughout the period of the works unless otherwise directed.

3

Deliv ery, Storage And Handl ing

A. As specified. B. Materials must be clearly labeled with product identification, handling, storage and safety instruction.

4

Environm ental Requirements

Temporary Lighting: Minimum 200W light source, placed (2.5m) above the floor surface, for each 2 (40m ) of floor being finished.

5

Products

A. Compounds, hardeners, sealers and slip resistant treatment to be used only with the prior approval of the Engineer.

6

Execution

A. Verify that substrates are in a suitable condition to receive the work specified. B. In areas designed with drains, maintain design floor elevation at walls; slope surfaces uniformly to drains at 20mm per meter nominal or as indicated on drawings. C. Maximum Variation of Surface Flatness For Exposed Concrete Floors: 6mm in 3m.

END OF SECTION


Page 382 of 589

Section 03370

Concrete Curing

Section 03370, Concrete Curing 1

Submittals

A. The Contractor shall provide data on equipment, materials, organization, management and names of responsible crew, names of compacting crew, their skills and training received to perform the tasks on specified in the works.

2

Quality Assu rance

A. The Contractor shall maintain curing data register that is to be checked and signed by the Engineer daily.

3

Materials

A. Fiber mats, Canvas, wet sacks, moist sand or other satisfactory material approved by the Engineer can be used. B. Hessian shall be close knit, new. Hessian used previously for packaging shall not be used. C. Water shall be potable.

4

Execution

A. Curing shall be applied immediately after the concrete has hardened sufficiently to support the covering without damage. B. Immediately after finishing, the concrete shall be protected by placing overlapped polyethylene sheets of 500 gauge for the first 24 hours. Overlapping shall be at least 150mm. C. The polyethylene sheet shall be kept in contact or near contact with the surface of the concrete and prevented from displacement by wind, foot traffic or other disturbances. D. After the elapse of the first 24 hours, remove the polyethylene sheet. Overlapped hessian that has been pre wetted shall be placed in direct contact with the surface of the concrete. The hessian shall be overlapped by at least 150mm. E. Cover the wet hessian immediately with polyethylene sheet overlapped by at least 150mm. The overlapped edges of the polyethylene shall not be coincident with the overlapped edges of the hessian underneath it. Secure the polyethylene and wet hessian against displacement by wind, foot traffic or other disturbances. F. The concrete surface shall be kept moist for continuous period of at least 7 days after casting. G. A sprinkler system of similar to that used in the agricultural industry to keep the concrete wet shall be installed if instructed by the Engineer. The system shall be monitored and managed. Corrections and adjustments made if necessary by a nominated staff and approved by the Engineer. H. For free standing vertical columns the polyethylene for the first 24 hours and the polyethylene and wet hessian subsequently shall be wrapped helically and secured by tying tightly against the column. I. Exposed free ends containing protecting reinforcements shall be protected and kept wet by stuffing with crumpled strips of wet hessian and polyethylene into the spaces in between the protruding reinforcements. J. Ponding shall not be allowed. K. Where pipes and cavities enter the structure the open areas of the pipes shall be stopped with loose stuffing and the free openings taped up with polyethylene to prevent moisture loss from the concrete surface into such cavities. L. In manholes or completely enclosed spaces it may only be necessary to keep the cavity completely isolated and closed with a 10-liter bucket of water contained within. The Engineers prior approval shall be sought before implementing this form of curing. M. Chemical curing membranes shall not be used unless the geometry is of such a nature that there is no alternative upon which it shall be used with the prior approval of the Engineer. If curing membranes are used, at least three of four coats shall be applied depending on the nature and characteristics of the proprietary material.

END OF SECTION


Page 383 of 589

Section 03411

Pre Cast Concrete Unit

Section 03411, Pre-Cast Concrete Unit s 1

Desig n Requi rements

A. Design unit to withstand all loading such as service, wind, suction, hydrostatic, buoyancy, soil, deflection, and thermal movement loads and restraint conditions from initial fabrication to the completion of the structure, including form removal, storage, transportation, and erection. B. Provide adjustment to accommodate misalignment of structure without unit distortion or damage. C. Design system to accommodate construction tolerances, deflection of other building structural members and clearances of intended openings. D. Design anchor bolts, inserts, plates, angles and other cast in items with sufficient anchorage and embedment to support applicable loads.

2

Submittals

A. Shop Drawings: Indicate layout, unit locations, configuration, unit identification marks, reinforcement, connection and joints details, support items, bearing seats, inserts, anchors, concrete cover, location of lifting devices, dimensions, openings, embedded items and relationship to adjacent materials. B. Submit design calculations for the reinforcing, hoisting and connection and anchorage devices, checked and approved by the Municipality’s Structural Engineer. C. Do not proceed with the fabrication until the Engineer approves the design calculation and the shop drawing. D. Submit method statement for lifting, transporting, and erection of the pre-cast units. E. Indicate standard component configurations, design loads, deflections, cambers, bearing requirements, and special design condition. F. Samples: Submit panels sample of sufficient size, illustration, surface finish, color and texture or as indicated in the contract documents. G. Submit design data reports indicating calculations for loading and stresses of fabricated, designed framing. H. Submit quality assurance and quality control procedures for the fabrication of the pre-cast units.

3

Quality Assu rance

A. Perform work as specified and in accordance with the requirements of PCI MNL-116, PCI MNL-123, PCI MNL-120. B. Designer and Fabricator shall be an approved Company specialized in performing the work of this section with min. 3 years experience in the successful completion of projects of a similar design and size. C. Erector shall be a company specializing in performing the work of this section with min. 3 years experience in the erection of projects of a similar size. D. Design pre-cast concrete members under direct supervision of a Professional licensed Structural Engineer experienced in design of this work. E. Welder: Qualified within previous one year in accordance with AWS D1.1 and AWS D1.4.

4

Regul atory Requi rements

A. Conform to ACI 318 and applicable code for design load and construction requirements applicable to work of this section.

5

Deliv ery, Storage, And Protection

A. Transport, handle, store, and protect products as specified. B. Handle pre-cast members in position consistent with their shape and design. Lift and support only from support points. C. Lifting or Handling Devices: Capable of supporting member in positions anticipated during manufacture, storage, transportation, and erection. D. Protect members to prevent staining, chipping, or spalling of concrete. E. Mark each member with date of production and final position in structure.


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Section 03411

6


Products

A. Cement, Aggregate, Water, Admixture and reinforcement shall be as specified. B. Connection and Supporting Devices shall be stainless steel, grade A4/316 in accordance with BS1449. C. Grout shall be non-shrink, non-metallic, non-ferrous minimum yield strength of 70MPa at 28 days Thermo-setting epoxy. D. Bearing Pads shall be high-density plastic or Stainless Steel grade A4/316. E. Bolts, Nuts and Washers: Stainless steel type, grade A4/316. F. Concrete: Class B35 as specified for concrete mix design.

7

Fabrication

A. To prevent formation of blowholes, reduce carbonation of concrete and chloride diffusion an approved form liner shall be used. B. Plain pre-cast concrete for shafts and manhole bases shall be strengthened by reinforcing fibers as specified. C. All external corners shall be chamfered 1.5cm x 1.5cm. Exposed surfaces shall be smooth and dense, free from blowholes, shutter marks and fins. D. Cast iron frames for manhole covers shall be cast in pre-cast concrete covers as shown on drawings. E. Joints between pipe sleeves and concrete shall be made watertight by means of sanding GRP sleeves and puddle flanges before the resin is set. Additional puddle flanges may be required to increase the surfaces of GRP sleeves in contact with concrete. F. Maintain plant records and quality control program during production of pre-cast units. Make records available upon request. G. Ensure reinforcing steel, anchors, inserts, plates, angles, and other cast-in items are embedded and located as indicated on Contract drawings. H. Place and vibrate concrete to ensure proper consolidation, elimination of cold joints, and minimize entrapped air on vertical surfaces. I. Locate lifting devices to permit removal after erection. J. Arrange the unit joints in acceptable way in relation to openings. K. Provide date of casting the product, either scratched or painted on the unit. L. Test concrete for pre-cast units as specified. M. Place and compact concrete for pre-cast concrete units by means approved by the Engineer. N. Ensure finish surfaces of pre-cast concrete units are uniform, and match the accepted sample. O. The interior shall be fairfaced finished surface. P. Do not move or transport pre-cast concrete from the place of casting until an approved curing period elapsed and the design strength has been attained.

8

Joints

A. Joints between pre-cast concrete units shall be made watertight as follows: a. Prime all surfaces, coming into contact with Butyl Rubber Hydrocarbon Bentonite strips (BRHB - strips) as instructed by manufacturer. b. Carefully place two BRHB-strips close to the edges of the joint, providing sufficient overlap to guarantee a continuous seal, on the top of the lower pre-cast unit. c. The BRHB-strips shall be preformed compressible butyl rubber hydrocarbon bentonite strips, suitably dimensioned to provide a 1 cm thick joint under load. They shall not deform for more than 60 % of the original thickness. d. Sealant shall be placed 24 hour after constructing the joint. e. Sealant shall be Polysulphide elastomeric joint sealant, gun grade, > 99% solid content and non-staining. It shall be resistant seal to weather, ozone, salt water, sulphates, heat >75oC, UV radiation and bio-degradation and suitable for the climate and environmental conditions prevailing on Site. All surfaces coming into contact with sealant and/or seal strips shall be prepared and primed as instructed by the manufacturer(s). Sagging, slumping, tackiness are not allowed. Shore-Hardness A equal 25.

9

Finishes

A. Ensure exposed-to-view finish surfaces of pre-cast concrete units are free from pinholes, fins and uniform in color and appearance.


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Section 03411


B. Cure members under identical conditions to develop required concrete quality, and minimize appearance blemishes such as non-uniformity, staining, or surface cracking as specified.

10 Execution A. Erect units without damage to structural integrity, shape or finish. Replace damaged units. B. Damaged units shall be repaired only by approved materials; repair works subject to the approval of the Engineer. C. Align and maintain uniform horizontal and vertical joints, as erection progresses. D. Maintain temporary bracing in place until final support is provided. E. Provide temporary lateral support to prevent bowing, twisting, or warping of units. F. Set vertical units dry, without grout, attaining joint dimension with lead or plastic spacers. G. Lift pre-cast unit from the design lifting hooks. H. Secure units in place. Perform welding in accordance with AWS D1.1.

11 Erection Tolerances A. Design and erect to the following tolerances: a. Maximum variation from plane or location indicated on Drawings is 6mm in 3m and 9mm in 30m, non-cumulative. b. Maximum offset from true alignment between units is 6mm. c. Maximum variation from dimensions indicated on reviewed shop drawings is +/- 3mm. d. Exposed joint dimension: 9mm +/- 3mm. e. When units cannot be adjusted to conform to design or tolerance criteria, cease work and advise Engineer. Execute modifications as directed.

12 Protection Storing, transportation and placing of units shall be such to avoid damage and/or overstressing at any time. Units shall be adequately braced and supported to ensure proper alignment during erection.

13 Pre-Cast Yards A. Forms for pre-casting shall be placed on clean concrete flooring, suitably dimensioned to carry the loads, enough forms shall be made available to enable curing as specified. B. The Contractor shall submit shop drawings to obtain the Engineer’s approval for the arrangements of pre-cast yards before starting installation works. C. The pre-cast yard shall be sized to provide sufficient space for storing. The following tables show the minimum requirements (but not limited to) for pre-cast yards. D. Pre-cast yard shall conform with the following: Description

Requirements

1 2

Area Floor

3

Roofing

4

Lighting

5

Water supply for Curing

Min. 1000m Concrete or Asphalt pavement with elevated working platforms. The yard shall be covered with a properly designed roofing system, the roof shall be either sufficiently high to accommodate the lifting and transportation equipment or provided with will designed opening for the same. Adequate illumination and overhead lights for night shift. GRP under ground tanks and overhead insulated tank shall be used to store the sweet water obtained from ADWEA or other approved sources. Water points shall be provided at convenient locations and equipped with flexible hosepipes. Adequate lifting & transportation equipment, poker and table vibrators, ladders, etc

6 7 8 9

Equipment Testing facility Boundary wall Curing facility


2

Concrete samples moulds, Slump app., Thermometer, concrete cube curing, etc. 2.0m Height provided with gates at suitable locations. Adequate water, hessian and polyethylene sheets etc.

Page 386 of 589

Section 03411


Reinforcement Yard Description

Requirements

1

Area

2

Roof

3 4

Floor Equipment

Min. 400m It shall be provided with proper roof designed so as to accommodate the lifting and transportation equipment. Concrete / Asphalt with elevated working platforms Teflon mandrels, Re-bar bending tools, bending and cutting machines…etc.

2

Coating Yard Description

Requirements 1. 2.

1

System

3.

4. 1. 2. 2

Applicators 3.

2

Fully covered and enclosed with minimum area of 50m . Equipped with both manual and spray painting equipment and provided with a sand blasting facilities. Provided with coating testing facilities such as as coating thickness, pull-off, holiday tests etc. and temperature and humidity measuring devices shall be readily available. Experienced and qualified QC personal shall supervise the coating works. Coating shall shall be carried carried out only by the applicators specialized specialized in this field. The applicators applicators shall be approved by the Engineer Engineer and Department Department prior to proceed with the works after site demonstrations have been carried out and the standard workmanship is established. established. The performance performance of these applicators applicators shall be appraised appraised on regular basis. basis. Stores

Description

Requirements

1

Area

Closed area min. 50m to store material at ambient temperature.

2

Temperature

Air-conditioned ir-conditioned with approved approved facilities facilities to maintain maintain inside temperature temperature at 22 C at all times.

2

o

E. Site laboratory a. A sufficient equipped laboratory shall be provided on site to carry out the concrete and aggregates tests as per the updated requirements of the Department. b. Qualified and trained QC-personnel shall shall be appointed to carry out the testing works in the site laboratory. c. Minimum requirements for the site laboratory shall be established on site depending on the Contractor’s proposal if he intends to employ independent testing laboratory.

END OF SECTION


Page 387 of 589

Section 04300

Masonry

Secti Section on 0430 04300, 0, Mason Masonry ry and Plasterin g 1

General

A. Prior to the start of each major type of masonry masonry work, meet at the site and review the installation installation procedures and coordination with other work. Meetings shall include Contractor, Engineer and Major Material Manufacturers as well as others whose work must be coordinated with the masonry work. B. Ensure coordination between masonry work and concrete work such that all inserts and flashing reglets required for the proper installation of masonry work, are correctly pre-installed. C. Examine all parts of the supporting structure and the conditions under which the masonry work is to be installed, and notify the Engineer in writing of any conditions detrimental to the proper and timely completion of the work. Do not proceed with the installation of masonry work until satisfactory conditions have been corrected in a manner acceptable to the Engineer.

1.1.1 Submittals A. Submit manufactu manufacturer's rer's printed printed literature literature indicating indicating product product specification specification and installati installation on instructions instructions for each product required by this Section. B. Submit manufacturer's certification that the following comply with the requirements specified: a. Sulfate Resistant Cement SRC. b. Hydrated Lime c. Mortar Aggregates and sand d. Concrete Masonry Units (all types specified) e. Reinforcing Bars f. Plasticizer, Plasticizer, etc. C. Submit, in accordance with the requirements of the Contract Documents, and following the submittal of manufacturer's literature and data, 3 samples of each unit masonry hereinafter listed. Samples will be reviewed for color and/or texture only. Compliance with all other requirements is the exclusive responsibility of the Contractor. Samples to be submitted as follows: a. Hollow concrete blocks; two of each size. b. Solid concrete blocks; two of each size. E. Submit Shop Drawing indicating details of anchors, inserts, joints, connections to adjoining adjoining work or materials. Also include elevations indicating setting out and placement of all joints, openings, cutouts, etc. F. In addition to above submit Shop Drawings for fabrication, bending and placement of reinforcement bars for unit masonry work. Show bar schedules, diagrams of bent bars, stirrup spacing, lateral ties and other arrangements and assemblies as required for fabrication and placement of reinforcement for unit masonry work.

1.1.2 Quality Assurance A. B. C. D.

Work is to be carried carried out by persons persons skilled skilled in laying laying unit unit masonry. masonry. Paint mixer drums white on outside and keep white. Keep all equipment, used for mixing transporting and laying mortar, cool Place a recording thermometer at each location of of unit masonry masonry work during its construction.

1.1.3 Qualifications A. Manufacturer(s) Manufacturer(s) shall be companies companies specializing specializing in manufacturing manufacturing the Products Products specified specified in this section with minimum three years experience.

1.1. 1.1.4 4 Regulato Regulato ry Requirements Requirements A. Requirements Requirements for fire-rated or lateral support support conditions conditions are to be regulated regulated in compliance compliance with local building codes and are not necessarily fully defined on the Drawings. B. Whenever a fire-rating is shown for a wall, use masonry units in that wall complying with the requirements established by the local governing authorities.


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1.1.5 Mockup A. Provide mockup of masonry. masonry. B. Prior to the installation of unit masonry work, and preceding pre-installation conference, provide a sample wall mock-up for all types of masonry units. C. Construct a masonry wall into a panel sized 2 m long by 1.5 m high, which includes mortar and accessories, structural backup, wall openings, flashings, wall insulation, air barrier, vapor barrier and parging indicating the proposed range of color, texture and workmanship to be expected in the completed work. D. Locate as directed by the Engineer. E. Provide each sample wall panel using materials, together with bond and joint tooling, shown or specified for final work. Provide special features as directed for caulking and contiguous work. F. Obtain acceptance of visual qualities of each sample panel before proceeding with the final work. G. Retain each sample panel mock-up during construction period as a standard for judging completed masonry work. Do not alter, move or destroy mock-up until work is completed. H. Mockup may [may not] remain as part of the permanent permanent work.

1.1.6 1.1.6 Delivery , Storage, Stor age, and Handli ng A. Deliver, store, store, protect protect and and handle handle products products to site as specified. specified. B. Do not change brands or sources of supply for masonry materials during the course of the work. C. Deliver unit masonry materials, other than bulk materials, to site in manufacturer's unopened containers, bundles, pallets or other standard packaging devices, fully identified with name, type, grade, color and size. D. Protect all unit masonry material material during shipment, storage and construction against wetting and soilage or intermixture with earth or other types of materials. E. Take all necessary precautions to prevent all masonry items from chipping, cracking or other damage during transportation, unloading and storage on site. Damaged units will not be allowed to be installed. F. Do not use use metal reinforcing or ties having loose rust or other coatings that will reduce or destroy bond. G. Outside storage of masonry masonry units and reinforcement shall be on plank plank platforms, off the ground, in dry locations. H. Inspect for damage.

1.1.7 Environmental Requirements Take all necessary precautions to keep mortar and blocks and other materials cool and in particular: o a. Do not mix mortar or lay units while shade temperature is above 40 C. on a rising o thermometer or above 43 C. on a falling thermometer. o b. Do not allow temperature of fresh mixed mixed mortar to exceed 32 C. Take suitable measures to ensure this. c. Do not lay masonry units having a film of water on their surfaces. d. The Contractor will be deemed to have allowed in his Tender for all steps necessary for compliance with the above.

1.1.8 Coordination A. Coordinate Coordinate the masonry masonry work with veneer, veneer, installation installation of of window anchors. anchors. B. The Work of of this Section shall be completely coordinated with the work of other sections. Verify dimensions and Work of other trades, which adjoin materials of this Section before the installation of items herein.

1.1.9 Protection o

A. When the the ambient ambient air temperature temperature is more than than 30 C. in the shade and the relative humidity is less than 50% protect the masonry from direct exposure to the wind and sun for 48 hours after installation. B. Protect partially completed unit masonry walls against weather when work is not in progress, by covering top of walls with strong, waterproof, non-staining membrane. Extend membrane at least 600 mm down both sides of walls and anchor securely in place ensuring that there is free air flow sufficient to prevent heat build-up. Contract 106 , Volume II

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C. Keep completed walls clean and protect from staining. Use suitable corner guards to protect the corners of exposed masonry walls.

1.1.10 1.1.10Extr a Materials A. Provide 50 units units of each size, color color and type of glazed glazed pre-faced pre-faced..

2

Products 2.1.1 Concrete Blocks 2.1.2 2.1.2 Mix Design

A. Blocks shall be manufactured manufactured with cement and fine aggregate aggregate in approved approved vibrated pressure machines. B. Blocks shall be made made from a mix of 250 kg sulphate resisting cement to 1,500 kg fine aggregate. If for any reason the strength requirement is not obtained the cement content shall be increased until the specified strength has been achieved. C. The water cement ratio of the mix shall be kept to the minimum but shall be sufficient to allow complete hydration of the cement.

2.1.3 Dimensions A. Blocks shall be hard, hard, sound, square and and clean with sharp, sharp, well defined arises. arises. Allowable tolerance tolerance on any dimension shall not exceed 1 %. B. The blocks shall be 40 cm long and 20 cm high and to the width specified. C. The thickness of the membranes or solid portions of the hollow blocks shall not be less than 2.5 cm each for blocks 10 cm wide and not less than4 cm for hollow blocks ≥ 15 cm wide. The combined thickness of the solid portions shall exceed one third of the total thickness in either horizontal direction. D. The design of the cavities and webs of hollow blocks shall be submitted to the Engineer Engineer for approval before manufacture.

2.1. 2.1.4 4 Manuf Manuf acture, Storin g A. Blocks shall shall be manufact manufactured ured in an approved approved vibrating vibrating pressure pressure machine. machine. B. Immediately after moulding, the blocks shall be placed in the shade on a clean level pallet and shall be cured by being continuously sprayed with water or other approved means for a period not less than 7 days. C. All blocks shall be carefully handled to prevent damage and shall be protected at all times. They shall not be stored on earth or in a honeycomb fashion. Solid stacking will not be permitted. D. All blocks shall be at least one month old before being used in the Works.

2.1.5 Sampling, Testing A. For a sample of twelve blocks, randomly randomly selected from a days production, production, the average average 28 days compressive strength shall not be less than 3 N/mm² and no block of the twelve shall have a strength less than 2.5 N/mm² on the gross area. Similarly, the solid block at 28 days compressive strength shall not be less than 6 N/mm² and no block of the tested batch shall have strength less than 5 N/mm². Should the sample fail to comply with these requirements, the whole batch from which the sample was selected shall be rejected.

2.1. 2.1.6 6 Sand Sand Lime Facin Facing g Brick s 2.1.7 2.1.7 Dimens ion s, Shape, Streng th A. Sand lime facing facing bricks shall shall be solid, 220 x 108 x 67 mm, yellow yellow beige colour colour as approved approved by the Engineer. B. They shall be be uniform in colour, clean, with sharp well defined defined arises and shall be free from cracks, balls of clay or loam or visible particles of lime or any visible damage or other imperfections due to transport or handling. 2 C. The compressive strength shall be 15 N/mm . Contract 106 , Volume II

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2.1.8 Handling, Storing A. All bricks shall shall be delivered delivered neatly neatly stacked on wooden wooden pallets pallets and stored stored on Site to the the satisfaction satisfaction of the Engineer. B. Loose bricks shall not be unloaded by tipping but shall be carefully unloaded by hand. C. All stacks shall be covered by tarpaulins for protection against damage before use.

2.1.9 2.1.9 Glass Masonr y A. Glass masonry masonry shall be constructed from hollow glass stones stones 190 x 190 x 80 mm thick complying with DIN 4242 and DIN 18175 cast into panels. B. Every third horizontal joint shall be reinforced with a 4 mm high tensile reinforcement bar welded to the steel profiles surrounding the panels. C. Frames for panels shall be manufactured manufactured from H - channels, profiles and other other steel profiles, being standard steel profiles and not be especially manufactured, hot dipped galvanised after assembling. D. Bolts, nuts, washers shall be in stainless steel grade A4/316. E. Frames shall be securely anchored to the concrete columns and beams beams and shall have a neat appearance. F. 2 cm wide expansion joints, filled with a compressible non rotting joint filler shall be foreseen at the top and on one side of the panel. G. Joints between steel frames and masonry or concrete shall be covered by a flat anodised aluminium profile or stainless steel fixed with screws to the concrete. H. All dissimilar material shall be protected from connecting to each other by using appropriate measures recommended by manufacturer and approved by the Engineer to avoid galvanic corrosion. I. Protection system for frames shall be as follows: a. 1 layer approved Mist coat (BS 729) b. 2 layer approved epoxy coating 150 micron each each c. 1 layer approved polyurethane 50 micron.

2.1.10 2.1.10Mort ar and Grout Grou t A. Mortar for brick- and block-works block-works shall consist of 1 part sulphate sulphate resisting cement and 3 parts of sand, measured by volume. B. An approved mortar plasticizer shall be used in accordance with the manufacturers recommendations. C. Mixing shall be carried out by means of an approved mechanical batch mixer. The cement cement and aggregates shall be mixed dry until a uniform mix is obtained. Sufficient water shall then be added and the mixing continued until a homogeneous mix has been achieved. D. The mortar shall be used immediately after mixing but in no case after the initial setting commences. Mortar shall not be remixed and used after the initial set has taken place. E. The ingredients shall be mixed in an approved mechanical mixer or shall be mixed together dry on a clean wooden stage until the mix is homogeneous in color. Water shall then be added in sufficient quantity to give no more than stiff workability. The whole shall then be turned until perfectly mixed. F. Mortar shall be used within 30 minutes and shall not be remixed or worked up again after it has stiffened. Any mortar that has commenced to set shall be removed from the site.

2.1.11 2.1.11Damp Proof Proo f Course Cour se A. All masonry walls at ground floor level shall be protected protected against against rising humidity by a bituminous bituminous felt layer to be placed approximately 20 cm above concrete slabs or foundation beams on a 2 cm thick mortar bed. Overlaps of minimum 20 cm at joints and at corners shall be arranged. B. Surfaces of all blinding below floor slabs, foundations for guard houses and administration building shall receive a protective coating of an approved brand as specified. C. Preparation of concrete surfaces and application of coating shall be as recommended by the manufacturer of coatings.

2.1.12 2.1.12Flashi ngs ng s A. Sheet Metal Flashings: Flashings: As shown in the drawings, drawings, recommended recommended by the manufacturers manufacturers and approved by the Engineer. Contract 106 , Volume II

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2.1.13Accessories A. Joint Filler: compressible joint filler of closed cell PVC, SBR or Neoprene, either solid or tube type, of proper dimension to serve as back-up for joint sealant at face of masonry. B. Preformed Control Joints: solid rubber "key section" joint filler ( 60 to 80 Shore A durometer hardness) designed to maintain lateral stability in masonry wall. Provide with corner and tee accessories, heat fused joints. C. Do not use control joint filler at building expansion joints. D. Joint Fillers: use approved fire resistant material to meet the required fire rating. E. Wood Nailers: for wood nailers and similar items to be set into the masonry work see other relevant sections of these specifications. F. Sealants: use approved fire resistant sealant as specified to meet the required fire rating Cavity Vents: Aluminum grilles; insect/mosquito resistant. G. Cleaning Solution: Non-acidic, not harmful to masonry work or adjacent materials.

2.1.14Lin tels A. Pre-cast Concrete Lintels as shown in the drawings and / or instructed by the Engineer.

3

Execution 3.1.1 Examination

A. B. C. D.

Verify that field conditions are acceptable and are ready to receive work. Verify items provided by other sections of work are properly sized and located. Verify that built-in items are in proper location, and ready for roughing into masonry work. Report unsatisfactory conditions to Engineer and do not proceed until rectified to satisfaction of Engineer.

3.1.2 General A. Comply with the manufacturer's printed instructions and recommendations for the installation of each type of masonry product, unless otherwise shown or specified. B. Build masonry construction to the full thickness shown, except for single width masonry walls, which may be built to the actual thickness of the masonry units, using blocks of nominal thickness shown. C. Form chases and recesses as shown and as may be required for the work of other trades. Do not chase hollow blocks. Do not cut horizontal or diagonal chases in load bearing work. Provide not less than 200 mm of masonry between chase or recess and jamb of openings and between adjacent chases and recesses. D. Leave openings for equipment as shown or required to be installed at later date. Complete masonry work after equipment is in place using materials identical with those immediately adjacent to the opening. E. Step back unfinished work for joining with new work; tooting will not be permitted. Before new work is started clean exposed surfaces of set masonry, wet units lightly (if specified to be wetted), and remove loose blocks and mortar prior to laying fresh masonry. F. Do not build in concrete blocks until at least 28 days after manufacture and until they are fully cured.

3.1.3 Preparation A. Direct and coordinate placement of metal anchors supplied to other sections.

3.1.4 Workmanship A. All masonry work shall be set out and built to the dimensions as shown on drawings or as instructed by the Engineer. B. All blocks or bricks shall be carefully handled to prevent damage. No cracked, chipped or broken block or brick will be allowed on the Works. C. The Contractor shall cut and fit brickwork or block work as required, leave or form chases for edges of concrete, pipes and conduits and generally perform all cutting away for all trades and making good after completion to the satisfaction of the Engineer. D. End blocks for hollow block masonry as at doorjambs, window openings, etc. shall be solid. Contract 106 , Volume II

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E. Broken blocks or bricks shall not be used except for bonding purposes. F. Walls and partitions shall be bonded to one another at junctions.

3.1.5 Wetting A. Before use the suction rate of all blocks and bricks shall be adjusted by wetting. B. The tops of walls left unfinished shall be wetted before work is being recommenced.

3.1.6 Placin g Of Bloc ks/Bri cks A. Blocks and bricks shall be laid in true and regular courses on a full bed of mortar of approximately 1 cm thickness. B. They shall be well buttered with mortar before being placed and all joints shall be thoroughly flushed up as the work proceeds. All horizontal joints shall be properly level. The vertical joints shall be properly lined and quoins, jambs and other angles plumbed as the works proceeds. All walls shall be plumbed vertical. C. Walls shall be carried up in the stretcher bond regularly without leaving any part more than one meter lower than the other. Wall sections left at different levels shall be raked back.

3.1.7 Pointing A. The external joints of brick facing shall be raked out for a depth of 20 mm as the works proceeds. All dust shall be carefully brushed out. B. Before pointing the joints shall be thoroughly wetted. The mortar used shall be of an approved mix and a colour matching that of the bricks.

3.1.8 Bonding To Concrete A. All masonry work shall be bonded to concrete structures by means of horizontal strips of galvanized expanded metal lathing 80 mm wide cast into concrete and left protruding for building into horizontal joints at every 60 cm approximately.

3.1.9 Cavity Wall A. Cavity walls shall consist of a 20 cm thick hollow block wall and a 108 mm thick facing brick wall with approximate 5 cm thick cavity. B. The two walls shall be bonded together with wall ties spaced one meter apart horizontally and approximately 40 cm apart vertically and staggered. Extra ties shall be provided at reveals, quoins and openings. C. Wall ties shall be the butterfly twist type 3.2 mm zinc coated mild steel wire having a finished length of 26 cm. D. The cavity shall be kept clear by lifting screeds or by other approved means and shall be left clean at completion. E. Each 5th vertical joint of the bottom layer and of the top layer in the brick facing shall be left free from mortar to provide ventilation. F. Do not permit mortar to drop or accumulate into cavity air space or to plug weeps. G. Build inner wall ahead of outer wall to receive cavity insulation and air/vapor barrier adhesive.

3.1.10Reinforcement and Anchorage A. If specified provide horizontal joint reinforcement and vertical reinforcement in masonry walls. B. Space horizontal reinforcement 600 mm centers for interior walls and 400 mm centers for exterior walls unless otherwise shown or specified. C. Lap reinforcement a minimum of 150 mm at ends and do not bridge control and expansion joints with reinforcement except at wall openings. D. Use matching prefabricated "T" and "L" sections of reinforcement at corners and wall intersections to provide continuity. E. Center reinforcement in wall to provide a minimum mortar cover of 15 mm at side rods. F. Place masonry joint reinforcement in first and second horizontal joints above and below openings. Extend minimum 400 mm each side of opening. G. Place joint reinforcement continuous in first [and second] joint below top of walls. H. Reinforce joint corners and intersections with strap anchors 400 mm center.


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3.1.11Boundary walls A. The boundary wall shall be constructed from reinforced concrete foundations, ground beams and columns with panels built from sand lime bricks with a color matching that of the pumping station. The average distance between columns shall be 4 m, all as shown on drawings.

3.1.12Masonr y Flashi ngs A. Extend flashings horizontally at foundation walls, above ledge or shelf angles and lintels, under parapet caps, at bottom of walls and where instructed. B. Turn flashing up minimum 200 mm and bed into mortar joint of masonry or seal to concrete or otherwise required. C. Lap end joints minimum 150 mm and seal watertight. D. Turn flashing, fold, and seal at corners, bends, and interruptions.

3.1.13Lin tels A. Lintels shall be the prefabricated reinforced concrete type as shown on drawings and / or as instructed.

3.1.14Bui lt-In Work A. As work progresses, install built-in door and window frames, anchor bolts, plates, and other items to be built-in the work and furnished by other sections. B. Install built-in items plumb and level. C. Bed anchors of door and window frames in adjacent mortar joints. Fill frame voids solid with grout. Fill adjacent masonry cores with grout minimum 300 mm from framed openings. D. Do not build in organic materials subject to deterioration.

3.1.15Toleranc es A. Maximum Variation From Alignment of Columns: 6 mm.

3.1.16Cuttin g And Fitti ng A. Cut and fit for chases, pipes, conduit, sleeves, grounds and any other items. Coordinate with other sections of work to provide correct size, shape, and location. B. Obtain approval prior to cutting or fitting masonry work not indicated or where appearance or strength of masonry work may be impaired.

3.1.17Field Qualit y Contro l A. Inspect and test all masonry work. B. Inspect and test engineered masonry work. C. Inspect and test parging work.

3.1.18Cleaning A. During the completion of masonry installation and the tooling of joints, enlarge any voids or holes and completely fill with mortar. Point up all joints at corners, openings and adjoining work to provide a uniform, neat appearance, properly prepared for the application of sealant compounds and other work to follow. B. All exposed work shall be cleaned without the use of acid. Cleaning shall not be done until mortar is thoroughly set and hard. C. Before wetting wall, remove large particles of mortar by means of wood scraper, or, if necessary, by means of chisel or wire brush. D. Pre-soak the wall, saturating the masonry with clean water and flush off all loose mortar and dirt. E. Using a stiff fiber brush only, scrub down the wall with a solution of 0.25 liter household detergent and 0.25 liter of tri-sodium phosphate dissolved in 4 liters of clean water. F. Thoroughly wash off all cleaning solution, dirt and mortar crumbs using clean pressurized water. G. If after this cleaning procedure is completed, the wall or portion of the wall is not clean, in the judgment of the Engineer, clean with an acid solution by means and methods acceptable to the Engineer. If cleaned with an acid solution, all sash, metal lintels and other material shall be thoroughly protected. Contract 106 , Volume II

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H. Particular care shall be taken to prevent smearing mortar on surfaces of concrete masonry units. If mortar smearing occurs, it shall be removed while soft, when possible; if dry and hard, it shall be removed by rubbing with a small piece of concrete masonry. All mortar smears, drippings, etc., on expanded faces of concrete masonry units shall be removed.

3.1.19Curing A. Walls shall be properly cured by water sprinkling for a period of not less than three days after construction.

3.1.20Protectio n of Finish ed Work A. Protect finished Work as specified. B. Without damaging completed work, provide protective boards at exposed external corners which may be damaged by construction activities.

3.1.21Curb Stones A. Pre-cast curb stones shall be manufactured from concrete B45 to the dimensions shown on drawings. They shall be placed on a 2 cm thick cement and sand (1:3) mortar bed with vertical joints 2 cm wide. Foundation and haunching shall be in-situ concrete B35. B. Joints between curbstones shall have a width of 4 mm and be filled with a sand/cement (1:1) mortar with one fifth (1/5) part hydrated lime and sufficient water to make the mixture plastic and easily smoothed. At each 4 meters the joint between curbstones shall be filled with an approved joint filler 20 mm thick to form an expansion joint. The filler shall extend through the curbstone, bed, backing and channel, and shall be trimmed to the finished shape of the curbstones. C. Curbstones shall be placed before asphalting or paving is being carried out. D. Material used for Curb-stone shall meet the requirements of Abu Dhabi Municipality as specified.

3.1.22Flag Stone Pavement A. Interlocking blocks shall be placed to falls and cross falls in an approved regular pattern on a 5 cm thick (after compaction) sand bed laid over a 15 cm thick base course layer. Edge stones shall be prefabricated or neatly cut to fit. Broken stones or stones with damaged edges will not be accepted. The block’s permeability shall not exceed 2.5 cm when tested as specified under Section Concrete herein. Cement used shall be sulphate resisting cement. Colors shall be non-fading. B. Material used for interlocking blocks shall meet the requirements of Abu Dhabi Municipality as specified.

3.1.23Dimensional Toleranc e A. Length or width of unit shall not differ by more than 1.6 mm from designated dimensions. Height of unit shall not differ by more than 3.2 mm from the specified standard dimensions. B. The thickness of interlocking tiles shall be 8 cm for carriage ways and 6 cm for footpaths.


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4

Masonry

Plastering A. Plaster shall consist of 1 part cement and 3 parts of sand, measured by volume. An approved mortar plasticiser shall be used in accordance with the manufacturer’s recommendation. The proportions of the mix shall, if necessary be adjusted as recommended by the manufacturer. Mixing shall be carried out by means of an approved mechanical batch mixer. The cement and aggregates shall be mixed dry until a uniform mix is obtained. Sufficient water shall then be added and the mixing continued until a homogeneous mix has been achieved. The plaster shall be used immediately after mixing but in no case after the initial setting commences. It shall not be remixed and used after the initial set has taken place. B. Plastering of walls shall be composed of two layers to make up a total thickness of 15 mm. All surfaces shall be finished true and smooth and be brought to fair plumb and level. The backing coat shall consist of an approximately 10 mm thick layer and shall be scratched to form key. The finishing coat shall be 5 mm thick and shall be finished with a steel float to approval. C. Joints in block masonry, to receive plaster, shall be thoroughly cleaned and shall be raked out to form key. D. External angles in plastered walls shall be protected by fabricated metal angle beads for a total height of 2.00 m, measured from the finished floor level. E. At joints between masonry and concrete a 1 cm wide 1 cm deep groove shall be foreseen. The edges of these grooves shall be absolutely straight.

END OF SECTION


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Section 07105

Bituminous Waterproofing Membrane

Section 07105, Bitumi nou s Waterproofing Membrane 1

General

A. Application of water proofing system shall be in strict compliance with the manufacturers recommendations and instructions, all subject to the approval of the Engineer. B. Waterproofing membrane shall be applied to all concrete surfaces in contact with soil and/or groundwater. C. Vertical Waterproofing System shall be capable of resisting water pressure of 2bar for structures ≤ 18m deep and 2.5bar for structures > 18m deep, preventing moisture migration to interior. D. Horizontal Waterproofing System shall be applied to upper smooth faces of concrete blinding layers and upper horizontal smooth faces of substructures below finished ground level and protected by 5 cm thick, approved concrete screed. E. The finishing of the membrane above ground level shall be considered as work fundamental to the integrity of the tanking system and shall be completed immediately following the application of the membrane.

1.1.1 Submittals A. The Contractor shall submit for the Engineer’s approval: a. Product data of primer, bitumen, mastics, plywood and characteristics of reinforcement fabric b. Detailed method statement for installation and repairs of damaged tanking c. Shop drawings indicating details of membrane and flexible flashing, control and expansion joints, sealing at openings, projections, penetrations, reglets, and waterproofing of holes, slots and sleeves d. Names of tanking applicators along with training certification and experience profile e. Certificate confirming that products meet or exceed specified requirements f. Manufacturer's installation instructions indicating special procedures and perimeter conditions requiring special attention, handling and storage requirements g. Guarantees for performance h. Details of equipment.

1.1.2 Quality Assurance A. The Contractor shall test material samples in accordance with applicable standards. B. The membrane shall withstand an elongation as specified without showing signs of distress and of withstanding cracking of the substrate up to a crack width of 6mm. C. Applicator shall be a company specializing in performing the work of this section acceptable to the manufacturer with documented experience and to be approved by Department / Engineer. D. Applicators shall perform site demonstrations in the presence of the Engineer if requested. E. The performance of these applicators shall be appraised on regular basis. F. Handling, Storage and application details for tanking shall be in accordance with the membrane manufacturer’s recommendations, all subject to the approval of the Engineer. G. Appropriate documentation in approved format shall be prepared by the Contractor for the following steps and made available to the Engineer on request: a. Surface preparation b. Primer application c. Torching of membrane d. Installation of protective cover/board H. The Contractor shall construct a mockup of horizontal and vertical waterproofed panel representing finished work including internal and external corners, sealing, base flashing, control and expansion joints, between concrete surfaces and pipes and over pipes. I. The mockup may remain as part of the permanent Works, subject to approval of the Engineer.

2

Products

A. Damp-proof courses shall be Bitumen Type B complying with BS743. B. Mastic for pointing shall be approved mastic butyl joint sealing compound of approved color applied by gun in full accordance with the manufacturer instructions and as approved by the Engineer. C. The primer shall be from the same manufacturer of the membrane or as recommended by the manufacturer. Contract 106, Volume II

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D. Membranes used for tanking shall be torch applied, reinforced with non-woven type polyester fabric as specified. E. Self-adhesive tanking membrane shall not be used. F. The membrane shall be in compliance with the following table: NO 1 2 3 4

Thickness Reinforcement Bitumen type Tensile

5

Elongation

6

Tear Resistance

7 8 9 10 11

3

Item

Longitudinal Transverse Longitudinal Transverse Longitudinal

Transverse Softening Point of Matrix Coating UV-Radiance Resistance (if exposed) Water Vapor Permeability (gr/m²/24hr) Water Absorption Puncture Static @ 25kg Resistance Dynamic @ 9.0 Joule

Requirement Min. 4.00mm Polyester fabric – Min. 175 gr/m² APP modified bitumen Min. 800 N/5cm (ASTM D146) Min. 600 N/5cm (ASTM D146) Min. 40% (ASTM D146) Min. 50% (ASTM D146) 200 N (ASTM D4073) 250 N (ASTM D4073) Min. 150 °C (ASTM D36) Required – (ASTM G53) <0.50 (ASTM E90) 0.25 % (Max.) – (ASTM D-750) 800 N (ASTM 154) 13 N (ASTM 154)

Execution 3.1.1 Preparation and Appl icatio n of Primer

A. Water proofing system shall not be applied before 28 days from casting the concrete unless otherwise recommended by the Manufacturer and approved by the Engineer. B. Concrete surfaces shall be dry to below 5% moisture (measured by an electronic moisture meter) before application of the primer. C. It is the responsibility of the Contractor to verify the substrate conditions before application of water proofing system. Waterproofing shall not be applied to surfaces unacceptable to the Engineer. D. Surfaces to be waterproofed shall be dry and completely cleaned. E. Any dust, sand, oil, dirt, grease, loose aggregates, debris, laitance, protruding ribs, nails and any imperfections that will prevent the subsequent tanking from lying flat and in intimate contact with the surface shall be removed. F. Voids, cracks, holes, handling/lifting indentation etc. shall be repaired with approved material. G. External edges/corners shall be chamfered to 20mm x 20mm. Internal corners shall be filled with approved angle fillet to 20mm x 20mm. H. Adjacent surfaces that are not designated to receive waterproofing shall be protected. I. The primer shall be applied evenly and allowed to dry until tack-free, as stated by the manufacturer and approved by the Engineer. J. The Contractor shall verify that items, penetrating surfaces to receive waterproofing system, are securely installed. K. Approved mastic material shall be applied to seal penetrations, small cracks, or minor honeycomb in substrate.

3.1.2 Appl icatio n of Membrane A. Membranes applied to vertical and inclined surfaces shall terminate 300mm above ground level except where otherwise shown on the Drawings, by turning into a 20mm by 30mm chased groove which shall subsequently be neatly pointed with a sealant recommended by the tanking manufacturer and approved by the Engineer. B. The membrane shall be applied in one or two layers so that the total thickness is at least 4mm for single layer applications and at least 6mm for double layer applications. C. The tanking edges shall be overlapped on the next sheet by at least 150 mm. Where two layers are applied laps shall be staggered from one layer to the next by a minimum of 300mm.

Contract 106, Volume II

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Section 07105


D. The sealant and the felt shall be trimmed with an aluminum flashing fixed to the concrete wall above the membrane as shown on the Drawings and approved by the Engineer. E. Free ends of membrane shall be secured in place to prevent peeling, stripping or dislocation of the tanking. F. Seams of membrane shall be heated and smeared to form a continuous layer of membrane. G. Beads of molten material that appear at seams shall be smoothened.

3.1.3 Protecti on of finished Work A. All the membrane sheets shall be protected using new 4.0 mm thick approved plywood sheets or protection board unless otherwise specified or directed by the Engineer. B. Traffic over unprotected or uncovered membrane is not permitted. C. Membrane and external protection shall be protected from damage. D. Membranes shall be applied in a single uninterrupted operation and shall be protected immediately following the completion of application. E. The protection material shall be placed against the membrane and firmly held in position by temporary struts or other means while backfill is being placed. Struts that apply point loading shall not be used. F. Damage to the membrane during protection or backfilling shall not be accepted. G. Damaged membranes shall be repaired by methods approved by the Engineer.

END OF SECTION


Page 418 of 589

Section 07920

Sealants

Section 07920, Sealants 1

General

A. This section specifies material and installation of external and internal joints as shown on drawings and / instructed by the Engineer. B. Not-withstanding the types of sealant specified herein, the Contractor shall in all cases be responsible for providing sealant materials being the best of their respective kinds, compatible with adjoining materials and suitable for the purpose intended.

1.1.1 Submittals A. The Contractor shall submit for the Engineer’s approval at least but not limited to the following: a. Detailed description of material, specifications, test results etc. b. Published data or manufacturer's letter, clearly indicating that each product to be furnished complies with these Specifications, is recommended for the application shown and is compatible with other material in the joint system c. Manufacturer’s recommendations and instructions for handling, storage, mixing, priming, installation, curing and protection of each type of sealant d. Test certificates for each type of joint sealant delivered to site. e. Fully cured samples of each type of sealant 300 mm long forming a sealed joint between materials to be sealed. The Engineer will review such samples for colour and texture only, the Contractor shall be solely responsible for the proper functioning of the sealant. f. Detailed method statement covering all aspects of installation for all types of sealants utilized. g. Guarantee stating that the sealant system installed will be watertight and free from defects for a period of not less than ten (10) years from date of handing-over of the Works.

1.1.2 Mock Up A. If requested by the Engineer, the Contractor shall provide sample applications of sealants at locations designated by the Engineer. B. Such samples shall represent the primary types of materials, substrate surfaces, joint size, exposure and other conditions to be encountered in the work. C. The Contractor shall allow at least one week for preparation, curing examination of samples prior to execution of permanent works. D. Samples shall be visually examined for staining, dirt pickup, shrinkage, colour, general workmanship and appearance. E. The Contractor shall cut and pull the sealant from each sample joint to examine for internal bubbles or voids, adhesion and general compatibility with substrate.

1.1.3 Environmental Requirements A. The Contractor shall comply with the following: a. Do not proceed with installation of sealants during inclement weather unless all requirements and manufacturer's instructions can be complied with and unless the work can proceed in accordance with the agreements of the pre-installation meeting. b. Do not proceed with the installation of sealants under extreme temperature conditions which would cause joint openings to be at either maximum or minimum width, nor when such extreme temperatures or heavy wind loads are forecast during the period required for initial or nominal cure of sealants. c. Whenever possible, schedule the installation and cure of sealants during period of relatively low temperatures (but well within manufacturer's recommended range) so that subsequent tensile stresses upon the cured sealants will be minimised.

1.1.4 Delivery, Storage And Handling A. Materials shall be delivered in manufacturers' unopened containers, fully identified with brand, type, grade, class and all other qualifying information. B. Materials shall be stored in a dry location in such a manner as to prevent damage or intrusion of foreign matter. C. Material, which have once been wet or damaged shall be marked “REJECTED” and shall be removed from Site. Contract 106, Volume II

Page 419 of 589

Section 07920

Sealants

D. Temperature controlled storage shall be provided, if necessary to meet manufacturer’s recommendations and/or instructions.

1.1.5 Materials 1.1.6 General A. Requirements for products specified herein are stipulating minimum quality standards. B. If more than one of the manufacturer's products complies with the requirements for any item specified herein, the Contractor shall provide the specific product recommended by the manufacturer for the particular application. C. Products equal in quality to, or better than those specified will be considered acceptable at no additional cost to the Department. D. Only products of manufacturers, certified for ISO 9000 or equal and approved, will be accepted. E. Sealants and joint primers shall be compatible with the joint surfaces and backing or filler materials as stated in the manufacturer's published data or as certified by the manufacturer for each application. F. The Contractor shall determine the proper hardness or consistency of elastomeric sealants in consultation with the manufacturer, considering joint movement and exposure for the size of joint shown. o G. Sealants shall be provided with the following ranges of hardness (fully cured sealant at 24 C) for joints subject to: Exposure

Shore A Hardness

Maximum movement, nominal weather exposure and abrasion.

15 - 25

Moderate movement, severe weather exposure & moderate abrasion

25 - 40

Minimum movement and severe abrasion

35 - 60

H. Elastomeric sealants having the lowest modulus of elasticity consistent with the degree of exposure to wear and abrasion shall be provided. I. Sealant, exposed to traffic, shall have strength and modulus sufficiently high to resist damage by traffic. J. The colour for exposed joint sealants shall match the colour of adjoining material. The Contractor shall submit for the Engineer’s approval the colour proposed by him. K. At the start of the installation, and periodically as work progresses, the manufacturer shall provide the services of an experienced technical representative at Site to advise on all phases of this work at no additional cost to the Department.

1.1.7 Sealants A. Sealant shall be: a. Two part Polyurethane / Polysulphide elastomeric b. Prevalently gun grade c. > 99% solid content d. Non-staining o e. Resistant seal against weather, ozone, salt water, sulphates, heat >75 C, UV radiation and biodegradation f. Suitable for the climate and environmental conditions prevailing on site. B. All surfaces coming into contact with sealant and/or seal strips shall be prepared and primed as instructed by the manufacturer and approved by the Engineer. Sagging, slumping, tackiness is not allowed. C. Joint cleaners, primer, bond breaker and sealers shall be products recommended by the manufacturer and approved by the Engineer.

1.1.8 Execution A. Preparation, priming, application and curing of each type of sealant shall comply with manufacturer's recommendations and methods, all as approved by the Engineer. Contract 106, Volume II

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Section 07920

Sealants

B. Component surfaces and fillers of the joints to be sealed shall be examined. C. The Contractor shall not proceed with the work until unsatisfactory conditions have been corrected to the satisfaction of the Engineer. D. Bonding joint surfaces shall be cleaned removing all traces of deleterious material such as form oil, curing compounds and any surface laitance, which might interfere with bond or otherwise impair the work. E. Elastomeric sealants shall not be applied to joint surfaces previously painted or treated with sealer, curing compound, water repellent or other coatings unless a laboratory durability test of bondcohesion has been performed and successfully demonstrated that bond will be durable. F. Paint and other coatings or substances to surfaces adjoining joint surfaces shall not be applied until sealants have been installed and are nominally cured, so that adhesion will not be impaired by migration of such substances onto the joint surfaces. G. The Contractor shall comply with the following for concrete and masonry joint surfaces: a. Etch bonding surfaces with a 5% solution of muriatic acid to remove excess alkalinity. b. Rinse thoroughly with a diluted ammonia solution and then with clear water and dry before installation of sealants. H. Sides of the joint shall be treated with the approved primer as recommended by the manufacturer: I. Migration of primer or sealer onto adjoining surfaces shall be avoided and any spillage shall be promptly removed. J. Sealant shall be applied after surface appears tack free but not later than 60 minutes. K. Bond breaker tape shall be installed in joints as shown and wherever recommended by the manufacturer to prevent bond of the sealant to surfaces where such bond might impair the performance of the sealant. L. Surface or skin of compressible rod type bond breaker shall not be punctured. M. Unless otherwise specified all sealants shall be prevalently gun applied. N. Only equipment recommended by the manufacturer shall be used. O. Compounds shall be applied in continuous beads or rivers, filling joint from the bottom without openings, voids or air pockets. P. Compound shall be forced to sides of joint so as to carefully and thoroughly "wet" opposite joint bond surfaces, forming equal areas of contact with sealant. Q. Compounds shall be confined to joint areas shown by use of masking tapes or other precautions to prevent spilling and migration onto adjoining surfaces. R. Compounds shall be applied in concealed compression joints accurately so that excess compound will not exude from the joint. Apply to the depth and in locations shown. S. Exposed surfaces shall be tooled so as to compress sealants to the profile shown or tool surface slightly concave except provide a slight wash on horizontal joints where horizontal and vertical surfaces meet. T. Against rough surfaces or in joints of uneven widths, the appearance of excess sealant shall be avoided by locating the sealant well back into joint. U. Excess sealant shall be removed promptly as the work progresses and clean the adjoining surfaces as may be necessary to eliminate any evidence of spillage. V. If job progress or any other condition requires the installation of sealants at temperatures above those recommended by the manufacturer, the Contractor shall consult the manufacturer and establish the minimum provisions required to the satisfaction of the Engineer.

1.1.9 Curing And Protecti on A. Sealants shall be cured in accordance with the manufacturer's instructions to obtain maximum bond to surfaces, cohesive strength and durability at the earliest possible date. B. Sealants shall be protected during the remainder of the construction period, so that they remain without any indication of deterioration or damage at the time of completion of the Works. C. In the event that any defects occur within 10 years, the Contractor shall at the convenience of the Department, effect all repairs and replacements necessary to remedy defects all to the complete satisfaction of the Engineer, at no additional cost to the Department.

END OF SECTION


Page 421 of 589

Section 09900

Painting, Coating and Corrosion Protection

Section 09900, Painting , Coating and Corro sion Protection 1

General

A. This specification covers the requirements for surface preparation and application of protective coatings to Mild Steel, Cast and Ductile Iron, concrete and cementatious materials, wood and other items. B. Surface preparation and corrosion protection coatings application shall be carried out to the requirements of these Specifications, the relevant standards and the paint manufacturer's recommendation, all subject to the Engineer’s approval. C. The type of protective coating system required for any particular material depends on the environment to which it is exposed. Accordingly, for the purposes of the works, four main classes with subclasses of environmental exposure as identified and shown in this Section.

1.1.1 Submittals A. The manufacturer shall submit for each component of the system for the Engineer’s approval at least but not limited to the following: a. Generic identification of polymer system along with trade names. b. Surface preparation requirements. c. Acceptance of suitability for the environmental exposure condition. d. Measured values to the following: B. Bulk properties: a. Non-volatile content by weight and by volume. o b. Viscosity (and viscometer used) (at 30° and 50 C.). c. Setting tendency. o d. Sag resistance (at 30°C and 50 C.). e. Specific gravity. C. Applied coating film: a. Hiding power. o b. Tack-free and drying times (at 30° and 50 C.). c. Wet film and dry film thickness. o d. Over coating times (at 30° and 50 C.). e. Wet edge times. D. Cured or dried system. a. Adhesion to substrate b. Inter coat adhesion c. Cupping, pull of test or other d. Impact resistance (Falling ball, or other) e. Gloss (specify angle of incident beam) f. Hardness, Scratch resistance (identify test method) g. Abrasion (Taber or other) h. Accelerated exposure and ageing tests i. Weathering accelerometer (specify type) j. Scribed salt spray test k. Scribed outdoor panel test l. Chemical resistance test (at least 3 month immersion test where relevant). E. Additional properties for 2 component materials: o a. Pot life of pack sizes supplied at 30°C and 50 C b. Useable life of freshly mixed components. F. Additional information for each product: a. Mixing and application instructions b. Health and safety data sheet c. Thinning instructions d. Application data including equipment and nozzles and pressures to be used e. Surface preparations f. Limiting conditions of use g. Storage, handling, protection instructions h. The application method statement along with appropriate site QC-Forms. i. Qualifications of the Supplier / Applicators as specified. G. In addition to the above, the Contractor shall submit the following for epoxy coating works: Contract 106, Volume II

Page 422 of 589

Section 09900

a. b.


Pot-lives of the materials at ambient temperatures, pack sizes and methods to be adopted to ensure materials are used before the expiry of their pot-lives. The Epoxy manufacturer shall stipulate primer and high build epoxy re-coat intervals for all curing temperatures likely to be encountered.

1.1.2 Qualific ations of Suppliers and Appli cators A. Coating manufacturers supplying to the work directly or through agents or representatives shall have the following: a. Research and development facilities (local or overseas) or else a technological co-operation with a company or body with such facilities b. Quality control facilities, equipment suitable for quality production and assurance c. Test lab equipped to conduct all the tests required in the specification or the use of external laboratories suitably equipped d. Technical service staff suitably qualified and knowledgeable of applications and expected performances required by the specification. B. The Contractor shall submit all aforesaid information for the Engineer’s approval. C. Coating applicators shall have the following: a. Purpose built facilities for the proper application of coatings b. Equipment and facilities: Compressors with air tanks, pressure gauges and regulators, air filters, pressure hoses, spray guns, tips and nozzles, component airless spray equipment and spares, dust free and well lit spray booths or areas, high pressure water washers, soap detergent, hand washing and shower facilities, mechanical abraders, wire brushes, grinders, instrumentation for measuring temperature, humidity, paint properties gauges for measuring thickness of coating, holiday tester etc. c. Properly trained, experienced and skilled staff and inspectors shall be available. d. The ability to provide and erect dust-free and sheltered booths at the place of application e. The ability to set-up proper equipment and facilities at the place of application as specified D. The Contractor shall ensure that the coating applicator shall provide before the works begin to the Engineer, instruments for measuring substrate and coating properties listed below: a. Surface moisture determining instruments. b. Thermometer and Humidity Meter c. Surface temperature determining instrument d. Wet and dry film thickness instruments e. Holiday tester f. Adhesion testers E. Coating shall be carried out only by the applicators specialized in this field. F. The exact type and models of instrument for each measurement shall be agreed with the Engineer before the works begin. G. The applicators shall be approved by the Engineer and Department prior to proceed with the works after site demonstrations have been carried out and the standard workmanship is established. H. The applicator shall be a company specializing in performing the work of this section acceptable to the manufacturer with documented experience for at least 3 years. I. The performance of these applicators shall be appraised on regular basis.

1.1.3 Delivery, Storage And Handling A. The Contractor shall transport, handle, store and protect products in accordance with the manufacturers instructions and recommendations. B. Products shall be delivered to place of application in sealed and labeled containers. C. Container label shall include manufacturer’s name, type of paint, brand name, lot number, brand code, coverage applications surface preparation drying time, cleanup requirements, color designation, and instructions for mixing and reducing. 0 D. Paint and coating materials shall be stored at minimum ambient temperature of 15 C and 0 maximum of 25 C in ventilated area, and as required by manufacturer’s instructions and Health and Safety requirements.

1.1.4 Environmental Requirements A. The Contractor shall provide lighting level of candles 860 lux measured mid-height at substrate surface. Contract 106, Volume II

Page 423 of 589

Section 09900


B. Exterior coatings and painting shall not be applied during rain, sand storms, or when relative humidity is outside the humidity ranges required by the paint product manufacturer. C. All preparation and coatings at works shall be carried out under the following conditions: a. Coated in a protective enclosure o b. Ambient temperatures are not greater than 35 C c. Relative humidity is below 85 % d. Required DEW point as per manufacturer recommendation

1.1.5 Health And Safety A. The Contractor and Sub-Contractors should provide health and safety training to their staff. B. Protective clothing shall be provided to all staff employed on coating activities and shall include, but not be limited to overalls, masks, air respirators, goggles, gloves, head covers, blasting protective gear, protective boots, etc.

2

Products 2.1.1 Alip hatic iso cyanine-urethane coatin g

A. The coating shall be UV resistant, chalk resistant and resistant to the fading of colour. B. The coating immediately after application and curing shall have a gloss reading of a minimum of 85 when measured on a goniophotometer with the incident beam set to fall on the coating surface at o an angle of 60 . C. The marker post shall be clearly visible from a distance of at least 100 meters against a desert sandy background when viewed by a person with 20/20 vision during clear weather between the daylight hours of 0900 hrs to 1600 hrs.

2.1.2 Emulsion Paints A. Plastered surfaces whereas decoration paints (i.e., Emulsion paint system) are specified; it shall be high quality acrylic copolymer based emulsion paint with outstanding washability, color retention properties and give smooth silky durable finishing. B. Emulsion paint system shall comply with the following: a. Primer / Sealer: PVA copolymer, one layer b. Putty: PVA copolymer putty, min. two layers, DFT >=100 microns @ each layer c. Final Paint: Acrylic copolymer based emulsion, min. two layers, DFT >= 70 microns @ each layer.

2.1.3 Zinc Rich Primers A. All zinc rich primers shall consist of 90 : 10 electrolytic grade zinc : dry binder ratio by volume.

3

Execution

A. All painting processes, methods, materials, systems, surface preparation, equipment used, conditions under which application proceeds, staff utilized and safe conditions shall have the prior approval of the Engineer. B. The Contractor shall verify existing conditions before starting work. C. The Contractor shall verify that surfaces are ready to receive coating treatment in accordance with instructions issued by the manufacturer and by this specification. D. The Contractor shall examine surfaces scheduled to be finished prior to commencement of work. Report immediately on conditions that may potentially affect proper application or spoilt applications. E. The Contractor shall examine and test shop applied primer for compatibility with subsequent cover materials. F. Copies of manufacturer data sheets and of the relevant parts of this Specification shall be issued to all the staff and workmen concerned with the painting and/or coating process. G. The Contractor shall measure moisture content of surfaces using an electronic moisture meter. Do not apply finishes until moisture readings are within ranges given by coating manufactures. The following applies only as a guide. a. Plaster and Gypsum Wallboard: ≤10% b. Concrete: ≤5% c. Wood: ≤15%. Contract 106, Volume II

Page 424 of 589

Section 09900


H. All surfaces not subjected to the coating process shall be masked with proper materials. I. All products shall be applied in accordance with manufacturer's instructions and as approved by the Engineer. J. Where such instructions conflict with this Specification, a ruling shall be sought from the Engineer. The Contractor shall allow for any variation as a result of such ruling in his Contract Price. K. The Contractor shall not apply finishes to surfaces that are not dry. L. Each coat shall be applied to uniform thickness. M. Upon completion, the contractor shall clean installed work and shall collect waste material and remove from site, all to the satisfaction of the Engineer.

3.1.1 Fastenings A. Bolts, nuts and washers and other demountable fastenings of shall be mild steel galvanised or stainless steel to BS970: Part 4 Grade 316-S16. PTFE washers and isolators shall be used when fitting, fastening or bolting dissimilar metals. B. Fastenings of ferrous parts except high tensile shall be galvanised to BS EN ISO 1461 or sherardised to BS4921 and shall be primed and painted as specified. C. Electro-galvanised nickel cadmium plated fastenings shall not be coated.

3.1.2 Epoxy Coating to Concrete Surfaces A. All surfaces to be protected with the epoxy paint system are to be prepared as described below, maintaining the sequence of operations shown. a. Areas of concrete contaminated with machine oil or grease shall be cut out as necessary to remove all traces and made good with an epoxy mortar. b. Areas contaminated with release agent shall be scrubbed with suitable emulsion cleansers and any mold growth with water-soluble fungicide. c. Materials containing Acids and chloride shall not be used for cleaning concrete surfaces. d. All approved concrete and rendered surfaces to be treated shall be lightly blast-cleaned to remove the cement-rich surface layer. e. Grit and detritus shall be removed by vacuum just prior to priming. f. The moisture content of the concrete surface shall be ≤ 5% measured by approved electronic device. B. The surface of the concrete shall be smooth and free of surface defects such as blanches, pits and honey combs to receive primer. A minimum 24 hours to be elapsed before starting the epoxy coatings. C. The first coat shall be applied by a suitable nylon bristle brush or when sprayed shall subsequently be squeezed or brushed to wet the surface better. D. Cleanliness of the surfaces of the epoxy coats between coats shall be maintained. E. The surfaces of the coatings between coats shall be free of visible moisture throughout these operations. F. Any thick runs or collections of paint shall be removed before they harden. Not less than two coats shall be applied over the primer. G. Application tools and method shall comply with the instructions of the coating/paint manufacturer and as approved by the Engineer. H. Each coat shall completely cover the entire area without ”misses” or pinholes or any areas visibly low in thickness. I. A high voltage pinhole detector shall be used to determine the integrity of the coats. J. The coating system: Shall be as specified. K. Pinholes, misses and other defects in the coating shall be repaired by abrading the cured coating for about 50 mm greater than the area to be repaired and than re-applying the specified coating. L. The coatings shall be suitably protected against physical damages during the backfill operation by new 4 mm thick approved plywood sheets. M. The Epoxy manufacturer shall stipulate primer and high build epoxy re-coat intervals for all curing temperatures likely to be encountered and these shall be adopted with maximum tolerance of maximum 4 hours. Where this is exceeded the surfaces to be re-coated shall first be suitably abraded to remove gloss and give key.

3.1.3 Quality Assurance A. On completion, all coatings shall be checked with a holiday detector or spare tester like instruments to the Engineer’s approval to locate pinholes and other discontinuities in the finished Contract 106, Volume II

Page 425 of 589

Section 09900

B. D. E. F. G. H.


work. Such holes shall be neatly patched in accordance with the coating manufacturer's recommendations and to the Engineer's approval. The Contractor shall demonstrate all his methods, equipment and materials produces the desired quality to get the Engineer approval before any work commences. The applicator shall show adequate skill and experience in the use of chemically cured compositions for high performance application. An electrically operated mixer may be used but only where it can be shown that it does not entrain air in the paint. On no account are thinners or diluents to be mixed with paint or coating materials. Strict control shall be exercised in the issue of thinners for cleaning brushes and equipment. Fillers and topcoats shall be applied to done-dry surfaces. Adhesion tests will be carried out on the cured coating surfaces using approved test equipment’s. The test results specimens shall not show indication of poor adhesion to the substrate, residual laitance or inter coat adhesion weakness.

3.1.4 Concrete Pipes A. The external pipe surface shall be dried to surface moisture content in accordance with the coating manufacturer’s recommendations. The external surfaces shall be coated with minimum 2 layers of a two-component solvent-free epoxy coating as per manufacturer’s instructions. Min. DFT shall be 500 μm. B. All pits, blowholes and other surface defects shall be filled with a two component solvent-free epoxy based putty / mortar.

3.1.5 Stainl ess Steel A. Where the stainless steel has been welded, damaged through handling, cold or hot worked or if the manufacturers passivated surface has been damaged in any way, the stainless shall be repassivated using the following procedure. B. Stainless steel shall be worked upon in an isolated area from areas where iron contamination would occur. C. Stainless steel shall not be blasted with materials that could cause a corrosion cell to be set up upon the surface of the stainless steel e.g. the use of iron containing grit is not to be used. Shot peening using iron free glass beads may be permitted prior to passivation, subject to Engineer’s approval. D. The surfaces of the assembly must be degreased, cleaned of heat scale (if any) and passivated using proprietary materials recommended by the manufacturer of the stainless steel. Demineralised water shall be used washing the stainless at all stages of processing. E. The contractor shall submit method statements and product data sheets for welding and stress relieving (if applicable), degreasing, removal of scale and surface contamination and chemical passivation of the surface. F. The steel shall not come into contact with iron items, surfaces and devices or other contaminants during handling, transport working, assembly transport, storage and fixing. G. The passivating surface shall not be damaged in any way after passivation of the surface. H. The passivated surface shall be protected with foam and polyethylene sheet during storage and transportation.

3.1.6 Hot Cured Polyester / Epoxy Powder Coating for Alum in um A. The manufactured / fabricated aluminum items shall be immersed in diluted hydrofluoric acid for itching and removal of all oils resulting from manufacturing / fabricating process and handling. The treated items shall not be handled by hand to avoid recontamination with dirt. B. Immerse in water reservoir to remove the chemical residue produced. C. Immerse in diluted chromate acid to form a corrosion protection aluminum chromate film, which facilitates best adhesive to the final powder coating. (This step is very important because without this treatment the corrosion ultimately starts resulting in powder coating peeling). D. Immersion in two consecutive water reservoirs for removal of chemical reaction residue. E. Drying the items by heating.


Page 426 of 589

Section 09900


F. Apply the electrostatic charged powder on the earthed item building the required thickness as o specified. For cast aluminum items the application of powder must be executed at 200 C to ensure that all air within micro-cavities has expanded out. o G. Cure the powder coated items at 200 C for 15 minutes. o H. The items shall be remain inside 200 C oven for additional time calculated upon the thickness of the item, each 1 mm thickness requires 2 minutes, for example assume an item has 10 mm o thickness, it shall remain inside the 200 C oven for 20 minutes plus 15 minutes for powder coating curing. I. Insufficient curing time would result in peeling of the powder coating within a period depending on the impropriate curing even if the coating passes the pull test. J. Improper curing leads to deterioration of the powder coating and it is a function of time. K. For cast aluminum items, heat pretreatment is essential prior to powder coating application to ensure the expansion of air inside micro-cavities and avoid the formation of pinholes, which lead to spot corrosion and ultimately creep corrosion leading to serious dislocation of the powder coating film from the item. L. The following test certificates shall be submitted with item: 2 a. Pull-off test (ASTM D4541) = 3.5 N/mm b. Coating thickness test DFT =120 micron.

3.1.7 Emulsion Paints A. Substrate surface shall be fully cured, clean and dry. B. Surface imperfections shall be repaired to achieve level smooth surface, fair faced looking and all the stages of the system shall then be applied. C. The temperature of substrate should be >10 °C and minimum 3 °C above DEW Point of the air at all stages of application system. D. Coating applicators must be duly trained and certified by the reputable paint manufacturer. E. Pull-off (adhesion / cohesion) of all stages shall meet the manufacturer’s requirements. F. The following tests shall be observed to the Engineer’s satisfaction on mock-up sample: a. Visual inspection of prepared substrate b. Weather observation (Temperature, humidity, substrate temperature, DEW point temperature, etc.) c. WFT and DFT of each layer d. Final visual checks on color matching across manufacturer standard, surface finish, etc. e. Pull off tests f. Washability


Page 427 of 589

Section 09900


Preparation and coating application for metal surfaces Surface preparation and coating application

. s p s x l a E c

Surfaces

Preparation

Electrical posts, crane, frames, 1 A

gates,

DI-

pipes, fittings (external surfaces)

Primer

Pickle and hot dip galvanized

to

BS

729

Solvent

Intermediate coat

based,

Solvent based amine

components

cured two pack epoxy

etch primer one

2 coats DFT 250 µ

coat DFT 50 µ

each

two

Solvent free, amine n/a

cured two pack epoxy 2 coats DFT: 250 µ each

3 A 2 . A

and fittings (external

DI-pipes (external 4 . A

n/a Degrease grit blast

and

fittings

surfaces),

mh-covers,

Top coat

Solvent

based

polyurethane

1

550

coat DFT: 50 µ Solvent

based

polyurethane

550

1 coat DFT: 50 µ

Solvent free, amine

Steel works, DI-pipes surfaces)

l T a F t o D t µ

2 coats DFT: 250 µ

500

each

to SA 2.5, profile 80

Solvent free, amine

µ n/a

gratings


and frames

cured two pack epoxy 2 coats DFT: 250 µ

500

each Two pack vinyl ester glass filled epoxy 2 coats DFT: 250 µ

500

each

8 & 7 , 6 , 5 . A

DI-Pipes and Fittings

Degrease grit blast

(External

to SA 2.5, profile 80

Surfaces),

Valves

microns


500

2 coats DFT: 250 µ each

DI-Pipes and Fittings 0 1 & 9 . A

Solvent free, amine N/A

(External Valves,

Surfaces), MH-Covers

and Frames

Solvent free, amine

Degrease grit blast to SA 2.5, profile 80 microns

N/A

cured two pack epoxy 2 coats DFT: 250 µ

500

each Two pack vinyl ester glass filled epoxy 2 coats DFT: 250 µ

500

each

Notes: a. b. c. d. e. f.

Use this table in conjunction with respective specified requirements. Blasting surface profiles tolerance 10µm. DFT (Dry Film Thickness) is the minimum requirement. A complete system shall be sourced from one manufacturer. Complete method statement shall be submitted from the manufacturer. All coating systems shall be resistant to the exposed conditions in addition to specified requirements.


Page 428 of 589

Section 09900

g. h.

i.


The factory applied coating systems on external surfaces of DI-Pipes and Fittings shall be blasted and re-coated by reputable coating applicator in Abu Dhabi as specified. For metal parts where high coating thickness will interfere with the fit, backed enamels based on corrosion resistant coatings such as phenolics, polyamides, PVDF, PTFE and similar shall be used. Small items of steel or metal parts shall be electroplated, electro coated or subject to other proprietary process suitable for protection in aggressive conditions. Preparation and coating application for concrete surfaces

Exposure Class

Surface Preparation and Coating Ap plicatio n

E.g., Surfaces

Preparatio n

Primer

Intermedi ate Coat

Top Coat

Total DFT

Sweep blast, clean to make surface fair faced and smooth, Manhole

/

Chamber / PS – A.1

Cover

Slabs,

Buildings, Effluent

Tanks

(External)

free

from

cracks,

blowholes, pinholes, bug holes, pits, voids etc. Fill the small holes

with

epoxy

amine putty filler, big holes

with

Solvent

Surface Penetrating Sealer

free,

amine cured two pack

/

epoxy

2

Coats DFT : 250

Primer

microns each

Solvent based polyurethane 1

550

Coat DFT : 50

microns

microns

epoxy

amine mortar, cracks with

resin

as

applicable Surface Penetrating Sealer A.2

Buildings,

Skim

Rooms

Coating,

/ 2

Acrylic

emulsions

system

3

Coats

DFT : 100 microns

Component

N/A

300 microns

each

Epoxy Amine Valve A.3

Solvent

/

amine cured two

Inspection Chambers,

free,

pack

Dry

epoxy

microns each Solvent

A.4

microns

Coats DFT : 250

Wells

Wet

500

2

amine cured two

Wells,

Lifting / Pumping Stations

free,

OR

pack

epoxy,

2

Coats

N/A

500 microns

DFT : 250 microns each Two

pack

vinyl

ester glass filled epoxy,

2

400

Coats

microns

DFT : 200 microns each Solvent A.5, 6, 7 & 8

free,

Manholes,

amine cured two

Chambers,

pack

Effluent Tanks

Coats DFT : 250

epoxy

2

N/A

500 microns

microns each


Page 429 of 589

Section 09900


Sweep blast, clean and make surface fair

Settlement A.9 & 10

Tanks, Base of Drying Beds, Air Blower Tank

faced

and

smooth,

free

from

cracks,

blowholes,

pinholes, bug holes, pits, voids etc. Fill the small holes with epoxy amine putty filler, big holes with epoxy amine mortar,

Surface Penetrating Sealer

Solvent /

Skim Coating,

2

free,

amine cured two OR

pack epoxy

N/A

2 Coats

Component

DFT : 250 microns

Epoxy

each

500 microns

Amine

cracks with resin as applicable Two

pack

vinyl

ester glass filled epoxy

400

2 Coats

microns

DFT : 200 microns each

Remarks: a. Use membrane for embedded parts of RC-Structures b. Fillers, plasticizers, diluents etc. must be resistant to acid attack. Notes: a. b. c. d. e. f.

Use this table in conjunction with applicable tables and the specification. Blasting surface profiles tolerances 10µm. DFT (Dry Film Thickness) is the minimum required. A complete system shall be sourced from one manufacturer. Complete method statement shall be submitted from the manufacturer. All coating systems shall be resistant to the exposed conditions.

Colour Schedule Item Floor tiles and skirtin Duct covers (hardwood) Concrete steps, ramps and aprons Internal surfaces Tiles Ceilings External surfaces Internal doors surfaces External doors Skirting boards and dirt panels Door frames (wood) Aluminum surfaces GRP surfaces

Color To be agreed upon by Engineer or Department

Surface Preparation s Material

Surface Preparation

Wood Cabinet finish

Not applicable

Gloss or matt paint finish or varnish

Sand wood using 180 grit paper. Fill all holes, treat knots, sand to flat and smooth finish. Sand inter coating surfaces using 400 grit wet and dry paper.


Page 430 of 589

Section 09900


Concrete

Sweep blast, clean and make surface fair faced and smooth, free from cracks, blowholes, pinholes, bug holes, pits, voids etc. Fill the small holes with epoxy amine putty filler, big holes with epoxy amine mortar, cracks with resin as applicable

Cast Iron and steels

Degrease cast iron / steels, fettle, grind off fins, sand spots and round out sharp edges before grit blasting. 1 Grit blast to SA2 /2 to 80 microns profile. Fill all blowholes and minor cavities (if acceptable) with two component amine cured epoxy filler. No treatment unless specified

Stainless & Austenitic Steels Anodized Aluminum & all other non ferrous metals Galvanized Mild Steel

Wire mesh for embedding in concrete

No treatment unless specified If fresh and un-oxidized sweep blast If oxidized high pressure water wash (Before application of mist coat primer) 1 Sandblast to SA2 /2 and remove all oil, grease and other contamination and residues.

Metal: A. All metals surfaces shall be high pressure washed to remove deposits of grease, oil, tar and other residues and shall meet the requirements of coating manufacturer. Concrete: A. All concrete surfaces shall be cleaned of mould oils by washing, Sweep blast or needle gun to roughen surface. Make fair faced by applying an approved epoxy-amine surface, All surface blowholes, pits and surface defects, irregularities etc. must be filled with solvent free epoxy-amine filler. Exposu re of Surf aces (Metal and Concrete) Class

Location

Surface Exposure Condition

A.1

Atmosphere

A.2 A.3

Atmosphere Atmosphere

A.4

Atmosphere

A.5 A.6

Soil / Backfilling Soil / Backfilling

A.7

Liquid

A.8 A.9

Liquid Liquid

A.10

Liquid

Exposed to Atmosphere of Abu Dhabi above ground level and liable to cycles of condensation, Ultraviolet and drying Inside air conditioned building / fairly dry Inside but exposed to heavy condensation e.g., Inspection / valve chambers Inside / outside building but one side of surface exposed to H2S gasses / acid condensation, inside wet wells etc. Dry Moist, wet, saturated or condensed with capillary rise Recycled / effluent / potable water / storm water etc. Seawater, splash zone, ground water etc. Inside sanitary sewage, bacteria, liquids containing dissolved organic acids Highly aggressive medium e.g., sulfuric acid, H2SO4 formation with condensation of H 2S gasses, organic acids etc.


Degree Of Aggressi veness

Mild

Very Mild to Mild Aggressive Very Aggressive

Very Mild Aggressive Aggressive Very Aggressive Very Aggressive Extremely Aggressive

Page 431 of 589

Section 09900


Preparation and Painting Schedule for Surfaces Other Than Metal Surface Soft Wood (primer or unprimed)

Plaster (including plaster board)

Cement Rendering Concrete (fair faced)

Location

Finish

Interior

Gloss

Particul ar Preparation Sand down

Exterior

Gloss

Sand down

Interior

Flat

Sand down

Exterior

Gloss

Sand down

Interior

Multicolor

Sand down

Interior

Flat

-

1 Coat emulsion

Exterior

Gloss

-

2 Coats alkyd

Immersed

Wire brush

Zinc chromate spot primer to screw and nail heads Zinc chromate spot primer to screw and nail heads

1 Coat alkali resistant primer 1 Coat special primer 1 Coat sabilising solution 1 Coat emulsion

1 Coat hardboard primer

2 Coats alkyd

Brickwork

Exterior

Matte (Epoxy) Sandtex

Hardboard

Interior

Gloss

Interior

Gloss

Stiff brush

Primer 1 Coat primer

pink

Final Treatment 3 Coats alkyd

1 Coat primer 1 Coat

pink

3 Coats alkyd

1 Coat alkali resistant primer 1 Coat primer

2 Coats emulsion 2 Coats alkyd

1 Coat multicolor wall finish 2 Coats emulsion

2 Coats epoxy 2 sandtex

Coats

2 Coats emulsion

END OF SECTION


Page 432 of 589

Section 10080

GRP Accessories

Section 10080, GRP Accessories 1

General

A. GRP accessories shall be installed and have the dimensions and design criteria as indicated in the Drawings unless otherwise directed by the Engineer. B. All materials of construction, method of manufacture, methods of installation, application, curing and storage shall require the approval of the Engineer. C. The Contractor shall sequence the work to ensure bonding lugs, concrete anchors and GRP materials are in place before commencing Work on the ladders and railings of this section.

1.1.1 Submittals A. During the mobilization period the Contractor shall submit for the Engineer’s approval: a. Product data incl. specifications, characteristics, performance criteria, limitations etc. b. Manufacturer's installation instructions incl. special environmental requirements. c. Manufacturer's certificate that products meet or exceed specified requirements. d. Full details and type test results for his proposed products irrespective of whether any data was submitted with the Tender. Should any detail be altered during manufacture from those approved by the Engineer, the Contractor shall submit for the Engineer’s approval the revised details and test results. e. Product Samples

1.1.2 Mockup A. The Contractor shall provide mockup of materials as specified or required by the Engineer. B. The mockup may remain as part of the Work.

1.1.3 Quality Control A. The Engineer shall be entitled to carry out additional tests at his discretion on GRP products supplied by the Contractor and the Contractor shall supply all samples, equipment, apparatus and shall allow in his rates for all costs related thereto. B. “GRP” or laminate shall not be installed when temperature or weather conditions are detrimental to successful installation. C. The following tests shall be carried out for GRP ladders, handrails, and other GRP products. Results shall be within the limits set out in the Standards and the Specifications. a. Loss of ignition. b. Barcol hardness. c. Tensile test. d. Acetone test. e. Load test f. Water absorption.

2

Products

A. Nuts, bolts and washers used for fixation shall be stainless steel grade 316/A4, and shall be completely in situ laminated as specified using the same specified material of used GRP. B. Steel reinforcement, if employed for strengthening, shall be completely in situ laminated as specified. Surfaces shall receive a resin rich finish. C. GRP shall be UV resistant if exposed to UV-Radiation. D. The structural components shall possess Class I fire retardance, with an ASTM E84 maximum flame spread rating of 25.

2.1.1 Ladders A. Rungs shall be able to withstand a point load of 5000N when applied at the center of the rung or close to one end. B. The clear width between uprights shall be 300 mm and the climbing face of the ladder shall be 150 mm from the surface of the manhole shaft when measured at the center of the rung. Rungs shall be spaced 250 mm from center to center. The bottom and top rung shall be = 400 mm from the top of benching and = 500 mm from top of cover respectively.


Page 433 of 589

Section 10080

GRP Accessories

C. Fixing brackets shall be GRP integrally molded into the ladder laminations and they shall be not more than 500mm apart (every 2 steps/rungs). D. The fixing brackets shall be designed to be anchored securely in concrete. E. When supported horizontally over a span of 1.00m with the climbing face uppermost and with a load of 1000N applied at the center of the span there shall not be a deflection greater than 15mm at the point of application of the load and shall show no permanent deformation after removal of the load. The loads shall be remaining in place for 24hours after which the ladder shall be inspected for defects. F. Fastener of ladders shall withstand a shear and pull-out loads of 5000N. G. Structural glass reinforced ladders and safety cages formed from a glass rich layer of Advantex or similar corrosion resistant chopped strand mat, continues rowing and vinylester resin with a protective coat of resin rich vinylester reinforced with a “C” glass tissue as appended herein. H. Hardwood stiffeners are to be provided inside both the rungs and the rails as a former, and shall be fully encased in GRP laminate. I. The wall thickness of the laminate shall not be less than 5 mm at any point and there shall be no sharp edges. J. The resin shall not be pigmented. K. Rungs shall be provided with a non-slipping surface as specified. L. Ladders shall be in compliance with following: Item

Testing Frequency (*)

Requirements

1

Lamination thickness

Min. total 5mm

2

Surface glass veil

Approved C-Glass (30gr/m²)

Weight: 2%

3

Glass mat

Approved Chopped Strand Mat (CSM) (7x300gr/m²)

Weight: 2%

4

Roving

Approved Continues Roving (CR) for stringers (2400 Tex)

5

Resin: Glass Ratio

70:30 (+/- 5%)

6

Resin Type

Approved Vinyl Ester

-

7

Water Absorption

0.15% (ASTM D570)

4%

8

Barcol Hardness

Min 35 (ASTM D2583) prior to dispatch

9

Point load

10

Deflection implied load

11

Resistance to shear and pull out load

Shall be resistant against 5000 N

4%

12

Resistance to fire

Required – Additives / inhibitors shall be incorporated

N/A

under

2%

TEX: 2% 4%

Each Unit

Each rung shall withstand a point load of 5000 N applied at center and close to one end One meter horizontally supported with climbing side shall not deflect greater than 10mm at the point of applied load of 1000 N at temperature of 23 +/- 2 °C.

4%

4%

Remarks:  (*): or part thereof  CSM and CR type glasses shall be powder-bonded type Advantex or corrosion resistant approved type.

2.1.2 Safety Cages A. Safety cages shall be provided where the distance between the ladder landings exceeds 4.5m. B. Safety cages shall be constructed of three flat vertical members supported by flat hoops with diameter of 750mm. C. The hoops shall be at a maximum of 700mm centers and the first hoop shall be 2.40m above ground or platform level. D. Each hoop shall be able to withstand a tangential point load of 740N and a vertical point load of 1200N applied at any point on the hoop. The maximum allowable deflection at the point of


Page 434 of 589

Section 10080

GRP Accessories

application of the load shall not exceed 25mm and there shall be no permanent deformation of the hoops after removal of the load after 24 hrs. E. An intermediate landing shall be provided where the rise exceeds 6.00m. F. Cages shall comply with following: Item

Requir ements


1


Min. total 7mm

2%

2

Surface glass veil (Inside and outside)

Approved C-Glass (30 gr/m²)

3

Glass mat

Approved Chopped Strand Mat (CSM) (450 gr/m²)

Weight: 2%

4

Resin : Glass Ratio

70 : 30 (+/- 5%)

4%

5

Resin type


N/A

6

Water Absorption (ASTM D570)

0.15%

4%

7

Barcol Hardness (ASTM D2583)

Min 35 prior to dispatch

Each Unit

8

Acetone Test

No tackiness

2%

9

Axial Tensile Strength (BS 5480 or DIN 53445)

Min. 100 N/mm²

4%

Weight: 2%

Remarks: 1. (*): or part thereof 2. CSM and CR type glasses shall be powder-bonded type Advantex or corrosion resistant approved type.

2.1.3 Handrails A. GRP handrails shall be the heavy-duty industrial prefabricated pultruded standard product of a reputed manufacturer.. B. Standard base shall be fixed on concrete slab by A4 stainless steel bolts. C. GRP hand railing shall be 1000 mm high and be provided with an intermediate rail 500 mm high. Standards shall be set at not more than 1.50m centers. D. Handrails and fixings shall be designed to withstand a vertical or lateral horizontal force at upper handrail level of 100 kg. E. The deflection of rails shall not exceed 0.8% of their span between standards and the deflection of standards shall not exceed 0.8% of their height after applying the specific load for 24 hours. G. Handrails shall be manufactured from square hollow sections. H. Removable standards shall be accommodated to socket type tubes attached to square type GRPBase platens that be fixed at four locations to the concrete using stainless steel 316 / A4 type bolts, nuts, washers. I. All metallic parts shall be over-laminated by approved in-situ lamination system. J. Connections between rails and standards shall be socket / spigot type and shall be laminated with approved in-situ lamination system. K. GRP hand railing shall be in prefabricated lengths complete with fittings. L. The Contractor shall ensure that unless otherwise specified, all hand railing shall be of uniform appearance and manufacture. M. GRP-Hand railing shall comply with the following:


Page 435 of 589

Section 10080

GRP Accessories

Item


Requirements

1


Min. total 7mm

2%

2

Surface Glass Veil

Approved C-Glass (30 gr/m²)

Weight: 2%

3

Glass mat

4

Roving

5

Resin : Glass Ratio

70 : 30 (+/- 5%)

4%

6

Resin Type


N/A

7

UV-Resistance

Additives / Inhibitor (if exposed to UVRadiation)

N/A

8

Water Absorption (ASTM D570)

0.15%

4%

9

Barcol Hardness (ASTM D2583)

Min 35 prior to dispatch

Each Unit

10

Acetone Test

No tackiness

2%

11

Ultimate Tensile (ASTM D638)

>=500 N/mm²

4%

12

Point load at the center of rail span (At ambient °C)

13

Resistance to horizontal force applied at the top of standard

Shall be resistant to 100 kg

4%

14

Resistance to fire

Required – Additives / inhibitors shall be incorporated

N/A

Approved Chopped Strand Mat (CSM) (e.g., 450 gr/m²) Approved Continues Roving (CR) stringers (2400 Tex)

Weight: 2% for

Resistance to loading. Shall withstand a point load of 100 Kg applied for 10 minutes without any crack Permanent deflection after unloading – Max. 1mm

TEX: 2%

4%

Remarks:  (*): or part thereof  CSM and CR type glasses shall be powder-bonded type Advantex or corrosion resistant approved type.

2.1.4 Grab Handles 2

A. Grab bars shall be made of high tensile deformed steel bars have a yield stress of 460 N/mm laminated with Vinyl Ester Resin and corrosion resistance CSM-Glass (e.g., Advantex) to 5 mm and C-Veil. 0.5 mm flow coat of Vinyl Ester resin shall be applied as outer layer. B. The ends of GRP-laminated grab bar whereas embedded in concrete shall be sanded for good bonding to concrete.

2.1.5 Miscellaneous Products A. ANCHOR BOLTS: All anchor bolts shall be 316/A4 stainless steel, and fabricated as shown on the Drawings, or as specified by the manufacturer. Expansion bolts may be used in lieu of anchor bolts at locations designated and approved by the Engineer. B. BONDING LUGS: The bonding lugs shall have a roughened surface to provide adequate bond with concrete and shall project a minimum of 100 mm into the concrete. The lugs shall be designed such that it shall not dislocate from either the rail or its fixing point in the concrete. C. HANGING CHAINS: Ladders and other openings shall be closeable with hook ended hanging chains.

2.1.6 GRP Shed A. GRP shed shall be constructed where indicated on the drawings, specification and/or instructed by the Engineer. Contract 106, Volume II

Page 436 of 589

Section 10080

GRP Accessories

B. The Contractor shall submit complete structural design taking into consideration wind load of 160 km/h & concentrated load of 80 kg. C. The Contractor shall submit shop drawings detailing the full dimensions and joints connections for all elements for approval of the Engineer. D. The Contractor shall obtain the Engineer’s approval for the GRP material and manufacturer before commencing the works as normal practice. E. The fabrication shall comply with the following table: % Age Of Raw Item

Structural Layer

Manufacture System

Thickness

/ Requirements

(Min. Mm)

To be as requirement

To be as per

of build up of raw

requirements

materials

of design

Flow Tailored edges

coated

Testing

Materials

Resin %

Remarks

Glass %

Frequenc y

1- Tolerance ± 5 % 70

30

2- To be designed to resist wind load

of

160

Km/h

&

80

kg

LOI : 4%

concentrated load

with

parafinnated resin and

N/A

UV-Inhibitor Required

Stiffening

(GRP

–

To be fixed during manufacturing as

Material)

Over-lamination of stiffeners

to increase the rigidity of the roof

Required

3 mm

Ditto

N/A N/A

Shall contain pigment

Contact (Gelcoat) Layers

and

UV-rays

Fire Resistance

Required

Raw

To be submitted for

materials,

0.50

details drawing

approval

Glass weight

450 gm/ m

To be verified

2

To be only from approved products

Advantex

Resin

Isophatic / Venyl Ester

Tackiness

Shall be free

Color of Shed

White

of

Channels, Posts

Weight : 2%

Ditto

N/A

Ditto

N/A Each Unit N/A

1-Technical

Coating

N/A N/A

Powder bonded E /

Glass Type

N/A

resistance additives

leaflet

and

method

1- Grit Blast : SA 2.5

statement to be submitted.

2- Polyamine Epoxy :

2- To be applied by certified coating

Solvent free 2 layers

400 µ of DFT

3- Polyurethane :

applicators. All

One layer

50 µ of DFT

QC

SA, WFT, DFT :

record

(Dew

point,

Each Unit

application date, WET, DFT, pull-off test etc.) required.

Bolts,

nuts,

washers & metal accessories Structural

Stainless steel : grade

N/A

A4 / 316 As specified above.

To be approved by the Engineer.

N/A

Min Clearance

As per shop drawings

To be approved by the Engineer.

N/A

Barcol Hardness

Min : 35

ASTM D2583

Analysis

Axial

Tensile

Strength Water absorption

Flexural Strength

Min : 100 N/mm

2

Each Unit

DIN 53455 / BS 5480

4%

ASTM D570 – not short term boiling

Max. 0.15 %

4%

method 2

Min : 130 N/mm

DIN 53452

4%

Remarks: 1. (*): or part thereof Contract 106, Volume II

Page 437 of 589

Section 10080

2.

3

GRP Accessories

CSM and CR type glasses shall be powder-bonded type Advantex or corrosion resistant approved type.

Installation 3.1.1 Ladders

A. GRP ladders shall be mechanically bonded into the concrete structure by means of suitable lugs or concrete anchors and be also bonded to the internal GRP lining of manholes and wet wells.

3.1.2 Handrails A. Fixings used for anchoring GRP hand railing shall be approved stainless steel anchors. All fixing holes shall be grouted with a two-component epoxy mortar and the exposed fixing material sealed with coal tar epoxy or GRP coating as appropriate. B. Horizontal mounting flanges shall be drilled for not less than three bolts with two bolts on a line parallel to and on the walkway side of the hand railing. Vertical mounting flanges shall be drilled for not less than two bolts the line through the bolts being vertical. Fittings shall be screwed or secured with stainless steel grub screws.

3.1.3 Grab Handles A. Handles shall have a 150 mm x 150 mm square opening when in their final positions. They shall be positioned <= 500 mm apart and centrally over the ladder as directed by the Engineer and shall be securely anchored.

END OF SECTION


Page 438 of 589

Section 013122

Pipeline Construction by NDM

Section 013122, Pipeline Constru ction by Non-Disruptive Method 1

General 1.1.1 Design Requirements

A

B

C

D E

F

The Contractor shall: a. Obtain existing utility information, and execute trial pits to locate and confirm services at pit/shaft locations and elsewhere as required. b. Employ only such plant and machinery suitable for the intended work c. Ensure that the design of the thrust wall and any other associated temporary works is such as to prevent damage to any part of the Permanent Works or any adjacent service or structure. d. Design thrust and reception pits/shafts to allow safe operation of the plant, equipment and handling of the materials and to withstand all loading imposed by ground pressure, superimposed loads from surface structures and maximum anticipated thrust force. e. Design pipes to withstand the maximum axial thrust with a factor of safety of 4 based on the full effective area and the ultimate compressive strength of the pipe material. For reinforced concrete pipes, use the full effective area at the joint. f. Design pipe joints in conjunction with resilient packing that avoid projections obstructing the travel of the pipe. g. Ensure that the joints will be watertight under axial loading and at the permissible deflection of the pipes. h. Design joints for concrete pipes such that with an angular deflection of 1°: 1. The areas available for transmitting the maximum permitted thrust force will be sufficient to ensure that there will be no pressure at any point greater than the maximum permissible pressure. 2. There will be no damage to the pipe or loss of structural strength. 3. There will be no ingress or egress of water or lubricant under the maximum operational or test pressures. 4. There will be no ingress of soil/groundwater onto the bearing surfaces. Where GRP pipes with concrete surround are proposed, GRP pipes shall not be subjected to any force during installation; the concrete surround shall be designed to withstand the maximum jacking force. Where pipelines shall be inserted into pipes with larger diameter and the annular space shall be grouted: a. Ensure that the difference between the external face of the inner pipe and the internal face of the outer pipe is not less than 150mm and no more than 250mm unless otherwise approved by the Engineer. b. The external pipe/sleeve may be of steel with full circumferential weld. The steel pipe and the grout shall be regarded as sacrificial and the inner pipe shall be designed as a stand alone pipe, capable of withstanding installation and grouting forces and soil, traffic and groundwater loads. Where pipe-brackets are used, rubber packers shall be placed between the steel brackets and pipe. The dimensions of drive and reception pits/shafts shall be limited to the minimum required for the permanent works or to construct the pits/shafts, whichever is larger. Where it is proposed to use a tail tunnel as the reaction surface the maximum permitted thrust force is not to exceed the lesser of the following: a. The maximum permissible thrust force. b. 50% of the sum of the maximum forces recorded at the rigs used to construct the tail tunnel, or c. If the over-break to the tail tunnel has been grouted up, 100% of the sum of the maximum forces recorded at the rigs used to construct the tail tunnel. d. Any tail tunnel which has been used as a reaction surface shall pass the specified water tightness test at a time not less than 14 days after the load has been removed. Lubricant fluid holes shall be threaded for plugs, withstanding the external pressure, to be screwed in. Non-return valves shall be fitted to prevent ground loss.


Page 439 of 589

Section 013122


1.1.2 Submittals A

B

C

D

NDM works shall start only after the following data have been approved by the Engineer and from all authorities concerned: a. Description & specifications of pipe material. b. Description & specifications of NDM equipment. c. Working program. d. Personnel (CV’s). e. Description of working method comprising: f. Layout 1:50, showing driving/receiving shafts, fencing, offices, control room, discharge lines & facilities for groundwater discharge, slurry / sludge pit etc. g. Structural analysis for driving / receiving shafts. h. Anticipated jacking loads. i. Method(s) of controlling ground water. j. Method of spoil disposal. k. Details of safety measures and equipment. l. Proposed method of dealing with different soil conditions. m. Notices of intent shall consider PWD’s Circular No. PWD/4-2 / 5239 / 500 / 10717, dated 17.07.1996; e.g. the Contractor shall provide a written declaration that the he will be responsible for repairing surfaces affected by the works (settlement or heave in paved surfaces) and will bear all costs for such repairs to be executed in accordance with the Specifications of PWD. The Contractor shall be responsible to inform PWD immediately of any settlement or heave occurring in paved surfaces. n. Soil report. o. Approval from authorities concerned. Design Calculation and Working Drawings shall be submitted for the following: a. Jacking- and friction forces in the axial direction of earth, traffic and surcharge loadings in the vertical direction and the pipes resistance to these loads. b. Allowable deflections at joints to limit damage to the joint from eccentric loading under drive and sealing limits and to ensure a completed pipeline with no leaks. c. Thrust and reception pits/shafts to resist external soil and water pressure and stresses resulting from the jacking machine. d. Working Drawings showing plan and sections, the method of supporting excavations including equipment layout. e. Predicted settlement. f. Submit details describing the measures to be taken to avoid the development and transfer of grout shrinkage or expansion stresses to the pipe and to avoid any adverse chemical reaction between the pipe and the concrete, grout or other materials comprising the pipeline. The Contractor shall submit for the approval of concerned authorities and the Engineer a detailed method statement including, but not limited to, the following: a. Recommendation of the NDM equipment manufacturer’s that machinery is suitable for intended works considering soil conditions, groundwater table, etc. b. List of all equipment and resources. Is appropriate for working under prevailing site and subsoil conditions. c. Detailed step by step procedure describing how work will be carried out. d. Support of existing services and adjacent structures. e. Safety arrangements for compliance with safety requirement. f. Arrangement for dealing with ground water, taking due regards to controlling the loss of material and preventing settlement around pits/shafts, pipe/pit interfaces and tunnel face. g. Locking pipe in position during insertion of the next pipe. h. Sealing working shafts and reception pits during exiting and entering of pipe. i. Control of over break. j. Mix grout design and method of grouting. k. Handling & fixing of the inner line pipe in the case of tunneling with oversize diameter pipes. l. Reuse/dumping of cuttings and slurry. m. Layout of monitoring points for detection of surface movement. The Contractor shall: a. Submit independently authenticated test results to demonstrate that the packing complies with the Specification. b. Include a graph of the stress/strain relationship over the range of conditions that will be encountered during the Works.


Page 440 of 589

Section 013122

c. d.

e.


Obtain from the manufacturer a certificate of the bentonite powder showing the properties of each consignment delivered to the Site. Ensure that this certificate is available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range (in Pascal seconds) and the gel strength range (in Pascal’s) for solids in water. Obtain pipe manufacturer’s guarantee that the pipe and its material are suitable for its intended use.

1.1.3 Quality Assu rance / Qualific ations / Regulatory Requirements A. The Contractor shall: a. Ensure that the quality assurance systems implemented by the installer meets the requirements and the Specification. b. Ensure instrumentation is calibrated for each drive. c. Ensure that a valid certificate is available to the Engineer upon request. d. Ensure that pipes, sleeves and lubricant are checked prior to installation B he Designer must be an approved qualified engineer experienced in the design of this work. C The Installer shall be an approved company with approved specialized personnel in performing the work with minimum 10 years experience in the application of non-disruptive method of pipeline construction of projects of similar size. D The Contractor shall ensure that all supervisor and operators in the employment of the Contractor and his sub-contractor are skilled and have a minimum of 5 years experience in their respective trades and in particular in operating a machine similar to the machine used by the Contractor. E Operators shall be subject to a probationary period of three months. F The Contractor shall obtain approval for the method statement from the Engineer and the concerned authorities as appropriate prior to excavation. G In the Notice of Intent enclose with request for approval to carry out the works from the concerned Authorities an undertaking formally executed, bearing the corporate seal and signed by the duly authorized signatory and endorsed by the executing authority

UNDERTAKING We undertake to inform the ……(*)…….. in the event of collapse, heave or settlement of a .......................*....................... road when we are carrying out excavation in, under or near to it. We hereby undertake to carry out the required reinstatement works exactly in accordance with

……(*)………….. specifications

and to pay all compensations/entitlements for any accidents

that may occur due to this road collapse, heave or settlement and any associated costs to replace/repair affected services. This is our undertaking in this respect. Contractor:

____________________________________

Corporate Name :

____________________________________

Chief Executive Officer :

____________________________________

Corporate Seal

____________________________________

Endorsed by the Executing Authority

____________________________________

Name of Authority

____________________________________

1.1.4 Site Investigations A B C

All the available information related to soil/sub-soil conditions will be given to the Contractor without obligation to the Department and the Engineer. Soil and ground conditions shall constitute the Contractor’s risk. The Contractor shall be solely responsible to investigate and ascertain the sub soil conditions likely to affect his works.


Page 441 of 589

Section 013122

D

E F G H

I


The Contractor must obtain sufficient data for the correct selection of NDM prior to start of Works. To this extent the Contractor shall carry out, through an approved soil laboratory, soil investigations in order to define all matters likely to affect his works. As a minimum soil investigations shall be carried out at the location of driving / receiving pits and central median. The results of such investigations shall be submitted to the Engineer and shall include recommendations for NDM works, excavation support and soil stabilization if required. The excavation system of the NDM method must be fully capable of excavating all material that it will encounter. The Contractor will not receive additional reimbursement or be granted an extension of time should the NDM works fail as a result of unforeseen sub-surface conditions. Such risks shall lie with the Contractor. The Contractor shall be responsible and allow in his rates for obtaining existing utility information and executing trial pits to locate and confirm services likely to affect his works.

1.1.5 Security A

The Contractor shall adopt safe working practices for tunneling in accordance with provisions of BS 6164 and BS 5228: Parts 1&2. B All work shall comply with applicable local safety regulations, good practice and shall be to the Engineer’s satisfaction. C A handheld gas detector, measuring H2S, combustible gases, CO2, Methane shall be placed inside tunnels at all times when workmen are inside such structures. D Tunnels and pipelines shall be provided with forced cooled ventilation supplying an air-exchange of 10 x per hour at the first 15 m behind the driving shield. E One first aid trained employee shall be present on Site at all times when works are under progress. F Works near services shall only be carried out in the presence of the representative of relevant operating authority. It shall be the Contractor’s sole responsibility to arrange for the attendance of said representative(s). G The site installation shall include a communication system between labor force working inside shafts and control room as approved by the Engineer. H Only authorized personnel shall have access to the site. I A Safety Officer, suitably experienced in tunneling operations and with adequate authority to control and implement safe working practices shall be present at all times. J Suitable arrangements at site for personnel including, Telephone service, Emergency escape or BA sets and transport shall be provided. K A separate cage type ladder bay for the shafts/pits complete with ladder in addition to any other bay or bays required for the construction of the works shall be installed. L The shafts/pits shall be fenced on all sides with close steel panels of a minimum 1.8 m in height equipped with orange safety warning lights. M Panels (maximum space between the panels is 100 mm) shall be joined by steel rods supported on concrete blocks. N Adequate lighting and ventilation to the shafts/pits shall be installed. Except where otherwise necessary, electricity shall be 110 volts from a CTE (center tapped to earth) supply and up to 220 volts with use of ELCB protection. O The control room at the thrust pit/shaft shall be air-conditioned and sufficiently spaced for a desk and chair for one inspector. P All electrical installations shall be protected against water and physical damage

2

Equipment And Products 2.1.1 Moling

A B C

Tunneling by impact mole (pneumatic punchers) may be used for pipes DN <= 300 mm. The carrier pipe shall be placed in a steel jacking pipe. Installation and operation of the impact mole and associated equipment shall be as instructed by the equipment’s manufacturer. Special care shall be taken by plugging compressor hoses when not in use so as to prevent foreign matter entering the impact mole.


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2.1.2 Micro Tunneling A

B

C

Micro tunneling work is executed to minimize settlement or heave during pipe jacking. It is a pipe installation technique using hydraulic jacks to press pipes from a jacking shaft. Excavation is being carried out using slurry tunneling equipment. The system consists of a micro tunnel boring machine, automated spoil transportation with related controls, steering system, remote control console, guidance system to continually monitor the position and movement of the MTBM and spoil separation or removal facilities. The over cut of the drilling head shall be such as to reduce the chance of settlement to a minimum. Over cut shall not exceed 15 mm on the radius of the pipe being installed. The annular space created by the over cut may be filled with lubrication material to reduce frictional drag on the pipe. Heave shall be controlled by proper control of jacking forces and rate of excavation. To prevent settlement (caused by over cut) suitable and approved material shall be injected whilst jacking is under progress.

2.1.3 Micro Tunnel Borin g Machine (MTBM) A

B

C

The MTBM must be capable of controlling rotation or roll by means of bi-directional drive on the cutter head or by the use of fins or grippers. The MTBM shall be articulated to enable remotely controlled steering of the shield. A display showing the position of the shield in relation to a design reference must be available to the operator at an operation console together with other information such as face pressure, roll, pitch, steering attitude and valve positions. The MTBM shall have a cutter face capable of supporting the full excavated area at all times and the capability of setting a calculated earth balancing pressure and positively measuring the earth pressure at the face.

2.1.4 Automated Spoil Transport ation A B

C

D

E

The Automated Spoil Transportation system shall match the excavation rate to the rate of spoil removal thereby maintaining settlement or heave within tolerances specified. The balancing of ground water pressures shall be achieved by the use of a slurry pressure or an auger earth pressure balance system. The system shall be capable of any adjustment required to maintain face stability for the particular soil condition to be encountered on a project. The system shall monitor and continuously balance the ground water pressure. In a slurry spoil transportation system the ground water pressure may be managed by use of the slurry pumps, pressure control valves and a flow meter. A slurry by-pass unit shall be included in the system to allow the direction of flow to be changed and isolated, as necessary. A separation process shall be provided when using the slurry transportation system. The process shall be designed to provide adequate separation of the spoil from the slurry so that the clean slurry can be returned to the cutting face for re-use. The type of separation process used is dependent upon the size of the tunnel being constructed, the soil type being excavated, and the space available for erecting the plant. The layout of the slurry tanks shall be to the satisfaction of the Engineer and shall be arranged so as to cause no nuisance or hindrance to local people or passers-by. Slurry shall be carted away completely and not spread locally to dry out. If an Auger spoil transportation system is utilized, the ground water pressures may be managed by controlling the volume of spoil removal with respect to the advance rate (Earth Pressure Balance Method) and or the application of compressed air. In soils with excessive ground water, approval of the Engineer will be required for earth pressure balance auger systems. Approval will be based on the evaluation of the equipment’s ability to balance soil and water pressures at the face, stability of the soils and the significance of the ground water present.

2.1.5 Main Jack s A

B

The main jacks shall be mounted in a jacking frame and located in the drive (starting) shaft. The jacking frame successively pushes the MTBM followed by a string of connected pipes toward a receiving shaft. The jacking capacity of the system must be sufficient to push the MTBM and the string of pipes through the ground. The main jacking equipment installed must have a capacity greater than the anticipated jacking load. The hydraulic cylinder extension rate shall be synchronized with the excavation rate of the MTBM, which is determined by the soil conditions.


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D E


Intermediate jacking stations shall be provided by the Contractor when the total anticipated jacking force needed to complete the installation exceeds 80 % of the capacity of the main jacks or the designed maximum jacking force for the pipe. The jacking system shall develop a uniform distribution of jacking forces on the end of the pipe by the use of spreader rings and packing. The thrust wall must be designed to be reasonably firm and, should any existing services etc. exist closely behind it, it must be designed not to move excessively to risk stressing and damaging these services.

2.1.6 Guide Rails A B

Special care shall be taken when setting the pipe guide rails in the jacking shaft to ensure correctness of the alignment, grade, and stability. Guide rails for supporting pipes shall be designed to prevent damage to outer surface of pipes and / or the protective coating.

2.1.7 Remote Contro l Syst em A B

A Remote Control System shall be provided that allows for the operation of the system without the need for personnel to enter the pipeline. The control equipment shall integrate the method of excavation and removal of soil and its simultaneous replacement by a pipe. The rate of jacking shall be equal to the rate of excavation. As each pipe section is jacked forward, the control system shall synchronize excavation and jacking speeds. The system shall provide complete and adequate ground support at all times e.g. the slurry pressure at the drill head must compensate earth and water pressure of the soil encountered and shall be kept constant at all times also during periods of stopping jacking. Gauges for measuring and controlling slurry pressure shall be installed in the control room.

2.1.8 Pipes A B

C D

E

Subject to alterations detailed in the following, the specifications for pipelines shall apply. The Contractor shall be responsible for the design of pipes and the method of construction. In general, pipe used for jacking shall be round, have a smooth, even outer surface, and with watertight joints that allow for easy connections between pipes. The pipe manufacturer has to guarante that the pipe and its material are suitable for the intended use. Pipe ends shall be square and smooth so that jacking loads are evenly distributed around the entire pipe joint, such that point loads are minimized when the pipe is jacked. Pipes shall be capable of withstanding all forces that will be imposed by the process of installation, as well as the final, in place, loading conditions. The driving ends of the pipe and intermediate joints shall be protected against damage as specified by the manufacturer. The detailed method proposed to cushion and distribute the jacking forces shall be specified for each particular pipe material.

2.1.9 Joints A

B

C

Joints used in conjunction with a resilient packing shall be capable of accepting repeated angular deflections up to 0.5o without damage to the pipe and joint or loss of structural strength or loss of water-tightness. Joints shall a. be absolutely watertight, remain watertight when pipes are deflected within limits as specified by the pipe manufacturer and under the shear force test as per DIN 4060 b. be able to transfer jacking forces c. provide a corrosion resistant connection (for pipe material requiring corrosion protection) Joints shall be designed and manufactured to perform all the above listed functions regardless of any foreseen internal sealing.

2.1.10Concrete Jack ing/Carrier Pipe A B C

Concrete shall be waterproof. Cement for reinforced concrete pipes shall be MSRPC / Type II. Exterior protection shall be 500 micron DFT corrosion and abrasion resisting solvent free epoxy coating. Pipe installation shall continue until at least one length of pipe beyond the limit of construction is exposed. Where the pipe has failed a second pipe shall be jacked through and inspected. Where in


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D

E F G


the opinion of the Engineer the pipe or coating has been damaged during installation, the Contractor shall submit to the Engineer a proposal demonstrating the adequacy of the pipeline installed. Extra payment will not be made for the pipelines jacked beyond the limit of construction or for remedial measures etc. Costs for these works are deemed to be included in the rate for installing pipes. Lining shall be u-PVC, GRP or HDPE. To prevent damage or deformation of GRP lining cast into concrete the GRP pipe shall be wrapped by a compressible material. Dimensions and stiffness of GRP pipes for gravity pipelines shall be the same as for the GRP pipes executed in the open cut method. The concrete shall be designed to take all the pressure exerted by jacking forces. Pressure transfer rings placed between pipe ends shall be of a material with the least lateral extension and may be made from chip board. The width shall not exceed the minimum thickness of pipe wall; a small off-set is recommended.

2.1.11Jacking / Carri er Pipe A

B

C

Where the Contractor elects to construct carrier pipelines inside larger diameter pipes and grout the annular space the jacking pipe may be of steel with full circumferential weld. The steel pipe and grout shall be regarded as sacrificial and the carrier pipe shall be capable of withstanding installation, grouting forces, soil, traffic and groundwater loads. A low strength, non-shrink grout or foam concrete shall be placed at low pressure. The carrier pipe shall be fixed true to line and level by spiders or other means. Pipes and joints shall be protected from adverse physical and chemical effect of grout and compressive material shall be wrapped around GRP - pipes. During grouting the carrier pipe shall be filled with water to prevent flotation. Proper ventilation shall be foreseen at both ends of the pipeline to be grouted to restrict grouting pressure to the limits specified by the pipe manufacturer. The grouting system shall be equipped with pressure gauges to control grouting pressure and to ensure that pressure is not exceeded.

2.1.12Joint Packing A

B

Joint packing material when subjected to the maximum permitted bearing pressure shall have under dry conditions: a. A restoration after 1 hour of at least 65% of the original thickness. b. A compression of at least 50% of the original thickness. Independently authenticated test results to demonstrate that the packing complies with the Specification shall be submitted and shall include a graph of the stress/strain relationship over the range of conditions, which will be encountered during the Works. The material used for packing to withstand all imposed loading applied during the installation of all pipes for each completed length without showing signs of deterioration or distress.

2.1.13Lubr icatio n System A

B C D

E

A pipe lubrication system may be utilized when anticipated jacking forces on the pipe are expected to exceed the capacity of the main jacks or exceed the pipe design strength with the appropriate safety factor. An approved polymerized bentonite based slurry shall be injected at the rear of the jacking head and, if necessary, through the pipe walls to lower the friction developed on the surface of the pipe during jacking and thereby reduce the jacking forces. Slurry shall be suitable for the substrata conditions encountered on site. Lubricant injection overpressure shall be avoided. It shall be sufficient to fill the overbore voids to avoid collapse and upward migration of the void prior to permanent grouting. Bentonite shall be mixed thoroughly with clean potable water to make a slurry 24 hours before its usage. When saline or chemically contaminated groundwater occurs the bentonite suspension shall be modified or pre-hydrated in fresh water and polymer shall be mixed up so as to render it suitable for the intended purpose. Tests to determine density, viscosity, shear strength and pH-value shall be carried out on bentonite supplied to the pipe bore. Tests shall be carried out until a consistent working pattern has been established. All tests and sequence of tests shall be as proposed by the Contractor and approved by the Engineer. In the event of a change in the working pattern retesting shall be re-introduced if required.


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F G H

I


The density of the mixed bentonite shall be measured daily. The measuring device shall be calibrated to read within 0.005 g/ml. After completion of works the injection points in pipes shall be sealed and made watertight. Injection points in pipe walls shall be corrosion resistant threaded fittings, cast into the pipe wall at locations proposed by the pipe manufacturer. Fittings shall be equipped with a puddle flange and GRP / uPVC - surfaces, in contact with concrete, shall be sanded to provide a good bond. uPVC fittings shall be dimensioned to sustain loads applied during casting of concrete. After completing works, and before fixing liner (if any), the injection joints shall be sealed. All works and material used shall be to the satisfaction of the Engineer. In suitable ground conditions water alone may be used. For clay soils, non aqueous lubricants shall be used.

2.1.14Grout A B C

3

As over break grouting sulphate resistant Portland cement and water, determined by geo-technical data and approved by the Engineer, shall be used. 2 The nominal strength shall be at least >= 7 N/mm . Admixtures shall be used only if tests have shown to the satisfaction of the Engineer that their use improves the properties of the grout, e.g. by increasing workability or slightly expanding the grout.

Execution

A. The Contractor shall: a. Confine surface operations to pits/shafts and the area immediately adjacent to such shafts. b. Keep the working area to the minimum practicable for the proper construction of the works. c. Take any measures necessary to prevent damage or deterioration of the soil reaction face during the construction of the temporary and permanent works from whatever possible cause, such as ingress of water, softening, corrosive soil or loss of fines from a granular soil. d. Program activities (including setting up and dismantling of site installations, construction of driving / receiving pits, clearing site etc.) in such a manner that all site works are completed within the following calendar days: Construction driving / receiving pits 10 days   Jacking pipes up to OD 1000 20 to 30 m/day  Jacking pipes up to OD 1400 15 to 20 m/day  Jacking pipes up to OD 1800 10 to 15 m/day  Jacking pipes > 1800 3 to 5 m/day Dismantling and clearing site 10 days 

3.1.1 Minimum Cover A B

The minimum depth of cover to the pipe being installed should generally be > 2.0 m or 1.5 times the outer diameter of the pipeline or as required by Authorities Road Section. Special precautions must be considered if this depth of cover is decreased.

3.1.2 Thrust System A

B C D E

The rig shall distribute the thrust to the pipes via a thrust ring and packing. The jacks shall apply the thrust to the thrust ring by means of a symmetrical distribution. Inter jack stations shall be used where frictional resistance or other causes would otherwise result in unacceptable thrust forces. If used, spacer blocks shall be true and free from any distortions. All thrust rings shall be true and free from any distortions and sufficiently stiff so as to transfer the load from the jacks uniformly to the packing. Other than at the shield, each group of jacks shall be interconnected to ensure that an evenly distributed load is app sufficiently lied to the thrust ring. Fitted with automatic thrust recording equipment monitoring load cells incorporated in each jack together with a pressure - metering device.

3.1.3 Pits / Shafts A B

The Contractor may select interlocked sheet pile cofferdam or reinforced concrete caisson as the most appropriate for the site conditions and for the soil profile. All the joints of caisson rings shall be sealed with the joint sealant to make the caisson watertight.


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Section 013122

C D E F G H I

J K


Interlocked steel sheet piles shall be braced with steel framing welded to the sheet piles. Struts shall not be used for bracing. The pit bottom shall be sealed with a concrete plug, cast underwater, and designed to resist water uplift as well as forces of the jacking equipment installed in the pit. Exit and entry eyes for jacking pipes, properly braced, shall be provided. Pits/shafts shall be maintained dry at all times. Standby pumps are to be provided., ladders etc. Pits shall be provided with sufficient light The Thrust wall shall: a. Be perpendicular to the proposed line of thrust. b. Be dimensioned to accept repeatedly the maximum permitted thrust force without undue movement and without thrusting directly off any part of the permanent works unless this part is specifically designed to withstand the thrust reaction. c. Not be joined to the jacking rig base. Any void between the soil face used to provide a reaction to the thrust force and the thrust wall filled completely with grout or concrete. Entry and exit sealing rings shall be provided.

3.1.4 Tunneling A

The Contractor shall: a. Provide sufficient pipes before any particular tunneling commences and, if required, provide intermediate jacking station assemblies to ensure continuous operation. b. Limit the thrust force to the maximum permissible as determined and based on approved calculations. Consideration shall be taken of the behavior of the pipe joint at the maximum permitted angular deflection of 0.50 with the maximum permissible bearing stress in conjunction with the stress/strain relationship obtained from the packing compression tests. c. Ensure that excavation rate does not exceed the horizontal drive rate throughout the operation. d. Prevent both subsidence and heave during all stages of the setting up, tunneling operation and dismantling. B Earth pressure counter balance tunneling systems shall incorporate a polymerised bentonite based slurry system. Earth pressure balance system without bentonite slurry application shall be used only with the express permission of the Engineer. C Slurry/excavated soil mixture shall be removed properly from the excavation, settled in a stilling basin and transferred to a suitable location. Stock piling on site is not permitted. D The tunnel face support shall be maintained for balancing full earth pressure and groundwater pressures. E Tunneling operation shall run continuously between drive and reception pits/shafts. F Full earth and ground water pressures at the tunnel face shall be maintained during short stoppages needed for pipe jointing or other approved reasons. G Cuttings spoil removal and cutter face operations are not permitted when the pipe thrust is not being carried out. H The annular overbore voids shall be filled around the outside of the pipe to avoid collapse and upward migration of the void prior to permanent grouting. I Drilling fluid injection overpressure shall be avoided. J Casing and carrier pipes shall be placed and joined individually within the sleeve or mount on guide rails or trolleys in such a manner as to transmit the pulling/pushing forces through the carriage and not through the pipe. K Packings shall be: a. Cut to dimensions ensuring that the full bearing width of the joint is protected. b. Designed and of a material to achieve 8 mm minimum thickness of final joint gaps is achieved upon completion of the pipeline. c. Shall cover the full face of the pipe but stopped approximately 10mm at outer face of pipe wall. L Pipelines, not inserted in sleeves, shall be extended until at least one additional length of pipe beyond the limit of construction is exposed. M The Engineer shall inspect the exposed pipe and its exterior coating. Where in the opinion of the Engineer the pipe or coating has been damaged during installation, the Contractor shall submit a proposal, for review by the Engineer, for demonstrating the adequacy of the pipeline installed. N Where the pipe has failed a second pipe shall be jacked through and inspected. O Gaps in the joints between the pipes shall be sealed by approved method. Contract 106, Volume II

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3.1.5 Caissons A B C D E

F G H

Subject to acceptable subsoil conditions the driving / receiving pits for carrier pipes DN <= 300 shall be executed in the caisson method. Caissons shall be constructed in pre-cast concrete rings suitably dimensioned for easy handling. The wall thickness shall be designed to withstand soil and groundwater pressure. To prevent friction between shaft and surrounding soil the bottom ring shall be widened and outfitted with a cutting edge manufactured from steel L-profiles. The first ring to be sunk shall be placed true to horizontal and vertical alignment. While excavating care shall be taken that the walls of the shaft are kept in the vertical position. In areas with groundwater the ring shall be lowered sufficiently below the formation level required for jacking to enable placing a water tight concrete plug of sufficient dimension to prevent water from entering the shaft and to counteract uplift. Depending on site conditions the upper rings may be removed for re-use. “Soft eyes”, suitably dimensioned to enable installation of pipelines, shall be foreseen in ring walls at the levels required. When working in areas with groundwater the joints between rings shall be made watertight by placing preformed compressible Butyl Rubber Hydro Carbon Bentonite strips (BRHC - strip). Very generally the sequence of construction shall be as follows: a. Level area of shaft, compact b. Place ring with cutting edge, check vertical alignment c. Excavate, taking care that ring sinks vertically, if required the annular space between shafts and soil shall be filled with bentonite for lubrication the caisson’s passage through the ground and to stabilize the sides of excavation d. Where groundwater is encountered place BRHC strips e. Place next ring f. Construct bottom slab: g. in dry condition, compact formation and place a concrete layer of sufficient thickness and strength to withstand loads from jacking equipment and jacking operations h. in groundwater, cast concrete layer under water using sulphate resistant cement. i. Thickness of concrete to be sufficient to prevent leakage and up lift. j. Pump out water, place a 30 cm thick layer of concrete, construct sump 50 cm diameter (or 50 x 50 cm) 30 cm deep for drain pump k. Construct thrust block for jacking equipment l. After completion of jacking and construction of manholes the upper rings may be re-use in jacking works.

3.1.6 Line and Level Contro l A

B C

D E

The setting of the laser and target line and grade shall be controlled by a laser guidance system that relates the actual position of the drilling head to a design reference by a laser beam transmitted from the jacking shaft along the center line of the pipe to a target mounted in the shield. Lasers shall be installed in positions that are not affected by displacements caused through jacking. The laser equipment shall be suitably designed to permit fine adjustments during jacking. Where pipeline diameter allows, manual checking of line and level shall be carried out by conventional theodolite and level techniques. If the deviation exceeds the specified tolerance, work shall cease immediately and the Engineer informed forthwith. Submit proposals to rectify the deviation and work shall only recommence on the written instruction of the Engineer. Unless otherwise approved by the Engineer, all NDM pipeline construction shall be carried out in an uphill direction from the drive pit/shaft. The steering information shall be monitored and transmitted to the operation console. The minimum steering information available to the operator on the control console shall include the position relative to the design reference, role, inclination, attitude, rate of advance, installed length, thrust force, and cutter head torque.

3.1.7 Grouting A

Upon completion of a section, if grouting is required or specified, the grout shall be pumped through all lubrication holes. The pressure and quantity of grout injected shall be calculated by the Contractor and approved by the Engineer.


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B

C D E F


Grouting shall commence at the lower holes systematically working from one end of the pipe-jack to the other. Where injection holes can be opened without loss of ground, grout shall be pumped through the lower injection holes until it emerges from the upper holes. Grouting progress shall be monitored continuously to ensure no heave. To avoid floating of pipes, excessive hydration temperature and to resist forces during grouting, the carrier pipe shall be filled with water. A free venting standpipe of not less than 100mm diameter shall be installed on the grout injection feed to restrict grouting pressures to a m. On completion plug lubrication holes watertight and make good pipe lining. The pressure of the lubricant shall be maintained when it is to be replaced by grout.

3.1.8 Tolerances A B C D

Lateral deviation of any part of the pipeline: shall not be more than ±5 0 mm. Level of any part of the pipeline: deviation shall not be more than ± 10 mm. Maximum lapping between the edges of adjacent pipes shall not exceed ±3 mm. Movement of ground or roadway surface above the pipe centerline and at adjacent structures shall not exceed 6 mm measured after maintenance period.

3.1.9 Drilli ng Fluid Tests A

B

The Contractor shall carry out control tests on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pipe bore. For average soil conditions the results shall generally be within the ranges in the following table.

3.1.10Tests on Benton ite Slurry o

Property to be measured

Range of results at 20 C

Test method

Density

Less than 1.10 g/ml

Mud density balance

Viscosity

30 – 90s or

Marsh cone method

Less than 0.020 Pa-s

Fan viscometer*

1.4-10 Pa or 4-40 Pa

Shearometer

Shear

strength

(10

minute

gel

strength) pH

Fan viscometer 9.5 – 12

pH indicator paper strips or electrical pH meter

*Where the Fan viscometer is specified, the fluid sample should be screened by a number 52 sieve (300 µm) before testing. A

B

C

D

The Contractor shall propose the frequency of testing bentonite slurry and the method and procedure of sampling for approval before the commencement of work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval. The Contractor shall carry out tests until a consistent working pattern has been established, account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behavior, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

3.1.11Monito ring Ground Surface Mov ement A

The Contractor shall continuously monitor the ground surface, adjacent structures, buried utilities and control activities such as excavation, tunneling and dewatering to prevent movement and/or damage to existing structures.


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B C

D

E

F

G H

I


Monitoring points within the existing structures and on the road surface shall be provided to the approval of the Engineer. Generally, monitoring points along the road surface shall be located along the pipe centerline and on each side. The distance for the location of the monitoring points along the same line shall be calculated to fall within the HS 20 wheel loads in each lane. Points on existing structures shall be located approximately 0.5 meters above the ground surface. Location of settlement points in the vicinity of the pits will be agreed with or at the direction of the Engineer. All points shall be surveyed with reference to benchmarks located outside the area of influence of the works. Monitoring shall demonstrate repeatability to 3mm. Levels of monitoring points shall be recorded as follows: a. For monitoring points within 20 meters of the heading, after each advance of 5 meters. b. For monitoring points greater than 20 meters but less than 100 meters away from the heading, daily. c. The monitoring point elevations shall be reported to the Engineer within 24 hours during the course of construction of the pipeline and related pits/shafts. Should surface movement occur greater than the specified limits, at any location affected by the works, the Contractor shall propose modification of the method or sequence of the work or a shutdown of the work to make appropriate changes in the construction operation. Changes required to keep surface movement within the specified acceptable limits shall be made solely at the Contractor’s expense. Upon completion of the pipeline, monitoring of point elevations shall continue during the maintenance period as required by the relevant authority, findings shall be recorded and reported to the Engineer on a monthly basis. If the specified limits are exceeded the Contractor shall report immediately and submit a proposal to rectify the road surface and prevent further settlement.

3.1.12Pipe Testin g A B

C D E F G

H I J

Quality control tests at the factory shall include subjecting the pipe joints, at maximum permissible deflection, to an external hydrostatic pressure of 2 bars. Unless independently authenticated test results acceptable to the Engineer are available, two o consecutive axial tests incorporating a 1 angular deflection with the application of double the maximum permissible thrust force (or, if greater, of the greatest thrust force that the proposed thrust equipment can apply) shall have been successfully conducted without any visible crushing, cracking or spalling of the pipe being evident before any pipes will be accepted for use. The tests shall be extended to record the loading at which any visible signs of failure become evident and shall be carried out in an approved manner to simulate actual working conditions. Pipes that have been submitted to the proof load test will not be permitted for use in the permanent works. Infiltration test shall be conducted upon completion of the permanent construction of the tunnel to verify that joints are watertight. The infiltration test shall be carried out after dewatering is stopped and the groundwater has attained normal levels. In the case of lined concrete pipes the leakage tests shall be carried out after installation and before the liners of the successive pipes are joined and sealed. After joining and sealing of the liners, there shall be no evidence of a build-up of groundwater pressure at the joints of the concrete pipe. Man entry pipelines shall be visually inspected only. Any leaks shall be repaired. Infiltration or pipe deflection is not permitted in sections of pipelines underneath roads, paved areas and services. In the event of the works failing the test, for whatever reason, the Contractor shall take such remedial action as is necessary, subject to the Engineer's approval. Works shall be re-tested until such time as the works pass the test.

3.1.13Project Record / Report Documents , Inspect ion A

The Contractor shall maintain and submit to the Engineer after each working shift a log recording the following: a. Identification number of pipes installed during shift and name of operator. b. Strata encountered.


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B

C D E


c. Position and orientation of the lead ten pipes. d. Forces used on both main and inter jack rams during driving of each pipe. e. Line and level. f. Roll of pipe-jacking shield. g. Maximum rate of advance. h. Distance moved i. Thrust from ground on face of machine. j. Volume of lubricant used, location of injection and pressure at point of injection. k. Volumes of material removed. l. Volumes of grout used, the points of injection and pressure at the points of injection. m. Cutter torque. n. Slurry flow and pressure. o. Supply pressure. p. Pitch of TBM. q. Gas readings at the excavating face (oxygen, methane and hydrogen sulphide). r. Gas readings in thrust pit. s. Level records of ground surface or road pavement. t. Accident and stoppage, if any, with full explanation. Upon completion of each drive, and if applicable after installation of carrier pipes, the Contractor shall prepare a report comprising data collected during jacking of pipes as specified, special events encountered, soil profile etc. and submit 3 copies of the draft to the Engineer for review. Approved forms for inspection of driving/receiving pits, of tunneling operation and of the as built condition shall also be submitted. Pipelines with a diameter < 1.40 m shall be inspected by CCTV. Results of inspection shall be compiled in a report, 5 copies of which shall submitted to the Engineer.

END OF SECTION


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Section 015000

Electro Mechanical Specifications

SECTION 015000 ELECTRO MECHANICAL SPECIFICATIONS 1

Part 1 General 1.1.1 Related Sections

A. These Specifications shall be read in conjunction with all other Contract Documents and the Contractor shall comply with all the provisions contained in these documents. The Contract Documents are deemed to be complementary and to describe and provide for a complete Work. B. Any clauses of the Specifications, relating to work or material not required by the Contract are judged not to apply. In case of contradiction or discrepancy between any two articles or clauses of these specifications, the clause, which stipulates the more restrictive condition for the Contractor, shall be binding.

1.1.2 Standards, Units A. Whenever reference is made to Standards such references are deemed to include the words "or equivalent standard subject to the prior approval in writing by the Engineer". If the Contractor proposes the use of alternative standards then those specified, he shall allow sufficient time for the Engineer for checking that materials, to be supplied under alternative standards, are acceptable. No claim for delay arising as a result of time required for carrying out such tests will be accepted. ADWEA (or other concerned authorities) – ETISALAT and Civil Defence Standards together with the USA Standard NFPA must be observed. B. Legal SI units and symbols only shall be used for the dimensioning and quantification of the entire works.

1.1.3 Engineer's Approval A. The Contractor shall not order any material nor execute any works without having the Engineer's prior approval to the materials and/or the methods he proposes to employ. He shall not t hereafter modify the source of supply or working methods without the Engineer's consent. Any approval given by the Engineer shall not r elieve the Contractor from his responsibilities under the Contract.

1.1.4 Manufacturers A. Manufacturing facilities for equipment and material delivered under this contract shall comply with ISO Standard 9001/2. B. Manufacturers shall have long experience in the design and manufacture of the articles supplied by them and the products shall have a proven and reliable service in similar installations and under similar conditions. Irrespective of any conditions specified herein the Contractor shall be solely responsible for supplying and installing the Plant as specified and implied in the Contract Documents. C. A list of manufacturers, already approved for supplying material, equipment and machinery for the Plant, is given in the Appendix. The Contractor may propose, in a separate quotation, other manufacturers as alternative. The Department shall not be bound to accept any alternative offer and need not to assign any reasons for the non-acceptance of any such alternative offer. D. All materials, equipment and machinery (including electrical motors) shall be manufactured in the original country of the manufacturer and similar items of plant like pumps, motors, etc. shall be obtained from one manufacturer only. E. Together with the submittals the Contractor shall provide comprehensive information and detailed schedules for each type of material / equipment proposed showing type, manufacturer, country of origin, local agent and all other data and information required for a technical appraisal. The submittals shall be accompanied by detailed technical descriptions, catalogues, lists of references, showing that the material / equipment is suitable for the climatic and environmental conditions prevailing at the Site. When evaluating the offers, emphasis will be paid to durability, ease of operation and maintenance, access to major items of the plants. Submittals shall, in addition to requirements listed elsewhere, include schematics and flow diagrams showing the built-up of the Plant. Contract 106, Volume II

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F. The Contractor shall include in his contract(s) with manufacturers / suppliers the condition that the manufacturer's technical expert shall inspect in regular intervals (not less than once a month) all sites where installation works are under progress and where materials are stored or used or installed. The expert shall report his findings in writing directly to the Engineer and shall comment on handling, storing and installation of said material. G. Together with the application for approval of material the Contractor must submit a written undertaking of the manufacturer to this extend.

1.1.5 Submittals A. Latest two weeks weeks after award of the the work order of the miscellan miscellaneous eous contract, contract, the Contractor Contractor shall submit a complete list of all documents, materials and other items, which are subject of approval, including the scheduled submission dates, divided into: a. Submittal List of shop drawings b. Material Submittals mechanical c. Material Submittals electrical d. Material Submittals Instrumentation e. Submittals for General Items B. Long lead lead items, critical to the contractual contractual time schedule, shall shall be listed separately. C. The Contractor shall shall allow in his programme programme of works for the time time required by the the Department and and the Engineer for checking submittals, inspection and t esting that may be necessary for assessing the quality of material proposed. D. At the end of each each month the Contractor shall submit submit a status list of submittals submittals containing: containing: a. No of submittal b. Short description of submittal c. Date of submittal d. Date of Engineer’s comments. if any e. Date of re-submittal(s) f. Date of Engineer’s comments on re-submittal(s), if any g. Date of Engineer’s approval h. Date of placing order (copy of the order to be enclosed) E. Each document, document, material, samples, etc. subject subject of approval by the Engineer Engineer and the Employer shall be submitted along with an individual submittal form sheet. F. Submittal form sheet for M & E Works shall be used for all material, plant, etc. proposed for mechanical/electrical works. G. The submittal sheet is working as a "curriculum vitae" of the item submitted submitted and shall be used separate for each individual document/material. H. Manufacturer’s catalogues / specifications etc. shall be submitted as one original plus three copies. Items proposed shall be highlighted on the original and on the copies. To enable copying, marks shall be by arrows or underlining, highlighting by markers is not accepted. I. All submittals shall be numbered successively. Numbers of re-submittals shall receive the original original number plus (a) and repetitions shall receive (b), (c) etc. Submittals related to one portion of the Works shall be submitted simultaneously showing all parts related to this portion. Submittals shall clearly indicate any deviation, substitution or variation from the Contract Specifications and shall state the reasons for the same. All corrections shall be highlighted on the re-submittal to expedite review. Submittals shall be accompanied by a cover sheet in the form approved by the Engineer. J. Delays to the works, resulting from incorrect and incomplete incomplete submittals, submittals, are the sole responsibility responsibility of the Contractor and claims, whatsoever nature, will not be entertained in this respect.

1.1.6 Materials A.

B.

All materials materials incorporated incorporated into the the Plant shall be be the most suitable suitable for the duty concerne concerned d and shall shall be new, of first class commercial quality, free from imperfection and selected for long life and minimum maintenance. Dissimilar material material to be in contact to each other other when installed installed shall be avoided avoided but where where necessary these materials shall be selected and / or isolated so that the natural chemical / electrical potential difference between them does not exceed 250 smV. Where required the contacting surfaces shall be durably treated to achieve the limits specified.


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C.

D. E.


All castings material material as cast iron, cast aluminium, cast alloys, bronze etc. shall be of the first class appearance free from blowholes and cracks. Repair of casting by plugging, filling or welding is not acceptable. All material, including protective coating, shall be suitable for working under the prevailing climatic conditions and shall be resistant against sewage or fumes and gases generated by sewage if any. All plant shall be inspected, tested and marked at the manufacturer's place as required by the Standards to which the material has been manufactured and as approved by the Engineer.

1.1.7 Tropicalisation A. When designing the Plant and selecting its material and finishes that quality and durability of material shall be employed suitable for tropical ambient conditions and shall be vermin proof.

1.1.8 Inter-Changeability A. All equipment equipment and/or parts of it performing similar duties shall be of a single uniform type and make and shall be fully interchangeable interchangeable in order to limit stock keeping of spare parts.

1.1. 1.1.9 9 Unifor mit y of Plant Plant A. To facilitate operation, maintenance and stock keeping of spares similar items of the Plant shall be obtained from one manufacturer only.

1.1.10 1.1.10 Samp Samples les A. In addition to specific provisions in the Specification for sampling and testing of materials, the Contractor shall submit to the Engineer, as the Engineer may require, samples of all materials, which he proposes to use in the Works. Such samples, when approved, will be retained by the Engineer. The Engineer may reject any materials or goods, which in his opinion are inferior to the samples submitted. The Engineer's approval of manufacturer or material for the Works, whenever required according to the Specifications shall not relieve the Contractor from his responsibilities under the Contract.

1.1.11 1.1.11Tests, Certif icates ic ates A. The Engineer Engineer may examine examine and may require testing any materials materials or goods to be used in the Works. The Contractor shall give the Engineer unrestricted access to his, and his sub-contractor's premises for such purposes at all times. The Contractor shall afford the Engineer all facilities, assistance, labour and appliances necessary for the convenient examination, testing, weighing or analysis of all materials and goods. The Contractor shall prepare test pieces which the Engineer may require. Tests carried out off the Site shall not relieve the Contractor of the responsibility of ensuring that the materials pass any required tests when they are incorporated in the Permanent Works. B. Should the Engineer not inspect any materials or goods at the place of manufacture, then the Contractor shall obtain through his supplier test certificates from an independent Testing Institute, approved by the Engineer, and forward three copies of such certificates to the Engineer. Such certificates shall certify that the materials or goods have been tested in accordance with the appropriate Specification and approved Standards, and shall give the results of the tests which have been carried out. The Contractor shall provide adequate means on site to identify the materials or goods with their respective test certificates. Costs for such tests and certificates are to be borne by the Contractor and are deemed to be included in his Contract Price.

1.1.12 1.1.12Delivery to Site A. The Contract Price shall allow for all costs encountered for the supply C.I.F. to the Site, storage, double handling, cranage, wharfage, porterage, customs, clearance charges, handling fees, other fees and dues levied on the export/import of the Plant.

1.1.13 1.1.13Pack Packin ing g A. All items of the Plant shall be adequately adequately packed and protected against rough handling, handling, corrosion and damage during transport, in transit and shall be clearly marked to ensure the safe Contract 106, Volume II

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conveyance and delivery to the Site. It shall be the Contractor's sole responsibility to ensure that the Plant is s o packed and protected for transport that it reaches the Site undamaged. undamaged. Packing of the Plant shall include one packing list inside, and one packing list outside the packing fixed in a weatherproof envelope. envelope. Any plastic material used for packing must be UV ray resistant in order to avoid deterioration during storage on site.

1.1.14 1.1.14 Sto Storag rage e A. The Contractor shall arrange for the proper storage, protection and watching of all equipment equipment delivered to the Site. Items of the Plant that may be affected by humidity, heat, dust or sand as panels, motors, meters etc. shall be st ored in closed air-conditioned rooms or otherwise protected against heat, humidity, dust and sand.

1.1.15 1.1.15Orders , Invo In voic ices, es, etc. A. The Contractor Contractor shall provide the Engineer Engineer with three copies of all sub-contracts, sub-contracts, orders, and invoices, certificates of origin, shipping documents related to the supply of services, materials and goods required for the Works. B. Payment for material on Site will be made only against the documentation specified above and subject to the following: C. The Contractor shall submit with his valuation of Works a list detailing material on Site, last valuation, material received on Site since last payment, material used during said period and balance of material on Site.

1.1.16 1.1.16Loc al Agent Ag ent A. The equipment used shall have local agents certified by the manufacturer to check, test, and commission and maintain the equipment and systems.

1.1. 1.1.17 17Appr oval of Sub-contr acts A. Before entering into into any sub-contract for the supply supply of any materials or goods goods the Contractor shall obtain the Engineer's approval in writing of the sources from which he proposes to obtain such materials or goods. Should the Engineer at any time be dissatisfied with such materials or goods or with the methods of operation carried out at such sub-contractor's works or place of business, he shall be empowered to cancel his previously given approval of such sub-contractor and to specify any other suppliers whom he may choose or to approve another sub-contractor for the supply of such materials or goods. The Contractor shall then obtain the said materials or goods from such other supplier and shall bear any additional cost thereof.

1.1. 1.1.18 18Workin g Program A. The Contractor Contractor shall shall submit submit the Working Program as specified specified in the Contract Contract Documents. Documents. B. It shall take into account the periods periods required for checking the Contractor's designs as detailed in the Conditions of Contract. C. The program shall include in chronological order of the start, the periods required for all applicable activities such as: a. Preparation of Design, its approval b. Manufacture and Works testing c. Packing, Shipping, Transport d. Erection e. Testing, Commissioning f. Running of Plant g. As-built drawings & O&M manuals h. PAC date

1.1.19 1.1.19Drawi Drawi ngs ng s A. All Drawings Drawings shall be of of the size DIN A1 (594 x 840 mm) mm) and shall shall be numbered numbered consecu consecutively tively and dated. Each drawing shall show at the title block the name of the project, the Contract Number, the


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name of the plant or structure, other items detailed on the drawing itself and other information as required by the Engineer. B. The Engineer's approval on any subject shall not relieve the Contractor from his responsibility under this Contract. C. Within the mobilization period the Contractor Contractor shall submit a complete list of drawings required for the Works including the scheduled submission dates. D. Construction / manufacture shall not commence commence until such time as the Contractor is in receipt of the approved drawings. After the Engineer's approval the drawings shall not be altered.

1.1.20 1.1.20Engineer's Engi neer's Tender Drawin gs A. Preliminary general arrangement arrangement drawings are provided for the guidance of the Contractor only. The Contractor shall maintain the arrangement of Plant as far as possible, subject to differences in dimensions of the equipment offered. The Civil Work structures have been dimensioned to cater for a variety of equipment. Should alterations of civil works become necessary in order to accommodate the equipment proposed than the Contractor shall carry out such changes. Any costs required for such alterations shall be included in the relevant items of the Schedule of rates.

1.1. 1.1.21 21Contract or to Review Review Tender Tender Drawings , etc. A. Subject to the requirements and limitations limitations of the Contract the Contractor shall be responsible for reviewing the design of the Plant and, if required, to redesign, to prepare a detailed design and to verify the proper performance of the Plant proposed.

1.1. 1.1.22 22Drawin Drawin gs to be sub mit ted w ith the Tender A. The following drawings, lists and schedules shall be supplied in duplicate together with the Tender: a. General arrangement drawings, typical details and dimensions of the Plant and associated pipe work, lifting equipment, power supply, control panels, distribution panels etc. and general mechanical / electrical installations. b. Detailed specifications of the various items proposed. c. Preliminary performance curves for all pumping units indicating net head / efficiency / power consumption and plotted against quantity pumped. d. Construction proposal for switchgear / control / distribution panels. e. List of long lead items. f. Detailed descriptions of all optional items.

1.1.23 1.1.23Shop Drawin gs etc. A. Shop drawings shall be submitted in triplicate to the Engineer, for the Engineer's Engineer's approval. One copy shall be returned to the Contractor stamped "APPROVED" and or marked up with any necessary alteration. Where any modification or revision is required the Contractor shall make the amendments and resubmit the drawing as specified. After the drawing has been approved the Contractor shall submit to the Engineer 6 copies. After the Engineer's approval the drawings shall not be altered. All drawings shall show the Plant fully dimensioned in suitable scale. B. Construction and / or manufacture shall not commence until such time as the Contractor is in receipt of the approved drawings. C. Documents to be submitted: a. General and detailed arrangement b. Installation drawings separately for mechanical and electrical works c. Surge analysis d. Plant Layout(s) e. Sectional views, with all material / equipment fully dimensioned, showing the Plant, systems, routings, type of material, etc. f. Detailed list of all Plant components g. All auxiliary equipment to be supplied under this Contract h. List of all symbols / abbreviation and typical details used. D. The Contractor shall prepare drawings showing all details details of civil works required in connection with the installation of all mechanical/electrical works, as box-outs, width and depth of pipe/cable Contract 106, Volume II

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trenches, duct works, minimum door sizes, roof curbs, service manhole/ covers, etc. and all other works which shall be incorporated into the civil works. Such drawings shall be submitted to the Engineer for approval together with the consent of the appropriate authorities (if so required under the regulations in force) so that necessary measures like ducts and chases, etc. can be included in the civil works during construction. E. Foundation / support drawings for each item of plant, showing all data necessary for designing the foundation, like weight, RPM, expected vibration, expected operation and shock loads, etc. as well as temporary loads during installation (including calculation of supports required to protect the structure), recommended kind of vibration isolation, kinds of material and finishes, detailing all plinths, thrust blocks, ducts, openings, recesses, motor support structural members, bolt holes, chases, etc. and all other work to be incorporated into the civil works. F. Lists, schedules, diagrams, etc. a. P&I diagrams, b. Wiring diagrams, including control and interlock diagrams, c. Pipe isometrics, d. Electrical load schedule e. Calculations / construction / installation plans and drawings, f. Complete lists for cable/ equipment/ valves/ conduit/ instrument/ clamping lists as well as any other schedules/ tables/ diagrams, etc., required by the Engineer, clearly indicating the material and type of the Plant proposed, as well as proposed layouts/ method of installation, systems, function, operation, etc. g. A complete documentation, including list of spare parts, plant description, maintenance and operating instructions, test reports and certificates, certificates with type approval of explosion protected equipment shall be submitted prior to commencement of installation. G. At the end of each month the Contractor shall submit a list of shop drawing submittals containing: a. No of submittal b. Short description of submittal c. Date of submittal d. Date of Engineer’s comments. if any e. Date of re-submittal(s) f. Date of Engineer’s comments on re-submittal(s), if any g. Date of Engineer’s approval

1.1. 1.1.24 24As-Buil t Drawings A. As-built drawings drawings shall be prepared prepared by the the Contractor to the satisfaction satisfaction of the Enginee Engineer. r. Drawings shall be true to scale and shall be produced on AutoCAD Release latest edition. The Contractor shall submit to the Engineer 3 copies size DIN A1 of all as-built drawings for review and approval. After the drawings have been checked and approved by the Engineer the Contractor shall submit one copy of CAD-programme used for the preparation of the drawings (to be licensed in the name of the Employer), 5 paper copies size A1, two sets of numbered CD-ROM discs including index of all drawings prepared. Discs shall be labelled showing the name of project, contract number, dated and the number of each drawing stored on disc. B. The Contractor shall shall also prepare and and submit 5 No's A3 box files each containing containing one set set of wiring programs on A3 size pages, each page individually laminated enclosed in rigid transparent plastic. C. The record drawings and and CAD programme shall become the property of the Employer and should operate and compatible with Micro-Station and Auto-Cad programs. D. Preparation of drawings shall be scheduled scheduled that copies are available for use during the hand-over inspection. E. The following drawings shall be provided: a. Station location plan. b. Station site layout. c. Station general plan. d. Sections and plan for the station. e. Flow chart. f. Station Mechanical – 3D – drawings. g. As built drawings. Contract 106, Volume II

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h. Single line diagram. i. Earthing and lightening and lighting drawings. j. Station circuit diagram. k. P & ID diagram. l. Pipe line profile. m. Valves and wash out chambers. n. Pump curves and duty points for pumps. o. Station aerial view. p. Soft ware of pump mechanical section F. The above drawings shall include all modifications to the equipment that may arise as a result of the testing and commissioning of the equipment and associated plant.

1.1.25Consumables A. The Contractor shall provide and allow in his rates for the supply of spare parts and consumables required for all testing and commissioning and operation of the Plant till the end of the Maintenance Period. The costs for electricity and water, required during the period between PAC and end of Maintenance Period will be borne by the Department.

1.1.26Design Criteria 1.1.27 General A. All plant, equipment and systems shall be designed and constructed to be suitable for open air installation and operation under ambient climatic conditions. Only the central control / LV electrical o switchgear panel and PLC panels, de-rated and suitable for +50 C ambient temperature, shall be installed in air-conditioned environment. B. Remote, outdoor installed, control elements and electrical switchgears, etc. shall be encapsulated in suitable panels made from reinforced and UV-resistant GRP material as detailed in the Electrical Specifications. C. Special care shall be taken to avoid condensate at plants and systems due to the existing ambient weather conditions. Weather protection covers for the outdoor installed equipment shall be provided to avoid overheating of equipment and systems due to direct sunshine. D. Protective measures against flooding (caused by rainstorms or others) are to be foreseen. The arrangement of plant shall be such to avoid, as far as practicable, cumulating of sand near installations. E. Plant installed in dry wells of pumping stations shall be designed to operate when the dry well is flooded 2 m above floor level.

1.1.28 Pumping & Lif ting Stations for Irrigation Pumping Stations A. Unless otherwise specified the pumping / lifting stations shall be designed to accept wastewater with solids of 75 mm diameter including plastics, wood, fibrous matter, metal parts and animal waste. The mechanical / electrical part shall include but not limited to the following: a. Fully submersible pumps / End suction pumps / Centrifugal pumps b. Manually operated Davit with hoist c. Operating control / switchgear system d. Pipe work including fittings, appurtenances, accessories e. Cabling / wiring with accessories f. Indoor / Outdoor lighting system g. Surge control system (if necessary) h. Lightning / earthing system, fire alarm, fire protection system i. Telephone system j. Emergency power supply connection facility


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1.1.29 Surge Protection A. The Contractor shall be responsible for designing, manufacturing, installing and testing a safe and proper functioning surge protection system suitable for the Plant proposed. The surge protection system may include pressurized, non-pressurized vessels, vent valves etc. whereby nonpressurized vessels without bladder are preferred. B. The surge analysis, attached to the Contract Documents, shall be considered as a guideline only. The Contractor, when redesigning the Plant, shall prepare his own surge analysis suitable for the system proposed. Such calculations shall be subject to the approval of the Department and the Engineer.

1.1.30 Hydraulic s and Velocit ies a. b. c. d.

Pressure pipelines > 0.7 m/s and < 2.5 m/s. Pump suction lines <= 1.5 m/s Potable water main lines <= 2.0 m/s Potable water branch lines <= 1.5 m/s

1.1.31 Vibration Control A. Rotating/oscillating parts shall be in static and dynamic balance. Any vibration and noise caused by rotating and/or oscillating equipment, by flow velocity and other operational functions, which are considered by the Engineer as irregular or which are exceeding the manufacturer's recommendations, shall be rectified by the Contractor. Rattling equipment, piping and squeaks in rotating/oscillating equipment components will not be acceptable. B. Vibration shall be measured as r oot mean square displacement RMS in [mm] at the machine bearing houses and the valuation of vibration readings shall be in accordance with the Hydraulic Institute Standard, USA, latest edition, regarding water pumps, and to VDI Standard 2056 regarding all other rotating / oscillating equipment. The manufacturer shall determine the field vibration limits based on above standards, subject of approval by the Engineer. C. Vibration of the equipment is also related to the stiffness of the supporting structure; therefore the structures' natural frequency shall be at least 25% above or below the natural frequency (reed frequency) of the equipment unit. Operation of the equipment unit near or at its natural frequency must be avoided. D. Measurement and valuation of noise shall be in accordance with DIN 45635. E. Foundations, base plates and other supports for rotating / oscillating equipment must be designed to be capable for absorbing, without any shift and without any transfer to surroundings, the forces, torques, critical speed frequencies, resonance, etc. caused by this equipment. F. Transfer of vibration and noise from the rotating/oscillating equipment to the connected pipe work, cabling, etc. and vice versa shall be avoided by adequately designed measures. G. The pump design, for directly coupled pumps and for pumps with the impeller assembled directly at the motor shaft, shall be such that the natural vibration frequency of the pump/motor set is at least 25% higher or lower than the operation vibration frequency when finally installed in the field.

1.1.32 Noise Control A. As all plants are located within residential areas, special emphasis shall be paid to avoid nuisance to public by noise and odour released by the plant under full and partial operation as well as under shut-down conditions at all weather situations. B. The maximum noise emission of the plant shall not exceed a sound pressure level of 45 dB(A) during the day and 35 dB(A) during the night (from 22h to 6h) measured outside the plant at a distance of 15 m to the boundary wall or fence surrounding the installations provided the ambient sound-pressure level is at minimum 3 dB(A) lower than the above limit levels at complete plant shut down.

1.1.33 Odour Control A. Possible odour emission, caused besides indols, skatols, merkaptans mainly by H2S gas concentrations in air emitted by the plant, shall not exceed under all weather conditions the threshold concentration causing a bad smell at the nearest dwelling around the plant if the dwelling Contract 106, Volume II

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or at a distance of 100 m whichever is the closest distance. The threshold value causing faint odour is for H2S gases 0.01 ppm.

1.1.34 Lubrication A. The type of lubrication for all components of the Plant shall be in every way suited to the operating conditions encountered on Site. The Contractor shall provide, for the approval of the Engineer, a lubrication schedule. The Plant shall be designed as to keep the number and type of lubricants to the absolute minimum required. When preparing his schedule the Contractor shall provide cross-reference to ADNOC - equivalents. B The Contractor shall provide at his expenses the first fill of lubricants for all plant and equipment, any further lubricant required prior to take-over of the Plant and all lubricants required for a trouble free operation of 12 months after the issue date of the PAC certificate of the Plant. C. Prior to the first start of machinery, equipped with forced lubrication system, the lubricating systems shall be flushed for 72 hours with suitable flushing oil. Oil filters must be changed after this flushing period. Fresh oil of a recommended and approved quality shall replace the flushing oil after the above period. The Contractor shall provide all the material and labour required for these works. D. Provisions shall be made for the efficient lubrication of all bearings and of all mechanism and moving parts by means of separate oil caps, transparent oil storage container or self-sealing grease nipples. Grease nipples shall be, as far as practicable, of uniform type and size and the Contractor shall provide grease guns for each type of nipples used at the Plant. E. Automatic lubricators shall be provided with emergency hand lubrication facilities. F. All lubrication filling points shall be located in easily accessible locations. Where necessary and required extension tubes shall be provided. Lubrication to machinery in motion shall be arranged external to the guards.

1.1.35Operatio n and Maintenanc e Manuals A. One month before the issuance of the Provisional Acceptance Certificate (PAC) the Contractor shall submit to the Employer six copies of the approved Operation and Maintenance Manuals in Arabic and in English. O & M – Manualson CD – Rom in PDF format and shall be produced in "loose sheet" form, DIN A4 size in suitable loose leaf box files separately for each station and subdivided into the major components of the Plant, after the draft has been approved by the Engineer.

1.1.36 Draft Copies A. Draft copies shall be produced and submitted by the Contractor during the Contract Period early enough ( at least 3 months) to allow for possible alterations and re-submission in addition to a language translation check. Taking over of the Plant shall not take place until the approved copies are produced and submitted. Draft manuals shall be submitted in their entirety. Submission of sections in isolation will not be accepted.

1.1.37 Preparatio n of Manuals A. The operation and maintenance manuals shall be prepared in such a way as to provide a step by step description of the erection, commissioning, testing, operation (setting to work and shutting down), maintenance, dismantling and repair and shall include: a. Schedule of equipment supplied, giving manufacturer's name and address and appropriate make/model No./ Catalogue No b. Schedule of routine maintenance of all equipment supplied, specifying the hourly, daily, weekly, monthly, yearly inspection, testing, and other actions to be taken for proper maintenance including supply of 1000 printed carton record sheets for each individual plant component. c. Schedule of spares with manufacturer's reference number, cross referenced with the sectional arrangement drawings d. Sectional arrangement drawings of all major items of the Plant ( Pumps, valves, penstock, etc.) with dismantling/ assembling instructions e. Plant layout drawings in a suitable scale showing the installation as erected. Contract 106, Volume II

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f.

"As wired" diagrams of all electrical and control circuits and connections between control panels and installed loads together with internal wiring diagrams for all equipment. g. “ As wired” Diagram for instrumentation h. Comprehensive cable schedules showing all cable and core allocations including spares. i. Full and comprehensive operation, maintenance, and trouble-shooting instructions for all items of equipment and systems supplied j. Set points for over currents, earth leakage for electrical protection and set points for instrumentation complete (e.g. – level measurement / float switches / alarm) k. Field and factory test records/ certificates for motors, pumps, compressors, pressure vessels, lifting equipment, all mechanical/ electrical installations and other works where appropriate for both works and site tests. l. Actual pump performance curves as tested m. System performance curves n. Schedule of recommended lubricants and their equivalents o. Comprehensive technical data and detailed drawings for each item of equipment p. Fault finding chart with a step by step description of action. q. Detailed procedures for ordering spares. r. All drawings and operations and maintenance documents for mechanical , electrical and instruments should be submitted on CD-ROM in PDF format. s. Software for the installed program logic control t. Handing over shall be provided as per the requirements of the Employer and engineer based on the check list format which will be provided to the contractor during the project execution. B. The issue of the Provisional Acceptance Certificate (PAC) shall be subject to receipt and approval of the Operation and Maintenance Manuals by the Employer. C. The above is applied also for any operation and maintenance manuals submitted under this contract i.e irrigation network, irrigation control etc

1.1.38 Workmanship A. All workmanship shall be of the highest quality and the installation of equipment and materials shall be in strict conformity with the manufacturer's recommendations. The Contractor shall provide skilled, semiskilled and unskilled labour, including such experts as may be required by the manufacturers, for the erection, testing and commissioning of the whole of the Plant. Before start of erection the Contractor shall verify that all foundations, openings, anchor holes, recesses etc. required for the erection have been constructed.

1.1.39 Alignment A. All items of the Plant shall be levelled, set to plumb and aligned in such a manner as to comply with the manufacturer's requirements and tolerances. B. Skilled craftsmen shall install all equipment with parallel, vertical and horizontal alignment. C. The Contractor shall furnish stainless steel shims, w edges and blocks as required to level and align the equipment. If there are more than two layers of shims necessary during alignment they shall be replaced by solid stainless steel blocks after final alignment. The thickness of shims shall not exceed 0.5 mm. D. Non-shrink grout shall be of a brand approved by the Engineer and shall be provided and placed by the Contractor in all voids and bed plates as recommended by the manufacturer. Mixture and application shall be as per grout manufacturer's instruction. The Plant shall be installed and aligned as per manufacturer's instructions. Alignment shall be checked after (a) levelling, (b) after joining with other parts of the Plant and (c) after initial operation of each individual piece of Plant. Any misalignment detected at any stage must be corrected immediately and before proceeding with the next steps of installation.

1.1.40 Welding A. Together with the description of working methods for welding the Contractor shall submit full details of the professional qualifications and experience of the personnel employed. The Contractor shall Contract 106, Volume II

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engage on Site only such certified welders that have passed the tests specified by International and National Standards for welding. All works shall be executed under the supervision of an experienced welding engineer. The working methods shall include a detailed description of the system proposed for the storage of material, control and treatment of consumables, heat treatment, non-destructive testing, spectrographic material checks on weld and parent material, repair and general quality control. B. Before welding works commence the Contractor shall submit to the Engineer a list of all electrodes and consumables to be used in the Works. Electrodes and consumables shall be in conformity with the approved Standards and shall be suitable for their intended use. C. In case of weld cracking, and prior to any repair, the Engineer may require that a full investigation shall be made in order to locate the cause/source of such cracking.

1.1.41 Temporary Supports A. The Contractor shall be responsible for temporary supports, props and packing required to facilitate erection and alignment. He shall also ensure that all supporting parts of the civil work structure are able to support any temporary or permanent load brought onto them by the Plant. The Contractor shall ensure that the Plant is not dislocated during backfilling, casting of concrete or grouting.

1.1.42 Inspection A. After the equipment has been assembled, levelled and aligned, each installed item shall be inspected by the Engineer. Permission for concealing, grouting or other finishing will only be given if the Engineer is satisfied with the works performed.

1.1.43 Cleaning A. The interior of all Plant shall be thoroughly cleaned prior to installation. Whenever work is interrupted the open ends of installations shall be temporary closed by plugs to prevent contamination. Pipe systems shall be sectional cleaned and flushed with water after installation and before initial plant start-up in order to remove foreign material that may have entered the piping during installation. Flushing operation shall be continued until the water is clear. Provisions shall be made for disposal of water released from the test outlets to avoid property damages. Flushing through pumps and other equipment shall be avoided and shall be done respectively through a temporary installed wire mesh filter/strainer. The pipe system up to DN 80 shall be flushed with a minimal flow velocity of 3 m/s; pipe systems with a size > DN 80 shall be flushed with following flow rates: Diameter [DN] 100

Flow Rate [l/min] 1,500

Diameter [DN] 200

Flow Rate [l/min] 3,800

125

2,200

250

5,700

150

2,800

300

7,600

B. The pipe systems serving gases or air shall be cleaned and flushed with compressed gas or air. Pipe systems serving liquid chemicals / agents that are fast reacting with water shall be cleaned and flushed with compressed dry and oil free air or nitrogen gas. Temporary by-pass provisions shall avoid flushing of equipment, instruments, etc with compressed air/gas. The Contractor shall provide and allow in his rates for all temporary machinery, equipment, testing facilities, flushing media, pipe-work and all other materials necessary for the cleaning including disposal facilities.

1.1.44 Assembling A. Care must be taken during the erection to ensure that no loads of any description are transmitted through to the flanges of any part of the Plant. Flanges shall be carefully aligned to prevent distortion when bolting together. Bolts and nuts shall be tightened uniformly and torque controlled so that the gasket pressure is evenly distributed around the cir cumference. Contract 106, Volume II

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1.1.45Protection A. The Contractor shall be responsible for the adequate protection of the Plant until the time of receiving the Provisional Acceptance Certificate. In particular the Contractor shall cover the Plant by adequate sheeting to prevent soiling caused by civil or other works.

2

Part 2 Mechanical Equipment (Prod ucts ) 2.1.1 Scope

A. This section of the Specifications covers the design, manufacture, supply, erection, connection, testing and commissioning of all mechanical equipment, systems and auxiliaries required for the project and as before mentioned in other sections of this contract. C. All necessary supports, including hangers, saddles, sliding shoes, slings, bolts, anchors etc. shall be supplied to support the pipe work and associated equipment. Heavy Valves and other pipe accessories etc. shall be supported separately. D. All metallic supports and brackets etc. shall be manufactured from stainless steel grade 316L.

2.1.2 Design A. The Tender Drawings show a general arrangement of the Plant, providing space for a wide range of equipment. The Contractor, when reviewing the plant layout and the auxiliary systems, shall have due regard to ease of operation, maintenance, repair, replacement and access to the various components of the Plant. Special care shall be taken to enable easy removal / replacement of valves, motors etc. without using additional temporary supports. B. If any departures from these layouts are proposed by the Contractor then such alterations shall be shown separately on drawings to be submitted by the Contractor together with his Tender. C. When reviewing and re-designing the Plant, the Contractor shall prepare, and submit for the Engineer's approval, his own technical and process calculations for all systems of the Plant detailing: a. Friction losses of the entire pressure pipe systems to be installed b. Dimensioning of all supports for equipment and pipe work, including thrust blocks, fixed and sliding points c. Surge protection systems including equipment design showing the maximum / minimum pressure along the pipeline during pump start, pump stop, and emergency or power failure pump stop situation. d. Design of all auxiliary facilities and equipment e. A/C, Ventilation System Calculation f. Any other documentation as required by the Contract D. Drain, vent, and clean-out points shall be provided in sufficient numbers to the satisfaction of the Engineer. E. Any water hammering, even by plant shut down due to power failure, etc. must be avoided by means of anti-water hammering measures. F. All instruments, connected to equipment and pipe work must be equipped with a self cleaning three-way isolation/test valve, the valve drain point shall be connected to the next drain with a visible outlet. G. All instruments connected to equipment with rotating / oscillating parts or to other equipments and pipes which are subject of vibration must be isolated against vibration transfer by means of flexible connections or other suitable measures, subject of approval by the Engineer. H. Service platforms, ladders, etc. (permanently fixed and / or mobile) must be provided wherever necessary and as required by the Engineer for easy inspection, maintenance and repair of equipment, instruments and plants. I. Any pipe, cable, equipment and installation of the plant shall not be used to support other pipes, cables, etc. of the plant.


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2.1.3 Pumps 2.1.4 Design A. Pumps shall be designed and shall be suitable for continuous and intermittently operation, materials shall be selected for compatibility with fluids handled, to avoid cavitation, erosion and corrosion, and as described in detail below. B. Pump design heads shall be determined from the sum of static head, dynamic head and all friction heads. C. The Net Positive Suction Head (NPSH) shall not exceed 80% of manufacturer's recommendations at run-out operating conditions. D. Pump design flow rates shall be determined from the range of process requirements with an additional allowance of 10% at maximum design flow. E. Pump Motors shall be designed for 10% excess power required under all operating conditions including the 10% allowance as mentioned above. F. Pump Motors shall be designed as detailed at clause 4.7, Section 4, Electrical Equipment. G. These shall include operation against closed valve / operation at run out conditions / start up conditions H. The pump performance characteristic shall be stable at all flow rates between closed valve and open valve and shall be steep enough to permit satisfactory operation in parallel with other pumps where required. I. The pumps shall be selected with low rotational speeds which shall not exceed 1500 RPM for sewage pumps and 3000 RPM for other centrifugal pumps. J. Pumps shall be fitted, where applicable, with casing drain, vent tappings (including valves and drain/vent pipes), with suction and discharge pressure gauges, suction and discharge isolation valves and discharge non-return valve. K. Non-sewage pumps shall be fitted with a strainer at the suction side designed for easy cleaning and equipped with an additional pressure gauge at the inlet side for measuring the pressure drop across the strainer. L. Non-self-priming pumps shall be installed with flooded suctions side or, if not possible, with automatic priming devices/units and shall be protected against dry running by means of a control / switch instrument. M. The Contractor shall provide with his tender full technical details of all pumps including head, capacity, power consumed, efficiency to ISO Standard, starting torque curves, NPSH curves, performance curves, pipe characteristic curves, and the kind of materials for all parts. N. Rotating / oscillating assemblies of pumps shall be statically and dynamically balanced and shall be designed so that the first critical speed of the pump and its drive is at least 50% greater than the maximum operating speed. O. Flushing facilities shall be provided for mechanical seals or packed glands where the pump fluid may be contaminated with abrasive and/or corrosive material. In case the flushing facility fails the pump shall trip. P. Where soft packed glands are used, means shall be provided for collection of the gland leakage water which shall be piped into the nearest drainage system. Lubrication arrangements shall be so designed that there is no contamination of the pumped fluid and vice versa. Pipe connections (suction and or discharge) shall be so designed that there is no transfer of vibration from the pump to the pipe work and vice versa. Suitable lifting eyes shall be provided at all pump sets with a total weight exceeding 10 kg. In closed location to each pump, an individual and separate rigid stand mounted emergency electrical control switch shall be provided and installed. Mounting of this switches direct at the equipment and/or direct at any other part of the plant is not acceptable.

2.1.5 Eye Velocity A. The velocity at impeller eye section shall not exceed 3.0 m/s for sewage pumps and <= 3.5 m f or potable water pumps. B. In case the individual pump performance characteristic parameters require a higher velocity to achieve efficient and trouble-free operation conditions, the Contractor may be allowed to do so, but he shall prove to the satisfaction of the Engineer that there is no cavitations and no higher abrasion effecting the pump life time, taking in account that there are solid particles in the waste water to be Contract 106, Volume II

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pumped. The pump impeller eye velocity shall be specified in the technical schedules provided together with the Tender.

2.1.6 Water Pumps A. The material of all water pumps shall be suitable and corrosion resistant, designed to cope with the highly aggressive wastewater mixed with solids and shall be of the quality listed below or better:

Part

Material Submersible, Dry Installed

Submersed installed

Pump Casing

SS 1.4517, DIN 17443, duplex

SS 1.4517, DIN 17443, duplex

Impeller Shaft Motor Casing

SS 1.4517, DIN 17443, duplex SS 1.4462, DIN 17443, duplex Cast iron As per pipe material, suction elbow with inspection opening G-X 150 CrNiMo405, special hardened

SS 1.4517, DIN 17443, duplex SS 1.4462, DIN 17443, duplex SS 1.4517, DIN 17443, duplex

Duck Foot Bend Cuter Impeller if any

SS 1.4517, DIN 17443, duplex G-X 150 CrNiMo405,special hardened

B. Accessories, like anchor rails, anchor bolts, hoisting chain, guide rails, bolts, nuts, washers and fasteners shall be made of stainless steel 1.4571, DIN 17440 to 17441 and 17455 to 17458 or 316L AISI/SAE or F66 ISO 2604 T.1 or 320 S31 BS or other Standards with similar or higher quality.

2.1.7 Dry Installation A. Pumps and motors shall be the submersible type, but permanently dry installed, with non-clogging impellers, adequate motor cooling shall be as specified in Electrical Equipment specifications B. In case of freshwater jacket cooling the Contractor shall provide the necessary equipment for the cooling circuit, like heat-exchanger, pipe work, water tank, circulation pump, etc.. Oil jacket cooling shall be avoided otherwise the Contractor shall verify that this method of cooling is sufficient enough under the existing ambient conditions, that the oil used is free from any toxic chemical and/or material and that the oil is not flammable by any type of ignition. C. A cleaning opening, suitably dimensioned shall be provided at the suction bend. A drain cock shall be installed and a DN 50 discharge pipe, for draining the pump and connecting pipes to the pump room's sump, shall be provided. The pumps shall be equipped with renewable wearing parts. D. The motor terminal box shall be factory wired and the cables (power and control) shall be provided in continuous length up to the junction box at suitable location approved by Engineer, joints in between by any means are not accepted.

2.1.8 Submersed Installation A. Submersible pumps shall be suitable for operation when either partially or wholly submerged. Material of pump and motor and accessories shall be as described above without any exemption, the general design shall be as specified above. B. Method of motor cooling shall be as per clauses Electrical Equipment. C. The pumps shall be equipped with a hoisting chain, guide rail and guide shoes. The guides shall be firmly fixed top and bottom, the chain shall be permanently fixed to the pump and the free end shall be hooked onto the frame of the cover. The design of the pump assembly shall be such to enable hoisting out of the chamber without the necessity to enter the well for disconnecting the pump. When being lowered into the well the pump shall automatically connect to the discharge pipe. The motor terminal box shall be factory wired and cables ( power and control) shall be provided in continuous length up to junction box provided out side wet wall, joints in between by any means are not acceptable.


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2.1.9 Horizont al End Suctio n Pumps A. Pumps for potable water shall be designed as centrifugal pumps, whereby, depending on required flow and discharge pressure, single or multi stage, direct or via coupling driven, end-suction or inline type pumps shall be used. B. Pump and motor units shall be continuosuly rated and designed for an operating life of 20 years without major overhaul. Components likely to become worn in the couse of normal operation, shall be capable of replacement, making use of readily exchangeable components. C. The pump and its driving motor shall be separate machines either close coupled, using flexible coupling to form an integarl unit mounted on a suitable common baseplate and bolted together. D. Shafts shall be of stainless steel, DIN 1.7440, 1.4462 adequately sized and fitted with renewable sleeves where they pass through the sealing arrangement. The lower section of any shaft drives shall be designed to be readily removable to facilitate maintenance. E. Bearing shall be oil or grease lubricated. Oil lubricated bearing shall be fitted with a constant level oiler. F. “V” ring seals shall be provided on the bearing housing. G. Bearing housing shall be a separte component and not integral with the casing to allow replacement of the bearings, seals and slaves without removing the top half casing when fitted with a spacer coupling. H. The impeller and side liners shall be manufactured from duplex stainless steel I. Shaft seals shall be of the mechanical seal type. Coupling shall be of the flexible spacer type. Pumps shall be factory assembled with the motor, but coupled pump / motor sets shall be mounted on a common base plate and shall be realigned in the field after installation. All components shall be designed for PN 10. Material shall conform to the following: Description Pump Casing Pump Shaft Impeller Shaft Sleeve Shaft Protection Sleeve Casing Wear Ring Bearing Brackets Base Plate Bolts, nuts, washer "0" Rings

Material Grey Cast Iron, GG 25, 0.6025 Stainless steel DIN 1.7440 Duplex Stainless Steel SS 1.4404 SS 1.4404 Grey Cast Iron, GG 25, 0.6025 GG 25 or mild steel St 35 SS, grade A4 EPDM

2.1.10Dosing Pumps A. Chemical dosing/metering pumps shall be the variable stroke mechanism for manual and automatic stroke adjustment between minimum and maximum flow whilst the pump is in operation. B. The pump shall be equipped with a step-less variable stroke mechanism for manual and automatic stroke adjustment between minimum and maximum flow whilst the pump is in operation. C. Plunger or diaphragm pump heads shall be used depending on the kind of fluid to be pumped and the pressure required. D. Variable speed shall be achieved by a variable speed drive motor operated via a frequency control unit which response to a 4- 20 mA electrical signal. E. Variation in suction pressure due to changes of static liquid height shall be avoided by use of short suction line and shallow solution/mixing containers with a large surface area.

2.1.11 Materi al A. Depending on chemical fluid properties, plunger or diaphragm pump heads shall be selected. Similarly the material proposed shall be highest possible class of resistance against chemical attacks. The Contractor shall submit with his tender a list of chemical resistance for the chosen type and kind of material.


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2.1.12 Plung er Pump Heads (Not Used) Product contact parts:

SS 1.4401; X 5 CrNiKo 17 122

or Polypropylene.

Plungers:

SS 1.4401; X 5 CrNiMo 17 122 or Glass or High alumina ceramic

Valves:

SS 1.4401; X 5 CrNiMo 17 122 or Nitrite rubber or PTFE

2.1.13 Diaphragm Pump Heads Product contact parts: Diaphragm: Valves:

SS 1.4401; X 5 CrNiKo 17 122 or Polypropylene Butyl or Hypalon or P TFE SS 1.4401; X 5 CrNiMo 17 122 or Nitrite rubber or P TFE

2.1.14 Drainage Pumps A. Drain pumps, installed in drain sumps, shall be the submersible vertically installed type, having a capacity of 41/s at a head sufficient enough to enable discharge above the emergency level of the plant. The pump shall be equipped with all necessary pipe work, valves, check-valves, vent-valves, controls, etc. for fully automatic and safe function including failure alarms.

2.1.15 Surge Protecti on A. The Contractor shall be responsible for designing, manufacturing, installing and testing a safe and proper functioning surge protection system for the plant proposed. The surge protection system shall include non-pressurized vessels, ventilation system, valves, drainage system, valves, fittings and appurtenances. B. The ventilation shall be connected to the drainage system of the vessel. The vessel shall be connected to pipelines constructed by others as shown in the drawings. C. Pipe line profile, attached to the contract documents, shall be considered as a guideline only. The contractor, when redesigning the plant, shall prepare his own surge analysis suitable for the system proposed. Such calculations shall be subject to the approval of the department and the engineer. D. Vessels shall be designed, manufactured and tested according to the relevant “pressure vessel, welding and safety codes and standards “welding tests and pressure tests shall be verified by an internationally organized quality assurance office. E. The surge control system supplier shall perform the necessary analysis of the pressure transient conditions within the piping system being protected. F. Computer based comprehensive hydraulic transient analysis calculations showing the performance of the surge control system installed in the piping system under various normal operating modes and sudden shut down of pumps shall be included in a report discussing the analysis of fully explaining the data used and results obtained. The form analysis and the report shall be such that it can be reviewed by the engineer. The cost analysis shall be deemed to have been included in the cost of the surge protection equipment.

2.1.16 Surge Vessel A. Vessels shall be designed in accordance with BS 5500, or equivalent European and American Standards. B. It shall withstand full vacuum pressure and be tested in accordance with the design code to the same pressures as the pipeline. C. The design temperature shall be 50 ºC. D. Vessels of capacity of 100 litres and greater shall have removable inspection cover. E. Vessels of size requiring a man access for internal inspection shall have a removable 500mm raised manhole with door and joint. F. Vessel shall incorporate a drain facility G. A pressure gauge shall be provided with separate isolating cock. The gauge shall be of a compound type, capable of measuring both positive and negative pressure, H. The vessel shall be protected as specified in Volume III Section’5’, Corrosion Protection. I. Pressure vessel shall be equipped with a safety relief valve. J. The material must be suitable for the media stored. Contract 106, Volume II

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2.1.17Bolt s, Nuts, Studs, Washers A. All bolts, nuts, etc. shall be of approved Standard and corrosion resistant material. Together with the shop drawings the Contractor shall submit a list of the manufacturers' recommended torque value for each kind of fixing. Washers, bolts and nuts shall be of the same material when used together. Adequate measures, i.e. insulation or catholic protection, shall be taken at locations where galvanic corrosion can be expected. Unless otherwise specified or approved, all bolts or studs shall be suitable machined on the shank and under the bolt head. Washers shall be provided under nuts and, if required, under bolts. Projection of bolt - or stud threads shall be >= 0.5 <= 1.0 diameter of bolt/stud. Bolts and studs used for electrical connections shall be >= 6mm if manufactured from brass and >= 4 mm if made from stainless steel or phosphor bronze. Lock washers shall not be used above 24 mm size except when a spring type is especially approved. Bolts, nuts and studs shall be tightened by means of torque controlled tools. In general the below listed materials shall be used for bolts, nuts and washers except otherwise specified. a. For pipe flanges: Stainless steel grade -A4, DIN 267 b. For structural steel: Galvanised steel, Sheradized c. For maintenance covers: Stainless steel A4, DIN 267, 1.4571, DIN 17440 d. For underground flanges: Stainless steel A4, DIN 267, 1.4571, DIN 17440, with Suitable tape wrapping e. For submersed installations: Stainless steel A4, DIN 267, 1.4571, DIN 17440-A4, DIN 267

2.1.18Anc hors A. Prior to manufacture the Contractor shall submit to the Engineer, for the Engineer's review and approval, the detailed design of the anchor system proposed for the various component of the Plant. The design shall consider: a. Loads applied (tensile, shear, bending moments etc.) b. Composition and strength of material where anchors are to be embedded c. Available anchor depth B. For fixing of steel structures, brackets, ladders, railing and the like only the following type and material is accepted: a. Expansion anchors in dry non-corrosive environment: Material A1, DIN 267(11) Grade 303, AISI/SAE b. Expansion anchors in partly damp environment: Material A2, DIN 267(11) Grade 304, AISI/SAE c. Adhesive anchors installed in wet areas, underwater, outdoor, highly corrosive environment: Stainless steel 316 L DIN, 17440, Destination 1.4462.

2.1.19Pipe Works 2.1.20General A.

B.

C.

This section includes pipeline systems for the entire plant including all works, supply of material, specials, testing etc. required for connecting pipe systems to pipelines executed by others, all as specified, shown on drawings and/or as instructed by the Engineer. The pipe line system shall be designed for a nominal pressure rating PN as listed below, whereby the actual operating pressure by closed valve operation or surge pressure, whichever is greater, shall be minimum 1.5 times the nominal pressure PN in order to allow for sufficient up grading of the flow in case of future expansion of the plant capacity. The pipe line shall be classified for safe operation up to the designed PN pressure rating and shall be marked with SOP….. bar (SOP = Safety Operation Pressure)


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Ac tual Operat ing Pressure as per hydraulic analysis U to 1.07 bar > 1.07 up to 1.67 bar > 1.67 up to 2.67 bar > 2.67 u to 4.00 bar > 4.00 up to 6.67 bar > 6.67 up to 8.33 bar > 8.33 u to 10.67 bar > 10.67 up to 13.33 bar


Nominal Pressure Rating to DIN 2401

Field Test Pressur e to DIN 4279

PN1.6 SOP PN2.5 SOP PN4.0 SOP PN6.0 SOP PN10.0 SOP PN12.5 SOP PN16.0 SOP PN 20.0 SOP

2.4 3.2 6.0 9.0 15.0 18.8 24.0 30.0

D. The Contractor, when preparing the plant layout, shall consider the necessity for providing flexibility in the pipe work at joints in order to allow for different settlement or thermal stresses. Flexible joints are to be foreseen in order to allow for minor discrepancies in the civil works. Unless otherwise specified joints shall be flanged. E. The material of pipe works for various services shall be in general as listed below, whereby deviations may be accepted for factory built-in machinery pipes and tubes. F. In general preference is given to the use of non-metallic pipe works and, therefore, the use of metallic pipes and fittings shall be minimised as much as possible. a. b. c.

d.

e. f.

Ductile Iron Pipes: for sewage / water pressurized discharge, pump suction lines and fittings inside chambers Stainless Steel Pipes: for drain, sewage vent lines, Instrument piping, Sump pump discharge, Oxygen Lines PVC-u Pipes: for potable cold water, chemical dosing (except chlorine), A/C drain lines, internal drainage, vent pipes, sewage water lines. Pipes exposed to direct / indirect sunlight shall receive a coating of two pack polyurethane high gloss paint to protect PVC-u against UVrays. HDPE- Pipes: for potable cold water, sewage pressurized discharge chemical dosing, vent pipes, sewage water. Pipes exposed to direct / indirect sunlight shall receive a coating of two pack polyurethane high gloss paint to protect HDPE against UV-rays. GRP Pipes: for ventilation systems, odour control system, instruments for wet well, sewerage water lines (pressure less and pressurised), aeration air lines, drains, Black Steel Pipes: for fuel lines, compressed air, steel structure,

G. Any other pipe material suitable and qualified for the systems, but not listed above, may be acceptable subject to the approval of the Engineer. H. Design pressure rating (PN) of pipe system shall be the next standard pressure rating above the highest possible working pressure, but not less than PN 6 for pressurised metallic pipes and not O less than PN 10 at 25 C for pressurised plastic pipes. I. Support spacing for horizontally and vertically installed pipes and the location of fixed and sliding points shall be in accordance with manufacturer's written recommendation under consideration of flow media density, pressure, ambient conditions and flow media, flow velocity and start / stop conditions of pumping system, taking also into account seismic wave vibrations in horizontal and vertical directions.

2.1.21Ductile Iron Pipes (DI) A.

Ductile iron pipes, fittings and appurtenances shall be used for sewage / water pressure pipelines ewand for installations inside sewage / water pumping stations. B. Ductile iron pipes and fittings shall be made from pig-iron melted in the blast furnaces inoculated with magnesium to transform the flake graphite to a spheroid form thus providing enhanced properties of strength and toughness. Centrifugally cast pipes shall be heat-treated to provide the required tensile strength. Products shall be protected with shop primer for surface protection during fabrication externally and shall be lined internally with Polyurethane ≥ 700 μm or two pack vinyl ester glass filled epoxy coating 1000 microns DFT. Full external surface coating including grit blasting shall be applied by an approved work shop in Abu Dhabi. The inside of the sockets and Contract 106, Volume II

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the faces of flanges shall be free from coating. External coating shall be epoxy as specified under Section – 5 Corrosion Protection. Flanged joints located in soil shall receive an additional protection by wrapping the entire joint. C. The dimensions and technical requirements shall be in accordance with DIN EN 545/ DIN EN 598 / ISO2531. Pressure pipes shall be manufactured in lengths up to 8 m and shall be of PN 16. At the manufacturers' place explosive bursting tests shall be made to prove that joints are as safe as pipe barrels and to demonstrate the assembly's ability to stand dynamic loads. Internal pressure tests shall give a factor of 2.3 as normal safety factor. Test bars shall be tensile tested in a testing machine and should comply with the mechanical properties specified. Pipes shall be carefully handled during transport, off loading and stacking to avoid damage of protective coating and lining. For loading and off-loading pipes with lining, only slings shall be used. When using crane hooks at socket and spigot ends, the hooks should be broad and protected by rubber to avoid damage to the lining. When lifting pipe bundles, the crane hook shall not be secured to bundling steel straps or to ends of pipes. Damage to linings or to the outside protection must be repaired before pipe installation. When pipes are stacked in single or multiple layers on wooden spacers, the end pipes must be secured by using wooden wedges to prevent the pipes from rolling off the supports. Stainless Steel Pipes A. Manufacturer must comply with ISO 9001/2. The material of stainless steel pipe work, including accessories, shall be to SAE / AISI Standard material 316L or to DIN 17440 to 17441 and 17455 to 17458 Standard Material 1.4571. Joints shall be threaded for pipes DN <= 32 mm and flanged for pipes >DN 32 mm, or press type joints. B. Pipe systems shall as far as practicable, pre-fabricated in a suitable workshop equipped and designed for stainless steel handling. If field welding is not avoidable, the WIG welding method (Inert-Gas Tungsten-Arc welding) shall apply and afterwards pickling and passivation shall be done. All tools and material used shall be suitable for handling stainless steel material. C. No black steel work is permitted close to the stainless steel working and installation place without adequate protection of the stainless steel material. D. All material deliveries shall be accompanied by the individual mill batch analysis certificate. E. Bolts, nuts, washers, pipe clamps and other accessories shall be of stainless steel as mentioned above. F. Pipe threads shall be made with a special designed thread die suitable for stainless steel threads. Before assembling the stainless steel threads shall be lubricated with a special lubricant to avoid "thread eating" during fastening. G. Sealant for Pipe threads shall be natural hemp only together with acid resistant sealant/lubrication paste. Teflon tape or any other sealant is not permitted. H. Acid and oil resistant rubber shall be used for flanged joints. Steel Pipes A. Dimensions of Steel pipes shall confirm to: a. DIN 2440 Medium Weight steel Pipe suitable for Screwing b. DIN 2448 Heavy Weight Steel Pipe suitable for Screwing c. DIN 2448 Seamless Steel Pips and Tubes d. DIN 2458 Welded Steel Pipes and Tubes B. The pipe surface treatment shall be suitable for hot dip galvanizing in accordance to DIN 2444 where required. C. The pipe material shall be mild steel, pressure rating shall be PN 10 in accordance to DIN 2401: a. St33-2, DIN 17100, Material no.; 1.0035 for pipes to DIN 2440 b. St33-2, DIN 17-100, Material no.: 1.0035 for pipes to DIN 2441 c. St 35. DIN 17007,Material no.: 1.0308 for pipes to DIN 2448 d. St 37-2, DIN 17120. Material no.: 1.0036 for pipes to DIN 2453 D. Applicable standards for mild steel pipes shall be for: a. Potable water line, galvanized, DIN 2440 up to DN 25, DIN 2441>DN25 b. Aeration Air, galvanized, outside the process tanks, DIN 2441 c. Pipe Sleeves, DIN 2440 d. Steel Structure, galvanized, DIN 2441 e. Fuel line, DIN 2448 E. Joints: Contract 106, Volume II

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a. Threaded joints up to DN 32 b. Flanged joints>DN32 c. Flange design shall be in accordance with DIN 2632 F. Pipe Fittings: a. Threaded fittings shall be in accordance with DIN 2900 b. Welded fittings shall be accordance with DIN 2606 ; DIN 2615; DIN 2616 to DIN 2619 G. Gaskets shall be selected considering: a. Nature of flow media b. Flow media quality c. Inside / outside temperature d. Internal pressure H. Mild Steel Pipe Work conforming to other internationally recognized standards can be used, provided the quality of material is similar or better.

2.1.22Valves and other Pipe A ccessories 2.1.23General A. All valves and accessories under this contract shall be designed, manufactured and tested in accordance with the appropriate standards and codes subject to the following. B. The Contractor shall prepare and submit for approval a complete valve schedule, showing for each individual valve the identification number, service, type & manufacturer, size, pipe identification number, location, mode of operation (normally closed [NC] or open [NO], drain, etc.). C. Valves shall be designed for a nominal pressure of 16 bar unless otherwise specified. D. Manually operated valves with a size ≥ DN 350 shall be provided with a gearbox for easier operation unless otherwise specified. E. For motorized valve actuators the closing/opening time shall not exceed 0.25 sec/mm hub, indication with flickering lamp during closing / open operation shall be provided at MCC. F. Valves (except pen stock valves), with a size > DN 150 shall be equipped with a drain/vent valve DN 25 at the upstream port unless otherwise specified. G. Valve spindle shall be of the non-rising type unless otherwise specified. H. Open/close direction shall be indicated at the operation wheels. Plastic hand wheels will not be accepted. All manual operated valves shall be fitted with locking facilities. I. Valves shall be of the self cleaning type. J. For directional valves the flow direction shall be clearly indicated with an arrow on the valve body. K. Each valve shall be fitted with a name plate (see also section "Signs and Labels"). The name plate shall incorporate the colour code corresponding to the service of the piping, and to the valve schedule reference number. L. The material of valves with accessories and corrosion protection shall be as described below for gate valves unless otherwise specified. M. Where valves are exposed to outdoor conditions adequate protection covers against dust, sand, etc. for the rotating parts shall be provided. N. Valves shall be arranged for convenient operation from appropriate floor level and shall be provided with extension spindles or gearing if necessary. Where extension spindles are fitted, all the thrust when operating the valve shall be taken direct on the valve body and all pedestals necessary shall be mounted directly on the floor. Full manual or semi manual operated valves installed at a height of more than 2 meter above floor or service level shall be fitted with a chain operated wheel.

2.1.24Penstocks Valves, Slu ice Valves A. Penstock, sluice valves shall be designed to ensure tight closure and shall suitable for wall mounting or channel mounting as shown on the tender drawing. Stem, stem nut and stem adapter including stem brackets shall be oversized and shall be designed for heavy duty load and shall not break b^ any means in case the gate is blocked.


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B. The penstock, sluice valve shall be designed to be suitable in function and material for sewage water as well as high salty water with a conductivity of 10000 μS/cm. Material of components shall comply with the following: Description

of

Frame & guides Gate Seating face Invert Seal Trust / operating Stem Stem Guides Stem couplings Stem Adaptor Fasteners Pedestal Hand wheel Bevel Gear Box Frame / thimble Bolts, nuts &

Material Stainless steel ASTM A-276, type 316L Bronze, BS 2874 CZ 114 EPDM Rubber Gunmetal, BS 1400 LG2 Stainless Steel, BS 970, grade 316 L Stainless Steel, grade A4 Grey Cast iron, GG 25 EPDM rubber Stainless Steel, grade A4

Note: a.

Pedestal including mechanical and electrical position indicator, position penstock gate shall be indicated at the MCC for "open" and "closed" b. Bevelled gear box, Non rising stem C. Corrosion Protection shall be as specified under Section "Corrosion Protection". D. Allowable Leakage for On-seat duty <= 1.25 l/min/m seal and for Off-seat duty <= 6 l/min/m seal at 6 m head.

2.1.25Gate Valves For Irrigation A. Gate valves for treated water and similar water shall be of the flanged type to DIN 3352, complete with hand wheel, gearbox for valves > DN 350, bolts, nuts, washer, gaskets, stem seals and wedge seals. Description Valve Body Bonnet Yoke Bonnet Stem Thrust Bearin Wedge for valves > DN 350 Wedge with EPDM rubber for valves <= DN 350 Bod / Wed e Seat for valves > DN 350 Wedge / Stem Nut Gland Cover Gland Packin Hand Wheel Bolts, nuts, washer Bonnet Gasket Spur Gear Box Housing Corrosion protection Pressure ratin

Material Ductile Cast Iron GGG 50 Stainless Steel, 1.4021, X20Cr13 Stainless Steel r. 316 L PTFE Cast Iron GG 25 Ductile Iron, GGG 50, fully encapsulated Stainless Steel 1.4301 X5CrNi 189 Ductile Cast Iron, GGG 50 Cast Iron GG 25 Aramide PTFE im re nated or similar Cast iron GG 25 Stainless Steel, gr. A4 EPDM rubber Cast Iron GG 25 See Section “Corrosion Protection” PN 16

For Sweet Water A. Pressure rating for all valves shall be >= PN 10. Valves <= DN 50  Material for valve body, bonnet, stem and wedge shall be in Bronze, 2.1096.01, DIN 1705 Material for handwheel shall be GG 25  Connection shall be threaded  Contract 106, Volume II

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Valves > DN 50 Material shall be as listed in above table for irrigation valves.  Connections shall be flanged  INSTRUMENT VALVES A. Instrument valves shall be the three - way self cleaning ball valves for vent-drain / isolation / open position, DN 20, PN 10, with female pipe thread. Material shall be stainless steel, X6 CrNiMo 17 12 2, material # 1.4571 to DIN 17440 to 17441 and 17455 to 17458, or equal and approved.

2.1.26Non-Return Valves For Irrigation A. Non-return valves for treated effluent and similar shall be of the flanged non-slam recoil type with a closing time not exceeding 0.5 sec. They shall be of the single door type with hand lever. Screwed plugged bosses shall be provided for the installation of drain valves and vent valves. Valve design shall be suitable for horizontal and vertical installation. Description Valve Body Flap Cover Lever Weight Gland Flap Seat, Flap Shaft, Body Seat Flap Lever Cover Gasket Gland Packing Pressure rating Corrosion protection

Material Ductile Cast Iron GGG 50 Cast Iron, GG 25

Stainless Steel, 1.4021, X20Cr13 Mild Steel, St 37-2, DIN 17100 EPDM Rubber Graphite PN 16 See Section “Corrosion Protection”

For Sweet Water A. Non-return valve for clear sweet water shall be of the design as described above in item 3.6.5.1 for valves > DN 50, suitable for horizontal and vertical installation. B. The non-return valve with a size ≤D N 50 shall consist of following parts: a. b. c. d. e. f.

Valve Body Spring loaded lift check Cover EPDM Gasket Material shall be for all parts stainless steel, 1.4401 Pressure rating shall be min. PN 10

Aeration Air A. Non-return valves shall be of the wafer type valve inserted between two flanges suitable for horizontal and vertical installation. Pressure rating shall be min. PN 6. B. The valve shall be designed suitable for a media temperature of 100°C. Material shall be for all parts stainless steel, 1.4401

2.1.27AIR RELEASE VALVES A. Air release valves shall be the "one floating ball" type for sewerage installations. The body shall be manufactured from cast iron GGG-50. The floating ball, seat rings, nozzles and connecting bolts shall be made of stainless steel grade 1.4571 or ABS plastic. Plastics used for seals, ball guides etc. shall be resistant to treated effluent water under the temperatures specified. To prevent sedimentation of solids the bottom part of the valve's body, connected to the gate valve, shall be funnel shaped. Valves shall be designed to prevent clogging of the floating mechanism and to allow the escape, and admission of air respectively to the pipe system. Air release valve Contract 106, Volume II

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shall be combined with gate valves to allow dismantling of air valve whilst the system is in operation. Material and coating shall be as for gate valves.

2.1.28Pressure Relief Valves A.

Pressure relief / safety valves shall be installed wherever damages due to excess pressure by malfunction or wrong operation can be expected. They shall be of full lift type, spring loaded, angle pattern, factory adjusted pressure blow out set point secured and sealed, and discharge pipe shall be provided where necessary in order to avoid any accident due to unexpected blow out. The discharge pipe shall be as short as possible and with a size double to the valve outlet. B. The pressure relief valve shall be spring loaded angle pattern type and shall be suitably rated for all working pressure and test delivery pressure. C. The valve shall be located on the main discharge header and shall modulate to relief access set point pressure back to the sump; it shall maintain constant pressure in the system regardless of demand changes. D. The valve material shall be as follows: a. Valve body Ductile cast iron GGG50 b. Seat Stainless steel 316 (1.4571) c. Disc Stainless steel 316 (1.4122) d. Stem Stainless steel 316 (1.4021) e. Bonnet Stainless steel GGG 40 (0.7040)

2.1.29Pressu re Reducing / Sus tainin g Valves A.

The pressure reducing valve shall spring loaded type and shall be suitably rated for all working and test delivery pressures. B. The pressure drop through the valve shall not exceed 0.15 bar under full flow. C. The spring loading should be adjustable from 0.00 to operating required pressure D. The valve material shall be as follows: b. Valve body Ductile cast iron GGG50 c. Seat Stainless steel 316 (1.4571) d. Disc Stainless steel 316 (1.4122) e. Stem Stainless steel 316 (1.4021) f. Bonnet Stainless steel GGG 40 (0.7040)

2.1.30Electr ic Remote Contro l Solenoid Valve Com plete w ith or without Pressure Regulating Module. A. B. C.

D.

E.

F.

The Contractor is advised to refer to relevant sections of the electro-mechanical specifications The Contractor is advised to refer to relevant sections of the electro-mechanical specifications The valve body and bonnet shall be constructed of heavy duty glass reinforced nylon body and internal parts shall be stainless steel diaphragm made of nylon reinforced nitrile rubber and provide for a positive seal between bonnet and body. Solenoid coils shall be encapsulated in moulded epoxy. Valves shall be normally closed diaphragm type with slow opening and closing action for protection against surge pressure. Actuation shall be by encapsulated type solenoids rated at 24 volts, 50 cycles, and 2.0 watts unless otherwise specified. Maximum pressure rating shall be not less than 200-PSI BSP inlet/outlet, solenoid plunger shall be incorporated with selfflushing type stainless or internal filter. There shall be provision for manual open/close and flow control stem with cross handle for regulating the flow. For valves specified with a pressure regulator, the latter shall regulate the pressure between 0.35 to 7 bar (within an accuracy of ± 0.35 bar regardless of upstream pressure). It shall provide full and accurate pressure capabilities irrespective of whether it is operated electrically or manually. The pressure measurement shall be possible via Schrader valve or integral pressure gauge. The pressure regulator shall be with a calibrated dial for setting the outlet pressure. The valve shall be capable for pressure regulating electrical and manual mode operation using external and internal bleeds. Valve shall be suited for dirty or treated sewage effluent water.


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G.

H.


The valves shall be inline or angle configuration as per the requirements. The valve construction shall be such as to provide for all internal parts to be removable from the top of the valve without disturbing the valve installation. Only moulded PVC-u/Brass fittings or materials approved by the Engineer shall be used with solenoid valve assemblies. 1.

Electrical wire for Solenoid Valves.

E.

All electrical wire for underground use shall be single core solid “underground feeder” type insulated with a flame retardant thermoplastic compound, rated for 600 volts and direct burial. The cables shall be suitable for installation in the ground flooded with Treated Sewage Effluent (TSE) water having corrosive chemicals.

F.

The insulation material shall be of low density and high molecular weight. Insulation shall be suitable for maximum conductor temperature of 60 degree Celsius. Minimum insulation thickness shall not be less than 1.2 mm.

G.

The cables manufacturer’s name or code, insulation type, gauge of wire and voltage should be marked at intervals of not more than 1m.

H.

The Contractor shall indicate valve number on each cable at both ends as well as at splices and pulling boxes. All the electrical wires should pass through PVC conduit pipes of size as follows: 1 to 6 cables 74 to 18 cables 19 to 30 cables 31 to 50 cables

F.

- 32mm - 50 mm - 63 mm - 90 mm

Wire connectors at the solenoid valve shall accomplish with moulded waterproof PVC plastic connectors. Joints shall be made up using copper crimps and a rapid hardening. Waterproof sealant, shall be used as recommended by the solenoid valve manufacturer. Irrigation control cables shall be colour coded as follows: Common wire Drip valve wire Bubbler valve wire Spray valve wire Sprinkler valve wire Spare wire 2.

- Black - Green - Blue - Red - Orange - White

Wire Connectors

C.

All wire connections at electric remote valves and all splices of wire in the field shall be made using wire connectors. The wire connectors shall be specifically designated to ensure waterproof underground wire connections. The connectors shall be under-writers laboratories listed water resistant wire connectors; rated 600 volts for PVC-u insulated copper wire with insulation temperature rating of 105°C.

D.

The connectors shall consist of precision moulded PVC base socket, moulded sealing plug, wire crimping sleeve and shall be easily installed in the field to give a permanent waterproof joint by using for joint make-up.

2.1.31Ball Float Valves A.

The float valve shall be flanged type and should be fixed at tank inlet with extended lever.


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B. C. D.


The valve shall be able to close and open when the reservoir level reaches to an adjustable set point between 300 mm to 0 mm below the inlet invert level. The valve material shall be stainless steel 316 L. The ball valve shall be provided with position indicator open / close and shall be connected to RTU and SCADA system

2.1.32 Diaphragm Valves A.

Diaphragm valves shall be used for the transport of liquid chemicals only. Design and material is depending on the kind of chemical to be transported and shall be, therefore, determined individually.

2.1.33 Globe Valves A. B.

Globe valves shall be used where flow regulation and control with suitable throttling characteristic is required. Design and material shall be equal to the gate valves described before

2.1.34 Butterfly Valves A. Butterfly valves shall only be used for flow media without fibre type solids contents and without sludge and slurries and, therefore, shall not be used for sewage water. B. The design shall be in accordance to ISO 5209/EN 19 with face equivalents to DIN 3202 and shall be of the flangeless wafer type with centric shaft construction for bi-directional tight shutoff. The inner parts of the butterfly valve shall be entirely rubber lined. Spur gears with hand wheel shall be provided for valves > DN 200. C. The inlet butterfly valve for the pumping station shall be provided with actuator suitably sized as per manufacturer recommendation and should be connected to RTU and SCADA system Descri tion Valve Body Disc Lever Body Lining Material Disc Linin Material Shaft & tapered Pin Plug Bushes Sealing Ring “O" Rings Gear Box Housin Hand Wheel External Coating

Material Ductile Cast Iron, GGG 40, DIN 1693 EPDM with WRC approval for drinking water Stainless Steel, 1.4057, DIN 17440 EPDM Rubber Cast Iron, GG 25, DIN 1691 2 pack epoxy coating system, 350 μm

2.1.35 Dismantl ing Pieces / Adapter Pieces A. Dismantling pieces shall be installed as indicated on drawings. They shall consist of a steel or ductile iron body, coated internally with 400 micron externally with 300 micron fusion bonded epoxy. Bolts, nuts, washers shall be stainless steel grade A4. Dismantling pieces shall allow a movement of at least 50 mm.

2.1.36 Pressu re Gauges A. Pressure gauges shall be installed at the suction and at the discharge side of the pumps, at strainer in- and outlet, and at other places where pressure control/reading is necessary for proper plant control. The gauges shall be provided with a pressure gauge cock with "T" passage to allow pressure vent and pressure reading. The dials shall be concentric 150 mm diameter and graduated in [bar]. Gauge graduation shall be such that the gauge is not used continuously beyond 70 % of the maximum graduation. The gauges shall be sealed from the treated effluent water by means of a diaphragm or capsule and shall be filled with silicon oil or similar and approved. All gauges shall be calibrated and a test certificate of an independent institute for each individual gauge shall be provided by the Contractor. Contract 106, Volume II

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2.1.37 Strainer A. Wherever necessary and required by the Engineer pipe strainer shall be provided and installed before the entrance side of equipment. The strainer shall be suitable to the flow media with a screen perforation and filter efficiency for cleaning the flow media in accordance with the requirements of the affected equipment as specified by the manufacturer. B. The strainer shall be single in-line basket flanged type. C. The strainer will be compact design and will incorporate large filtration areas giving low pressure drops. D. The strainer shall be rated for all working pressure and test delivery pressure E. The strainer basket shall be manufactured from stainless steel material grade 1.4571 to DIN 17006. F. The mesh will have 120 meshes per 25 linear mm. The size of each hole will be 0.920 mm giving a filtration of 920 microns. G. The body and cover shall be of cast iron GG25 and shall be fusion bonded epoxy coated internally and externally of 300 microns H. A differential pressure switch shall be connected between inlet and outlet of the filter, and if the pressure drop across the filter is exceeded by 50 % ( or other value recommended by the manufacturer and agreed with the engineer ) a lamp indication on the panel shall indicate “ filter blocked and signal shall be transmitted Via RTU with alarm, and if the value of the pressure difference is increased the pumps operation shall be disabled

2.1.38 FILTERS The Contractor is advised to refer to relevant sections of the electro-mechanical specifications A.

Screen Filter Automatic self-cleaning screen filter shall be provided at the pump head, which are specifically designed for use with organic contaminants. Cleaning shall be effected by hydraulically powered suction scanner automatically activated when the pressure across the filter reaches 0.35 bar. The capacity of the filter should match with the system flow.

1.

Primary stage filtration shall be performed by a one piece perforated having circular holes of 9mm diameter.

2.

Secondary stage filtration shall be provided by a stainless steel grade 316 with 200 mesh size (74 microns). Flushing line to be connected to an existing drainage manhole.

3.

Filter shall be equipped with electrical control system contained in a Nema 4X enclosure, which shall regulate the filter rinse cycles and prevent the filter from engaging in a continuous rinse. The control system shall be microprocessor based and shall be suitable for control of up to ten (10) filters. The system shall provide for rinse cycle activation by one of four options: differential pressure, timer external signal or manually, and shall include an integral rinse cycle counter which shall record the rinse cycles activated by each method. The system shall include local alarm and remote contacts to indicate filter malfunction.

4.

Filter shall have flush valve actuator of a heavy duty construction threaded into a brass valve body.

5.

The filter shall clean itself automatically without the need for an external energy source.

6.

The filter shall provide uninterrupted flow and also provide filtration during the flushing cycle.

7.

Fine screen elements shall be easily replaceable without requiring any changes to be made in the construction of the elements of the cleaning system or the need to remove the filter from the pipeline.


PVC coarse screen

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8.

Installation shall be possible in any desired position (horizontal, up-side down, vertical or inclined).

9.

Pressure drop across a clean filter screen shall not exceed 3 psi (20 kPa).

10.

Filter shall have isolation valves in the suction as well on delivery side for easy maintenance. The controller for the filters shall be equipped with timer and pressure differential control unit.

11.

Pressure gauges to be connected to suction and delivery side of each filter. 12. All nuts and bolts shall be of stainless steel grade 316 or A4-70.

B.

Media Filter The irrigation filter shall be automatic self-cleaning type. Specifically designed for use with organic contaminants. A hydraulically powered suction scanner, automatically activated when the differential pressure across the filter reaches an adjustable level, normally 5 PSI, shall effect cleaning. The screen shall be stainless steel grade 316 with 200-mesh size (74 micron). Flushing line is to be connected to the soak pits or nearest storm water drainage manhole. The control system shall feature a fail-safe timer to prevent continuous flushing due to malfunction. The control system for the filters should be such that it will not flush the filters if the pumps and /or irrigation system is not operating. Filters should flush only during the operating hours of the irrigation system. One number in line filter of capacity 9.5 lps shall be installed. The filters shall have less than 0.18 bar pressure loss. The screen area shall not be less than 274 sq.inch. Filter shall have gate valves in the suction as well as on delivery side for easy maintenance. The controller for the filters shall be equipped with timer and pressure differential control unit. Pressure gauges are to be connected to suction and delivery side of each filter. All nuts and bolts shall be of stainless steel grade 316 or A4-70. The filter body and internal parts including flanged connection shall be stainless steel.

D.

Y – Strainer Body shall be constructed from high heat and chemical resistant glass reinforced plastic, twopiece threaded housing with o-ring seal moulded. Outer support shall be woven stainless steel wire and inner screen shall be woven stainless steel cloth. Inner and outer screens shall be soldered together. Screen collar moulded from vinyl for long life and weather resistant. Screen shall be 120 mesh sizes. The pressure rating shall be 10 bar. Working pressure shall be 7-8 bar. The filter should be available in 25, 40, 50 mm size and flow capacity of each shall be 1.58, 3.15, 6.94 lps respectively. The whole filter unit shall be manufactured from the same manufacturer


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2.1.39 Expansion Joints A.

Expansion joints shall be installed wherever necessary or required by the Engineer in order to eliminate stress and vibration transfer from rotating / oscillating or otherwise vibrating equipment and/or thermal stress to the pipe work or vice versa. The expansion joints shall be of the single sphere bellow type with tie bars and flanges. Material: Bellow: Natural rubber or neoprene. Flanges: Stainless Steel 1.4571 to DIN 17006 Tie Bar: Stainless Steel 1.4571 to DIN 17006

B.

2.1.40 Flexible Hoses A.

To avoid damage and/or malfunctions of instruments and other sensitive equipment by vibration transfer flexible hose connection shall be provided. Pipe connection by integrated unions. Material: Inner Hose: Natural rubber or neoprene Armouring: Stainless Steel 1.4541 to DIN 17006

B. C.

2.1.41 Float Valves A.

Float operated valves >= DN 25 shall be supplied for potable water storage tanks. The valves shall be designed and manufactured as heavy duty industrial type. Floats, rods and accessories shall be made from stainless steel grade 1.4571 subject to approval by the Engineer. B. Where the valve body passes through the tank wall suitable dust and water proof union shall be provided enabling removal of the valve without disturbance to the connecting pipe work.

2.1.42 Ball Valves Plastic Ball Valves A. Plastic ball valves shall be made from the same plastic material as the related pipe work, including union at both ends, with EPDM gaskets and "O" rings.

2.1.11 Metallic Ball Valves A. Metallic ball valves shall be made from stainless steel, designation 1.4401, with PTFE gaskets and "O" rings, with solid metallic handle.

2.1.12 General A. a. b. c.

Valve actuators shall be provided for: Isolation valves > DN 450, function open / closed Control valves, function in accordance to process requirements Automatic operated valves, function open / closed

B.

a. b. c. d. e. f. g.

The valves shall be driven by electrical motors / gearbox or by electrical magnets depending on process requirements. Following accessories shall be provided for all types of valve actuators: Electrical position end switch, open / closed with local and remote position indicator (with signals to the control panel) Electrical intermediate position sensor for all types of process valves with local and remote position indicator (with signals to the control panel) Open / closed limit switches Torque overload switch with alarm signal to the control panel Local isolator switch and local operation switch End position run (NC or NO) in case of power failure (solenoid valves only) End position run (NC or NO) in case of power supply after plant shut down or power failure


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h. C. a. b. c. D. a. b. c. E. a. b.


Interlock of suction valve actuators with the related pump operation ( closed suction valve shall not allow the pump to run) Operating movement shall be: Continuous turn operation for gate valves, globe valves Part turn operation for butterfly valves, ball valves Linear trust operation for globe valve Grade of protection shall be IP 65 as standard IP 68 for submersible actuators (where flooding can be expected) Explosion proof EEx ed IIB T4 for installation in hazardous areas The actuators shall be suitable for following ambient air temperature: +5 to + 55°C Relative humidity 100%.

2.1.13 Act uators , Electric al Motor driven A. Heavy duty industrial type actuators shall be provided with appropriate gear and air cooled motor, including manual override device (hand wheel or lever) and as per general condition above. B. Closing / opening time shall be in accordance to the process requirements, but shall not exceed 0.25 sec/mm hub.

2.1.14 Solenoid Valve Actuator A. Heavy-duty industrial type actuators shall be provided, with direct acting actuator, sealed by an EPDM diaphragm against the flow media, spring loaded for reverse operation.

2.1.15 Gear Boxes A. Gear boxes shall be totally enclosed, of robust construction and shall be suitable for continuous duty under ambient conditions. Long-life seals on the input and output shafts shall be fitted up to prevent the escape of lubricants and the ingress of dust and moisture. The gearbox housing shall be of rigid high strength close-grained cast iron with a properly closing cover. Eye bolts for lifting purposes shall be provided. B. Oil level sight glasses shall be installed for easy viewing and ventilation (breather), oil filling caps and drains shall be provided. Where applicable gear boxes shall be equipped with a flexible coupling, including safe guards, between the motor and the shaft of the gear box. C. Lubrication of bearings etc. shall be by either splash or forced feeding system. The lubricant used for the initial filling and specified in the maintenance manual shall be adequate for prolonged operation without overheating in the temperature specified.

2.1.16Suppor ts and Anchors Supports and Anchors A. Pipe and equipment supports shall be situated at those points in the building where provisions have been made for the load imposed. The cutting of floor or roof beams or the reinforcement in slabs is not permitted. B. Piping attached to plant items shall be supported in such way that the weight of the piping is not taken by the plant item. All supports shall be shop fabricated. C. Where possible supports shall be positioned near to joints and valves and shall be located in order to facilitate easy maintenance. D. Since certain parts of the building are constructed in reinforced concrete, the position of all supports and anchors, and the resulting loads, shall be defined early enough to allow appropriate provisions to be made. The Contractor shall allow in his rates for cutting anchor holes etc. required for the installation of the Plant. E. Supports shall be designed for the load resulting from equipment and piping system under fully operational conditions (filled with water, etc.), during hydraulic testing, and under unexpected uncontrolled plant shut down. F. All design and fabrication, including loads and allowable stresses, shall be in accordance with the relevant codes and standards. Contract 106, Volume II

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G. A stress analysis calculation shall be submitted to the Engineer. The location of anchors, guides or restraints shall be based on the result of the final stress analysis. Spring type hangers shall be selected to allow the movements determined by the stress analysis. H. The Contractor shall design, locate and provide all supplementary steel required to properly secure and support all equipment and pipe supports furnished. I. Designs, generally accepted as exemplifying good engineering practice, using stock or production parts, shall be utilised wherever possible. J. Accurate weight balancing calculations shall be made to determine the required supporting force at each support location and the pipe weight at each equipment connection. K. Adequate provisions shall be made for supports that may be disconnected during maintenance works. L. Supports shall be designed to prevent transfer of excessive loads from support to support or to equipment as the line expands or contracts. M. Support components shall be attached in places only where they will not damage other construction either during or after installation. Wall brackets may be used where equipment / piping are adjacent to the wall or other vertical surfaces suitable for support use. N. All large pipes and all long pipes shall have at least two supports each arranged so that any length of pipe or valve or other device can be removed without any additional temporary support. O. Steel shall be of structural quality; perforated straps, wire, or chain shall not be used. P. Support components connected to building structural steel shall be done only by means of clamps or bolts’, welding is not permitted. Bolt holes shall be drilled and not burned. Supports components connected to concrete shall be by means of approved concrete stainless steel anchors only. Q. Where the equipment / piping is subject to shock loads, such as thrust imposed by the actuation of safety valves, isolation valves, etc. the support design shall include provisions for shock absorbing devices of approved design. R. Selection of vibration control devices shall be part of the Contractor's work. If vibration is encountered after the system is in operation, appropriate vibration control equipment shall be installed by the Contractor on his own costs. S. Hangers shall be designed to prevent being disengaged by movement of supported pipe. T. All anchors and fasteners shall be made from corrosion resistant material suitable for the designed and calculated load and suitable to that material to be anchored. Description Structural Supports Pipe Clamps < 1 ‘’ Pipe Clamps > 1 ‘’

Material Stainless steel 316L Plastic Stainless steel 316L

2.1.17Lifting Equipm ent 2.1.18General A. To facilitate maintenance and operation of the entire plant, lifting equipment shall be provided and installed at locations where heavy parts of the plant are to be dismantled, moved and / or lifted. B. The safety working load capacity of each lifting unit shall be sufficient for the heaviest load plus 50%. C. The lifting equipment shall be designed to provide sufficient clearance for offloading and lifting the largest single item of the plant. D. The safe working load shall be clearly marked in Arabic and English at the lifting device. E. Load chains and ropes shall have sufficient length in order to reach the lowest point. Hand chains for lifting device control shall extend to 1500mm above the operating floor level. F. A reliable braking and locking arrangement shall be provided and a load chain collection box shall be incorporated in the lifting device. G. The load hook shall revolve on a ball swivel and shall be equipped with a safety catch. H. Electrical driven devices like hoists, lifts, etc. shall have minimum two speeds.


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2.1.19 Davit A. Davit & Hoist Units shall be installed to facilitate maintenance and repair works. The clear height between top of concrete structure and davit arm shall be sufficient enough to enable movement of attached loads to a truck. B. The davit / hoist system shall include: a. Mechanical chain operated trolley, manual driven chain hoist and mechanical break devices and equipped with manually lifting device for manual lifting and down loading, chain container. b. Davit column and swivelling davit arm with long life load dust capsulated bearings, including foot plate, anchoring, grouting, warning and max. load sign board. c. Material shall be mild steel profiles, hot dip zinc coated after fabrication. d. Safety working load SWL = Heaviest parts to be lifted + 50 %, but not less than 500 kg.

2.1.20Overhead Bridge Crane A. Over head bridge crane shall be provided for the pumping station as shown on drawing including motorized lifting hoist equipped with manually lifting device for manual lifting and down loading, manual by chain operated longitudinal and transversal travelling gear and trolley, rails, single type girder, remote control box for hoist operation from the pump installation floor warning light and audible signal when the hoist is in operation B. The crane bridge shall be equipped with a catwalk bridge to be used for maintenance and repair of devices located at ceiling height and for crane, maintenance, including fixed ladder. C. Crane safety working load shall be as described above. D. Catwalk safety load shall be 100 kg/m2.

2.1.21Mono Rail Crane A. Mono rail crane, serving the incoming lay-down area and the middle area of work shops, shall be supplied and installed as shown on drawings. Design load shall be 2500 kg. The crane system shall comprise a. A double TEE steel profile suitably dimensioned and anchored to the concrete ceiling by means of expansion anchor bolts, designed to carry 200% of the design load. b. Chain operated hoist including chain operated travelling gear.

2.1.22Elevator A. Elevator, serving the pumping station (dry well), shall be supplied and installed as shown on drawings, carrying load shall be 750 kg, and speed of 60 meters / min. B. The control system shall be of variable voltage variable frequency (VVVF) with selective collective operation, the no of stops are four Nos. with four opening – all in the same line.

2.1.23 Machine A. Car ceiling, Lighting and ventilation shall be of painted steel sheet in colour selected and approved by the engineer, Indirect lighting through Milky-White plastic cover, ventilation by means of electric blower with plastic grills. B. Car Walls& Doors, entrance column and cabin transom panel and kick plate shall be in hairline finished stainless steel. C. Car flooring hard wearing vinyl tiles with colour selected and approved by the engineer, car and entrance landing sills shall be of extruded hard aluminium D. Car operating panel shall be mounted in front return panel of the cabin for better operational convenience with call buttons of micro tough which will illuminate on registration of a call. Face plate shall be in plastic dark grey. E. Indicators at all levels shall be vertical combined unit comprising of digital Led Dot-Display hall position indicator with direction arrows and call buttons of micro-stroke click type which will illuminate on registration of a call. Face plate shall be in glass fibre reinforced plastic in dark gray. F. Architrave, landing doors at all levels shall be lintel and narrow jamb in hairline finished stainless steel.


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2.1.24Arc hitrave A.

B.

Door operation shall be VVVF INVERTOR CONTROL DOOR DRIVE SYSTEM. The door opening size 800MM WIDTH x 2100MM HEIGHT, the hoist way doors at all levels shall be power operated 2 panel centre opening automatic doors. Cabin indicators with built in digital Led Dot-Display car position indicator with direction arrows shall be incorporated on top of the car operating panel to facilitate better view of the position of the car comfortably even during crowded condition.

2.1.25Special Features A.

B. C. D.

E.

F.

G.

H.

I.

J.

K. L. M.

N. O.

P.

Car arrival chime: shall be an electronic chime sounds to inform waiting passengers of the car Fireman emergency operation: when the fireman’s switch is activated during a fire, all calls are cancelled and the designated car returns immediately to a specified floor. To facilitate rescue afterwards, the car responds only to car calls. Emergency lighting in the car with trickle charger unit. Interphone: Interphone for three way communication between the elevator cabin, machine room and security personnel at ground floor lobby near the lift entrance. Overload holding stop: when a carload exceeds pre-determined capacity, the elevator will stop its operation with the doors open at the floor and a buzzer will found. The buzzer will stop when enough passengers have exited the car to reduce the load to below the excess capacity. Safety door edge: each leading edge of the car door panels can be equipped with a safety door edge. When a passenger or an object touches one of the edges, the closing doors will be opened immediately. Emergency landing device: emergency landing device which will bring the elevators to the nearest landing in the event of power failure and keep the doors open; for evacuation of passengers. Thereafter, the elevators will dis-continue its operation until restoration of normal power supply. Next landing facility with main power supply uninterrupted: if an elevator door becomes jammed for some reason, [ex. A pebble] and passengers are unable to get off at the desired floor, the elevator automatically proceed to the next floor with functioning doors. Safe landing with main power supply uninterrupted: this feature is to be designed to prevent passengers from being stranded in the car when an elevator malfunctions and stops between the floors. The source of this malfunction has to be automatically searched out and when elevator operation is determined to be safe, the car shall proceed to the nearest safe landing at reduced speed and the doors then open. Door load detector: when an object is caught in opening/closing doors, the doors will reverse its direction when an excess load is detected. For example, when a pebble becomes lodged in the door track, rather than force itself open/closed, the reverse cycle is to be repeated until the problem is eliminated. Car call cancelling: when a car responds to the final car in the ascending or descending direction, the system automatically checks for and clears them from memory, thus keeping operating efficiency high. Car light shut off - automatic: to save energy, car lighting is turned off automatically if there is no call registered within a predetermined period of time. Car fan shut off - automatic: to save energy, car fan is turned off automatically if there is no call registered within a predetermined period of time. Door nudging feature: in the event of any door safety device malfunction, a temporary override function is to be automatically engaged to close the doors, thereby preventing a fault in elevator operation. Once the doors close completely, the override has to be cleared and normal operation resumes. Attendant service: operation mode is switch able between fully automatic and attendant service using an override switch in the car-operating panel. Automatic door open time adjustment: the system judges the situation whether each car stops responding to a car call or a hall call and controls the time the doors stay open accordingly. The time spent waiting for the elevator is thereby shortened and operating efficiency is increased. Ultrasonic door sensor: door protection system which utilizes waves to detect boarding passengers or obstructions within a three dimensional area at the door opening.


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Q.


Elevator shall be equipped with emergency stop switch, expediting of door close, repeating of door close, door open & door close buttons, Hairline finished stainless steel hand rail on rear side of the cabin, DC alarm bell, Hand-winding operation for emergency purposes and safety shall be gradual type.

Buffers Guide rails Counterweights Power supply Lighting supply

spring type steel tee sections. cast iron blocks enclosed in a steel frame. 415volts 3phase 50hertz for elevator equipment. 240volts 1 phase 50hertz for cabin lighting and ventilation.

2.1.26Containers, Tank s, Vessels 2.1.27 General A.

B.

Containers shall be factory made and, depending on the size, field assembled. The container shall be installed on suitable designed concrete foundations at least 500mm higher than the surrounding level. Unless otherwise specified the containers shall be furnished with complete tank drain including drain sump by gravity, inspection and cleaning manholes, filling nozzles, suction nozzles, vent nozzles (including air filter for potable water storage tanks), level gauges, staircase or ladder, service platforms, roof railing, lighting/ illumination where applicable, earthing and lightning protection, catch basin of the same volume as the tank volume where hazardous material is stored, adequate corrosion protection, etc. Location of pressure gauges shall be such to enable easy reading from floor level.

2.1.28 Pressure Vessels A.

B.

Pressure vessels supplied and installed under this contract shall be designed, manufactured and tested according to the relevant pressure vessel, welding and safety codes and standards. Welding tests and pressure tests shall be verified by an international recognized quality assurance office. The material must be suitable for the media stored. Internal rubber lining shall be provided for the effluent filter tanks and surge vessels.

2.1.29 Prefabricated Tanks A.

B.

Prefabricated tanks shall be preferably constructed out of stainless steel grade 316 L. Baffles, weirs, internal pipe work, valves etc. shall be equally in stainless steel or especially designed GRP with the appropriate resins or epoxies. If other material is used special protective coating as specified hereinafter shall be provided ex works.

2.1.30 L D P E (Linear Low Density Poly-Ethy lene) Tanks 2.1.31Scop e A. The specification shall apply to the linear low density polyethylene tanks where used for, a. Potable water storage b. Effluent water / irrigation water storage

2.1.32General A.

B. C. D.

The submittal must be along with the relevant product catalogues / descriptive literature stating manufacturing process, materials, and instructions on construction, handling, installation, periodic inspection and maintenance. Tank material shall be virgin polyethylene, PE pellets shall be from local approved manufacturer. Recycle material is not accepted. Detailed drawing shall be mentioned with, capacity, tank type, mass, all dimensions including size of reinforcing ribs joineries and accessories fitted with. Cylindrical / Cubical tanks are applicable with vertically placed and flat supporting base.


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E. F. G. H. I. J. K. L.

M. N. O. P. Q.


The tank shall be one-piece moulded body has no joints, strong, durable and designed to be for easy handling and installation. o Tank shall be suitable for 100% humidity and > 50 C temperature, corrosion proof, UV stabilized, non-toxic, non-staining, smooth inner lining, algae resistant. Thermal insulator layer shall be provided to the over all shell structure of the tank. Colour of tank shell / body and protective wrapping / coating, shall be white as such to reduce the heat absorption. All domestic water tanks used shall be protected from excessive heat, direct sun and UV rays. Tank exterior pipe fittings, fasteners, supports, etc shall be protected against weather conditions. Tanks shall either be installed indoors or under a weather resistant protective structural shed from top and sides. Tank should be opaque to help reduce evaporation of disinfectant and inhibit algae growth. Maximum measured light transmission value inside a closure cover state tank shall not exceed 0.1%. Tank shall be erected above ground with a clear access of not less than 60cm all around. Flexible connectors (e.g., Flanged Rubber Below) shall be used to avoid stress & vibration transfer to the water tanks. Tank shall be fitted with all instruments required for the intended usage purposes (e.g., Irrigation, potable). All bolts, nuts and washers must be stainless steel, graded to 316 or A4. Manufacturer instructions and guidelines concerning storage of tank parts and accessories general site conditions of tank location, erection method, usage and operation of the water tanks shall be strictly observed.

2.1.33Qualit y Control A.

B. C. D. E. F.

G. H. I. J.

a. b. c.

Supplier shall take all necessary measures to satisfy the owner that water tank supplied for use within its domain meets requirements detailed forth. This shall be repeatedly done every five years or as and when called by the owner during guaranteed period. Tanks shall be erected, tested and commissioned for use only by the manufacturer. The manufacturer shall clarify the periodic inspection of tank algae growth and remedial measures. Whenever composition or process of manufacturing of particular component part is changed or modified, the affected component part shall have to be tested in presence of Engineer. All testing and inspection costs shall be born by the contractor. Tank material properties shall be tested and submitted in compliance with the Table. Verification tests shall be performed intermittently as per the Engineer’s demand. NO. TESTS ON PROPERTIES STANDA RD LIMITS 1 Melt Index ASTM D 1238 > 5.0 g/10 min. 2 Vicat softening BS EN 727 > 115°C 3 3 Density ASTM D 1505 > 0.935 g/cm 4 Tensile Strength (@ yield) ASTM D 638 Min. 180 Kg/cm² 5 Elongation @ break ASTM D 638 Min. 700 % 6 Water Absorption ASTM D 570 Max.0.2% 7 Shore D Hardness ASTM D2240 > 35 8 Opacity ISO 7686 Non opaque Air test shall be conducted on each tank and it must be of air pressurized to min. 1 Bar for min. 30 minutes with no pressure loss. Each tank must be tested using a vacuum pressure / negative pressure of min. 0.5 bar for min. 15 minutes without pressure increase or collapse of the tank. All in house QA/ QC records shall be provided along with tank supply to the site. Supplier shall maintain and preserve a record of every tank supplied. Until the expiry of the tank guarantee, updating it upon completion of every stage of work to reflect detailed required information below: Every tank assembled shall be with a serial number A record shall be kept ready for inspection along with the relevant certificates Tank type, size, capacity, serial number and other specific details.


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d. e. f. g. h. i. j. K.

Employer name and address Location (e.g. plot & sector) Name of tank assembler Date of manufacture Date of erection Dates and descriptions of routine testing Date approved by the Engineer A permanent nameplate / identification of not less than 10cm x 10cm in size should be securely and legibly imposed on tank exterior complying with the following. a. Plate, colour of plate and lettering materials shall not be affected by weather conditions, b. Name of manufacturer and trade name c. Serial number / product unit identifying number d. Capacity e. Date of assembly f. Usage (e.g. Irrigation water) L. Upon completion of the erection, tank shall be cleaned as per the manufacturer guideline and then be disinfected by the erector. Water shall be sampled and tested. Evidence of successful test results shall be submitted prior to commissioning the tank for use. Approval of Health A uthori ties A. The tank manufacturer shall be certified to meet the requirements of BS 6920 for products approved for potable water usage. B. Potable water tank must be conformed to BS 4994 or equivalent international standards. C. A guarantee of fitness for storing, of effluent water shall be obtained from concerned local government agencies (Municipality & Town planning / Environment & health section), and a copy provided to the Engineer. Provided Certificate should cover accessories and component parts of the water tank in question. Inlet, Outlet, Overflow Pipes A. UV stabilized compatible material to the parent tank material. Overflow pipe shall be placed in same level of inlet pipe and to be facilitated with stainless steel face fly mesh. Outlet pipes shall be kept level at least 10cm above the tank bottom. Drain Pipe A. Drainpipe shall be UV stabilized compatible material fixed at bottom most level of the tank and a sump zone of size min. 300mm dia. 50mm deep shall be designed to clean out the dirt easily. Vent Pipe A. UV stabilized compatible material fixed with stainless steel fly mesh down facing shall be facilitated. Manhole Entr y and Cover A. Manhole access diameter shall be min. 600mm and it shall be covered with a secure threaded or bolted and lockable cover of same tank parent material. Ladders A. Internal and external access ladders to be provided to ease man entry for the maintenance exercises. Material of ladder shall be with anodised aluminium having colour matching to the tank texture. Guarantee Certifi cates A. Manufacturer, importer or supplier of the water tank shall provide a certificate of guarantee, against manufacturing and erection defects covering a period of minimum ten years from the date of erection. During the guarantee period, tank component parts and accessories found deteriorated, corroded or defective shall be replaced or made purposefully at his cost.

2.1.34Ventilation 2.1.35 Design A. B.

The Contractor shall design, supply, install, test and commission a ventilation system operating with 100 % outdoor air as supply air. Supply air volumes and exhaust air volumes shall be balanced to ensure a positive pressure inside the entire buildings in order to avoid that sand, dust, etc. is drawn into the building via doors and other openings and gaps.


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C.

Outdoor air intakes and exhaust air outlets to outside shall be provided with suitable sand trap louvers. The following minimum air changes per hour shall be provided: Area to be ventilated Dry well Wet Well

D. E. a. b. c.


Air change/hr 10 15

Air exchange in screen pits and wet wells shall be achieved by the odour control ventilation system. The control system of the entire ventilation systems shall allow for the following operational conditions: Individual manual switched on/off Automatic switched off by the fire alarm system where required as per specifications under fire alarm and fire protection system and by Civil Defence Authority. Manual switched off/on by the fireman switch via an override panel installed closed to the central fire alarm panel where required as per specifications under fire alarm and fire protection system and by Civil Defence Authority.

2.1.36Equipm ent / Material and Accessori es 2.1.37 Air Handling Units A. All air handling units shall be suitable for outdoor installation, protected against corrosion caused by fumes, and shall consist of: a. Housing constructed of framed modules with common base frame designed for mounting on concrete foundation stripes and prepared for weather proof flashing, made from galvanized steel sheets and profiles, in double skin design with internal thermal and acoustical mineral wool insulation, outside coated with three coats of baked enamel paint. Access doors, with lockable quick release door links, shall be foreseen for easy maintenance and repair. b. Fans shall be the centrifugal type double suction fan with backward curved aerofoil wheel, statically and dynamically balanced complete with shaft, self aligning bearings lubricated for life, multi v-belt drive pulley with variable motor pulley for fine adjustment on site, anti vibration devices spring loaded, non combustible flexible connection between fan and housing and between housing and supply air duct, all metal parts made from galvanized steel, shaft made from stainless steel. c. The electrical Motors shall be the totally enclosed fan cooled type (TEFC) motor, IP 55, insulation class F, 3 phase, terminal arranged for Star /Delta or DOL start, as specified under section 4 electrical specifications, foot mounted (B3), 4 poles / 8 poles as per type of starter, mounted on rigid adjustable base plate. d. Air Filters shall be the throw-away type air filter, 2" thick with supporting wire mesh and frame plastic coated, installed in "V" banks for side removal, with gaskets around to avoid airleakages by-passing the filter. e. Opposed inlet air damper made from galvanized steel, with motorized actuator and actuator link mechanism. f. Sand trap louvers shall be manufactured from alloy aluminium, designed for removal of at least 85 % of typical dessert sand during a heavy sand storm, with self drained holes to outside. g. Isolator Switches shall be the rotary type on/off isolator switch, lockable by padlock to be provided together with the switch, protection grade IP 65, weather proof for outdoor installation, separate structural steel hot dip zinc coated stand mounted on the roof including flashing. h. Corrosion protection shall be as per specifications, Volume III , section 5


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2.1.38 Louvers A. All outdoor louvers shall be sand trap louvers, self cleaning type, designed to filtrate at least 85 % of a typical type of desert sand from the intake air volume. Material shall be alloy aluminium sheet metal, thickness > 2mm for frames and >1.5mm for blades. All fixing material shall be made from non-corrosive material.

2.1.39 Grills and Diffus ers A. Grills & diffusers shall be entirely made from extruded aluminium, with volume control dampers, separate wall/duct mounted frame, adjustable diffuser blades, non-corrosive fixing devices, removable without using special tools for easy cleaning and maintenance. For the dry well pump area, the supply and exhaust air grills shall be made from GRP material with stainless steel # 1.4571, DIN 17440 to 17441 and 17455 to 17458 wall mounted frame. The air velocity in the free area section shall not exceed 2.5 m/s.

2.1.40 Supply / Exhaust Air Ducts A. Air ducts shall be designed for the maximum airflow. The air flow velocity shall not exceed> 6m/s and < 10 m/s. Elbows shall have a minimum radius of 1.5 times of duct diameter or bent duct height. Duct and support material shall be: a. GRP Material for dry / wet well ventilation system, supports made from stainless steel no. 1.4571 as above. b. Galvanized sheet metal, thickness >= 1.2mm for all other systems used for indoor installation, supports made from hot dipped zinc coated steel. c. Galvanised sheet metal as above, but with additional three field applied paints of epoxy paint including a first layer of primer for systems as per item b), but for outdoor installation. d. Corrosion Protection shall be as per specifications, Volume III, Section ‘5’.

2.1.41Air Condit ioning Equipm ent A. The Contractor shall design, supply, install, test and commission an air-conditioning system conforming to the requirements of the Abu Dhabi Municipality Engineering Section.

2.1.42 Design Parameter o

o

A. Outdoor air condition: 46 C Dry bulb, 30 C Wet bulb, unit must continue working at external o temperature up to 52 C ambient o o B. Indoor room air condition 24 C Dry bulb, 17.5 C Wet bulb, Outdoor air volume minimum 10% of supply air volume, controlled by manual air volume damper C. Supply air filter class B2 DIN 24185 (throw-away type) D. Cooling capacity summer cooling load + 10%, derated to outdoor/indoor condition E. A/C type split type F. Control electronic micro processor for temperature and fan speed control, on/off, timer G. Supply air fan speed minimum 3 speed H. The derated output cooling capacity for each A/C unit shall be 3 tons of refrigeration (10.6 kW) as standard, in case of higher cooling demand multiple 3 ton units shall be used.

2.1.43 Material A.

Equal A/c units, each with a derated output capacity of 10.6kW (3 ton of refrigeration) shall be provided and the quantity of A/c units required shall be based on the result of the cooling load calcuation, subject to approval by the Engineer / Department.


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B.

C. D. E. F. G.

H. I.

J. K.


All material used shall be resistant to attacks of gases (H2S etc.). Corrosion resistant coating shall be factory applied. Special attention shall be paid to provide coating to all hidden areas. All bolts, nuts, screws, washers, supports shall be stainless steel. Heat exchanger shall be copper tubes with aluminium fins, coated with a corrosion resistant air drying phenolic type material Fan blades aluminium, coated with a corrosion resistant air drying phenolic material Housing shall be galvanised sheet metal with baked enamel coating Bolts, nuts, washers stainless steel A2 to DIN 267 Refrigerant pipe work shall be copper tubes, coated with a corrosion resistant air drying phenolic material, for change of direction prefabricated bends are to be used; bending of pipe is not permitted Condense water pipe work shall be HDPE Thermal insulation Gas & liquid lines shall be insulated separately. Material shall be ozone resistant, closed cell elastomeric plastic tube insulation, thermal conductivity <= 0.035 W/mK, thickness indoor >= 20 mm, >= 50 mm outdoor Thermal insulation covering indoors canvas with mastics, outdoor aluminium cladding Condense water discharge by HDPE pipe to an outdoor installed soak away

2.1.44 Electric Connection A. Power supply for indoor unit from outdoor unit. B. Power supply for outdoor unit from distribution board with outdoor installed isolator switch, near outdoor unit. C. Control of indoor unit shall be through hand held control unit, installed on small junction box on the wall connected with indoor unit through wires or wireless controlled.

2.1.45Emergenc y Power Supply 2.1.46 General A.

For stations with 1 duty and 1 standby pump 120% of the load demand of one pump plus 100% of other power load demand a. For stations with multiple duty and 1 stand-by pump 120% of the 50% of load of all duty pumps plus 100% other power load demand. B. The capacity of generator shall be rated at 55 °C ambient temperature and the capacity shall be calculated taking into consideration: a. Permissible starting current of the pump, using starter as per clause 4.8.12 – Motor Starter. b. Initial torque and voltage requirements as per manufacturer’s recommendations at the start of the pump. c. Loads other than pumps connected to MCC.

2.1.47 Diesel Engine A. The diesel engine shall be heavy duty, turbocharged, water-cooled multi cylinder 4stroke type, designed for cold starting, speed not exceeding 1500 RPM. The engine shall be continuously rated to give full load output under the worst climatic conditions. B. The engine shall be fully equipped and designed for electric push button start / stop, automatic start / stop facility for remote auto start / stop and manual start and stop and shall be provided with heavy duty maintenance free acid batteries installed in a robust container including charger, automatic cut out and cables etc. Machines shall be suitable for locally available distillate fuels.

2.1.48 Generator (Alternator) A. The generator shall be of the asynchron, self - exciting brush-less type IP 44 for mobile set and IP 22 for stationary set, class F insulation and shall be designed for 415/240 V, 3 phase, 50 Hz supply, providing a steady state voltage within +/- 5 % of the rated voltage under any load and equipped with anti condensation heater and thermistors.


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2.1.49 Electr ical Control Panel A. A totally enclosed, dust proof, vermin proof, steel sheet cabinet of IP 54 class with following equipment and accessories shall be provided: a. Main Triple pole MCCB (moulded case circuit breaker), 50 KA with adjustable thermal overload and magnetic short circuit protection. b. Remote – start – modules with selector switch for Off / Reset lamp test, auto and manual including high intensity LED’s indication system status, interlocking with protection devices to disable engine to start. c. Protection for the alternator against overload and short circuit d. AC - ammeter and Voltmeter with selector switch e. DC - ammeter on battery charging system f. Automatic voltage regulator g. Start/stop push button h. Visible and audible alarm system indicating: 1. High water temperature 2. Low oil pressure 3. Low fuel i. Oil pressure gauge j. Electrical shut-off shall be provided on the engine in case of low lubricating oil pressure, high water temperature and over speed. k. An adjustable time delayed relay to delay the shutoff of the generator to preset value once the normal supply is restored.

2.1.50 Statio nary Generator Set A. B.

C.

D.

E.

Permanently installed generator shall provide power supply to the pumping station through automatic change over switch provided in MCC. The set shall be mounted on welded steel common bed-plate. Flexible connections shall be provided to all exhaust, air, fuel and water piping to avoid fracture due to vibration and to minimize conduction of noise. Concrete foundation shall be designed to carry the load and shall be provided with proper vibration isolating material to separate the foundation from the surrounding structures. In addition to specifications mentioned elsewhere, the supply and installation shall include all power and control cabling between generator set and motor control panel. The radiator shall be the engine mounted heavy duty tropicalised folded core type with blower type fan sized to maintain safe operation at 55 °C. Duct works with flexible connecting section between radiator and fixed exhaust louvers shall be foreseen. Intake louvers shall be the sand trap type and shall be sized and located to provide sufficient intake air for engine combustion and to provide the required airflow through the radiator. The air intake system shall be equipped with sound actenuator, intake louvers, pre-cleaner, dry air cleaner with changeable filter and service indicator to optimize changing of filters. The exhaust system shall be a Residential Type silencer including stainless flexible exhaust fitting. The weight of silencer shall not be supported by the engine. The size of the exhaust pipe shall be sufficient to ensure that exhaust pressure does not exceed the maximum limit specified by the manufacturer. All indoor exhaust piping shall be lagged to ensure that the surface temperature does not exceed 65 °C. The insulation shall not interfere with the flexible exhaust fittings. Exhaust piping, supported from the ceiling shall have a minimum clearance of 30 cm and shall be slanted for condensation drain away from the engine. Supports shall be the vibration isolating type.

2.1.51 Fuel Tank A. The Generator set shall have two fuel tanks, one with 3 days capacity installed on concrete foundation provided under suitable steel structure shed and other installed as part of generator with a storage capacity required for 12 hours run under full load. It shall be installed complete with strainer, drain cock, filling cap, air vent, fuel level indicator and piping to the engine.


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2.1.52 Monito ring and Control of Generator A. Provisions shall be made to monitor all the parameters of Generator such as current, voltage, speed, oil pressure, and temperature etc. at display unit of MCC. Facility shall be provided for Manual switch ‘OFF’ and switch ‘ON’ of generator at MCC through selector switch, push buttons etc. in addition to automatic change over.

2.1.53Signs, Labels, Equi pment Identifi cation 2.1.54 Material, Language of Labellin g A.

B. C.

D.

E. F. G.

H.

All labels shall be plastic or metal and shall have the text or symbol engraved. When text and background are made in different colours, a light colour shall be used for the background and a dark colour for the text. The identification on labels shall be in the Arabic and English language. A list of label inscriptions shall be submitted to the Engineer for approval before manufacture. Labels shall be riveted or screwed to equipment and shall be positioned in such a manner that it does not follow the apparatus when the latter is dismounted or changed. Adhesive labels and marking type tapes will not be accepted. All switchgear, control gear and cables shall be labelled and marked to facilitate the identification of switchgear and control gear and parts thereof and their relation to relevant technical documentation in order to enable in a rational and simple manner the installation, operation, trouble shooting, maintenance and repair. Each unit of switchgear or control gear (such as a cell, panel, cubicle, or box) and all units of apparatus shall have a label identifying the unit and stating its purpose in the plant. Incoming and outgoing circuits shall be identified by stating the purpose of the circuit, the size of the connected cables. Internal wiring shall have each core or wire identified. The marking to be identical to the terminal marking to which the cable core is connected. Cables connected to switchgear, control gear and all external equipment shall be marked with cable numbers according to cable lists or external connection diagrams. All cable cores shall have identical marking as the terminals to which the cores are connected. All terminals of apparatus or units shall be clearly marked. Control devices shall have in addition to the marking of control position e.g. manual/automatic, open/close, on/off, etc. Cable terminals shall be identified with clear and unambiguous labels. The identification system shall be logically built up by letters and figures consistently used with the switchgear or control gear. Compartments with doors not interlocked to an isolator or removable covers having access to live parts shall have an external label affixed thereto stating "DANGER LIVE TERMINALS" in red letters on a white background in Arabic and English.

2.1.55 Equipm ent / Pipe Identifi cation A.

B. C. D. a. b. c. E.

Each equipment piece (pumps, valves, motors, instruments, fans, etc.) shall be clearly identified in the field by means of plastic / metallic labels, set on a name plate which is firmly fixed to the unit, with engraved inscription bearing name of equipment, equipment number and use of equipment. Nameplate and fixing screws shall be made from stainless steel and the minimum size of label shall be 100 x 50 mm. Equipment combined or connected with a driver shall have separate identification labels for driver and driven unit. Each pipe shall be clearly identified with plastic / metallic labels fixed onto nameplates as detailed above, bearing: Pipe identification number Kind of Media Use of Pipe Flow direction arrows are to be painted on pipes.


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2.1.56 Warning & Precaution Signs In accordance with the mode of operation and process, kind, type and use of equipment and systems, warning and precaution signs, size 200 x 100 mm, shall be provided in accordance with manufacturer's instructions and wherever necessary in order to avoid improper/accidental operation and to prevent accidents.

2.1.57 Colour of Labels and Insc riptions A. Identification Labels: B. Warning Signs (mechanical): C. Warning Signs (electrical):


White with black letters Yellow with black letters Red with white letters

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3


Part 3 Electrical Equipment & Material 3.1.1 General

A. This section of the Specifications covers, in conjunction with all other documents of the contract, the review, re-design, design, manufacture, supply, erection, connection, testing, and commissioning of all electrical equipment, controls, instrumentation, civil defence systems, and accessories required for the proper performance of the entire Project as specified and implied in the Contract Documents. The tender drawings shall be considered as a guideline only. The contractor, when reviewing the plant layout and the auxiliary systems, shall have due regard to ease of operation, maintenance, repair, replacement and access to the various components of the plant.

3.1.2 Design A.

B.

C. D.

E.

F. G.

H. I.

Drawings show a general arrangement of the plant, providing space for a wide range of equipment. If the Contractor proposes any departures from these layouts then such alterations shall be shown separately on drawings to be submitted by the Contractor together with his tender. When designing the plant, the Contractor shall prepare his own technical calculations and plant process for all systems of the plant, which shall be subject of approval by the engineer and shall be in detail, but not limited to: a. Electrical load schedule b. Sizing of all electrical conductors c. Illumination calculation d. Sizing of all supports/trays, conduits/trunking, Trenchs e. Lightning/earthing calculation and dimensioning f. Sizing of MCC g. Fire detection, protection and fire barriers h. Any other documentation as required by the Engineer MCCB, MCB, Contactor, capacitor bank shall have minimum provision of 20 % extra capacity for future extension of pumps. Sufficient space shall be provided for easy maintenance and repair of plant and special care shall be taken to enable easy removal/replacement of equipment and/or part of it without using temporary supports. All instruments connected to equipment with rotating / oscillating parts or to other equipment and pipes where vibration can be expected must be isolated against vibration transfer by means of flexible connections. All the electrical equipment shall meet the requirements of electromagnetic compatibility and shall have certification CE marking All electrical equipment, switches, push buttons, other electrical appliances, etc. installed in the pump rooms or exposed to immersion in water / sewage shall be of the watertight type protection class IP 68 unless otherwise mentioned. All outside installed electrical switches, isolator, junction box, push button stations etc. shall be protected with GRP UV resistant sunshade as per design approved by the engineer. Pipes, cables, etc. shall not be supported by any other pipe, cable, equipment and installation.

3.1.3 Electricity Supply Electricity supply shall be provided by the Abu Dhabi Government, Water and Electricity Authority (ADWEA) or other concerned authority with: a. Nominal voltage 415 / 240 Volts b. Frequency 50 Hz c. Phases 3 phase (4 wire) d. Fault level 50 k.A for 1 second. e. Voltage tolerances +/- 10% f. Frequency tolerances +/- (0.1 Hz in normal conditions – 1.5 Hz in steady state disturbed conditions – 3 Hz transient disturbed conditions) All electrical equipment and material shall be designed for continuous and satisfactory operation at above power data and specified ambient conditions. Contract 106, Volume II

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3.1.4 Protection A. In accordance with DIN 40 050, latest edition, the degree of protection for all electrical equipment supplied and installed under this contract shall be as listed below unless otherwise specified: Plant

E- Motors

Installatio n

Class

Submersed installation or subject to being submersed

IP68

Dry or indoor installation Outdoor installation High hazardous areas

Switchgear panels, junction box es, single isolators

Small power

Indoor installed Outdoor installed Indoor / outdoor subject to Indoor subject to immersion or In non industrial and non In industrial areas Outdoor

ex.-proof in the appropriate class of protection

In hazardous areas

Instruments

Submersed or subject Indoor installation Outdoor installation In hazardous areas

IP 54 IP 55 Ex.-proof in the appropriate class of protection for sewage pumps / macerator and where required. IP 54 IP 65 IP 68 IP 68 IP 44 IP 54 IP 65

to

IP 68 IP 55 IP 65 Ex. proof in the appropriate class of protection

B. The grade of protection for low voltage switchgear and control gear assemblies shall be IP 54 in accordance with BS EN 60439-1 Amend 2© 1996 Form 4b – type 6.

3.1.5 Approval of ADWEA (OR OTHER CONCERNED AUTHORITIES) A. The specifications, design, workmanship, manufacturer and material of all electrical components shall be subject to the approval of the Abu Dhabi Water and Electricity Authority (ADWEA). It shall be the Contractor's sole responsibility to acquaint himself with the conditions and requirements of ADWEA before preparing his designs. The Contractor shall obtain ADWEA’s written approval for his design, including but not limited to single line diagram(s) (showing all the proposed equipment with their detailed specifications) before submitting his proposal to the Engineer. B. The Contractor shall be responsible for the design, manufacture, supply and installation of all cables required for the power supply to the plant . He shall contact the ADWEA in order to apply, in the name of the Department, for the power supply from the ADWEA network and to obtain the approval of the installation including all connecting cables and shall co-ordinate with ADWEA for the survey of power supply, preparation of estimates, installation work including installation of kWh meter, release of power supply etc. C. The payment for power supply including inspection, services charges, testing and kWh meter shall be made by the contractor, all costs shall be deemed in the contractor rates in the B.O.Q

3.1.6 Derating Factor The Contractor shall ensure that all electrical equipment operates satisfactorily under Abu Dhabi o o climatic conditions i.e. 50 C, 100% humidity and at ambient temperatures up to +85 C inside the panels. The equipment, cables and wires shall be derated by the appropriate factors given in the latest issue of I.E.E. regulation, UK.


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3.1.7 Electric Motors A. Motors shall comply with the appropriate part of BS 4999 and BS 5000 or equivalents. Motors for use in all categories of potentially explosive atmospheres, as defined in BS 5345 or equivalent, shall have the appropriate BASEEFA/CENELEC or other similar National Testing Organisation Certification. Copies of the Certificates shall be submitted. B. Unless otherwise required by the Contract, motors shall be suitable for use on a 415V (± 6%) 3 phase, 50Hz (± 5%), or where specified -240v, 1 phase, 50 Hz electricity supply system. C. Motors shall be of low loss, energy efficient, high efficiency squirrel cage induction type. D. Vibration levels of the installed motor, in the coupled state, shall not exceed the vibration levels laid down in the manufacturer’s standard documentation - Vrms . E. All motors shall be capable of starting 10 times per hour. The stalled motor current shall not exceed 6 times full load current. F. Where motors are driving a pump fitted with a flywheel, then mechanical protection shall be provided through a sheer pin arrangement built into the flywheel. G. The maximum continuous rating (MCR) of each motor shall be as set out in Table 1 and shall be rated and designed to suit the climatic data stated in the general section of this specification. This reserve power requirement shall be added to the calculated power prior to any other adjustment e.g. high ambient temperatures at Site. TABLE 1 MCR RATINGS Application

Up to 75 kW drive

Above 75 kW drive

All pump motors (excluding positive displacement type)

10% above that required under all conditions of operation

Positive displacement pumps and compressors

25% above max. duty requirements

Aeration Cones

25% above power required for maximum immersion. This applies to all motor ratings.

All other drives including screens comminutors detritors tank scrapers etc. and process plant

25% above normal duty requirements

10% above requirements

normal

duty

H. Motors shall be capable of continuous operation under all duty conditions at:  Maximum brake power absorbed by the driven load not less than that stated in Table 1 above.  Maximum rated torque without adverse affect or overheating. I. Where flywheels are fitted to the main pump set, the motors shall be capable of starting and driving the pumps under these conditions. J. Motor characteristics shall allow starting of the motor by employing variable frequency drive and/or electronic soft starters, ensuring compatibility at all points in the operating range and de-rated accordingly with particular attention being given to the following: Heating carried by harmonics in the non-sinusoidal waveform produced by the inverter or soft starter.  Reduced cooling at low motor speeds due to the reduced effectiveness of the cooling fan. K. Rating plate information, as detailed in BS 4999 Part 101 or equivalent shall be embossed on a metallic, corrosion-resistant rating plate fixed to the motor casing. L. The motor and all components shall be rated and braced to withstand the maximum prospective fault level at the point of installation as detailed by the Contract. M. Unless required by the Contract, motors shall have a maximum speed corresponding to 4 pole construction at 50Hz. Where super synchronous operation is required, full details of the motor capability at maximum speed shall be advised.

3.1.8 Starting Current Requirements A. The motor shall be selected to satisfy the performance requirements and shall also comply with the water & Electricity authorities starting current restrictions, as detailed in the specification.


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3.1.9 Construction 3.1.10Motor Enclos ures A. Motor enclosures shall be selected from BS EN 60034-5 as follows:a. For submersible applications the enclosure shall be IP68 and be capable of being continuously submersed to a depth of at least 2 metres greater than the maximum immersion depth of the application. Where such motors are to be installed in an area designated as potentially explosive then it shall have the appropriate BASEEFA/CENELEC or other similar National Testing Organisation Certification. Copies of the Certificates shall be submitted. b. For indoor applications the enclosure shall be to IP54 of BS EN 60034-5. Immersible pumps that are to be installed in dry wells shall be to IP 68 of BSEN60034-5. c. For outdoor application the enclosure shall be to IPW55 of BS EN 60034-5. A certificate shall be issued by the manufacturer certifying the motor suitability for the out door application, in the service conditions as described under the general section of this specification. d. For high voltage motors the enclosure shall be protected to IP55 of BS4999 Part 105 B. Unless stated otherwise, stator frames shall be of cast iron, foot and flange mounted as required by the Contract. Aluminium frames are permitted for 2.2 kW motors and smaller only. Stainless steel frames shall be used, when specified, for aggressive sewage conditions, and shall be of grade 316L minimum. C. Lifting facilities shall be provided on all motors D. Submersible motors shall be protected by a tandem mechanical seal arrangement. Lip seals are not permitted. The Contractor shall provide complete data on the seal materials, seats, faces etc., and ensure suitability for the medium being sealed i.e. oil chamber, oil and supernatant. E. On pumps greater than 2.2 kW the mechanical seal performance shall be by monitoring equipment to detect the following:a. Moisture within the oil chamber. b. Moisture/water or oil within the motor casing. c. Temperature rise of the hydraulic driven end bearing. d. Loss of oil from the oil chamber.

3.1.11Motor Cooling A. Non-submersible motors shall be air cooled to IC 41 of BS EN 60034-6. B. Cooling of submersible motors shall be provided by one of the following methods with the contractor supplying and installing all of the necessary equipment:a. On units of less than 7 kW cooling may be provided by the casing provided that the application meets the manufacturer’s requirements for heat dissipation. b. Water jacket utilising treated effluent water or similar as the cooling medium. A filtering gap shall be provided to prevent large solids blocking the cooling passages. This cooling method is not permitted for sludge pumps. C. For immersible motors may be fan cooled.

3.1.12Motor Windin gs A. Motor windings shall be copper and treated to render them impervious to moisture, saline atmospheres, acid/alkaline fumes, oil and grease. They shall be adequately braced to prevent movement of coils during all conditions of service and be insulated throughout to Class F of BS 2757 or equivalent with a temperature rise limit of Class B. This provision shall be in addition to any o adjustments necessary for ambient temperatures at site of 55 C B. Motors operating voltage and connection type shall be clearly stated on the motor nameplate. C. Motor winding connection in motor terminal box shall be as per starting method, detailed in motor starter specifications D. For high voltage motors, the stator windings shall use a modern synthetic resin insulation system based on mica glass tape continuously wound on the coils to give a void-free homogeneous structure. The end windings shall be securely braced to prevent harmful movement arising from electro-magnetic and mechanical forces. The rotor bars shall be securely keyed into the rotor. The rotor shall be shrunk and keyed onto the shaft.


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3.1.13Thermal Protecti on A.

B. C.

D.

Class II thermal protection as defined in BS 4999 Part 111 or equivalent shall be provided on motors rated at 11kW and above and on all motors used with variable frequency/variable speed drives. A minimum of 3 no. PTC thermistors shall be incorporated in each motor. Refer to section ‘FBA’ motor starters and MCC for the type of motor protection. On motors rated at 55kw and above, two sets of thermistors shall be provided, one for alarm and one for trip functions. Additional continuous temperature monitoring shall be provided for motors rated above 250 kW. On submersible pump motors thermostats and/or thermistors shall be included, but preferably thermistors., as appropriate to the design. Where thermostats or thermistors are used in explosion proof designs, the devices must be of the same type used to obtain the potentially explosive hazardous area motor certification.

3.1.14Ant i-Condensati on Heaters A. All three phase motors, (except for submersible motors, or single phase motors less than 2.2 KW), shall be fitted with anti-condensation heaters of an appropriate size to maintain the temperature of o the windings 5 C above ambient.

3.1.15Terminals and termin al boxes A.

B.

C.

D.

E.

F. G.

H.

Terminal boxes shall be cast iron and shall be designed to accept XLPE or PVC armoured cable as detailed in the Contract. On non-submersible motors, terminal boxes shall be mounted on the right hand side when viewed from the driving end of the motor, unless otherwise required by the Contract. The motor stool base where appropriate shall be drilled at works vertically below the terminal box gland for the passage of the cables and the edges of the hole slightly countersunk or the hole bushed. Terminals shall be stud-type, substantially designed, anchored to a carrier terminal block and insulated from the motor frame. Terminals shall be identified in accordance with BS 4999 Part 108 or equivalent. A separate earth stud shall be included on each terminal box. Heater terminals shall be shrouded. Adequate space and glanding arrangements shall be provided, particularly on smaller motors requiring glanding and terminating of steel wire armoured cable for star/delta starting, anticondensation heating and thermistor winding protection devices. Where a common terminal box is used for main, heater and thermistor cable terminations, a permanent warning label shall be fixed to the terminal box cover. In addition, heater and thermistor cable terminations shall be clearly marked to identify their separate functions and operating voltages. Terminal box covers shall be gasketted to provide a degree of protection equivalent to or better than that of the motor. For Ex 'd' flameproof motors, terminal boxes may employ Type 'e' increased safety protection, utilising indirect cable entry to the flameproof enclosure. However, this must be of the same type used to obtain the potentially explosive hazardous area motor certification. 3.3kV motor cable termination boxes shall be high fault level type, with segregated phases, pressure relief diaphragm and sealing chamber.

3.1.16Submersible Motor Cables A. B.

C.

Submersible motors shall be complete with lengths of flexible cable for Power, Signalling and Protection purposes. Each cable shall be a minimum of 8 metres long or as otherwise required by the Contract, and shall be rated in accordance with the cable routing details. Cables shall be continuously rated to carry the motor full load current when laid in a classified area to the approval of ADWEA. The cable shall be 3 cores only and factory fitted according to the connection of the motor winding and type of starting method. Flexible cables for use in potentially explosive atmospheres shall be identical to those types used to obtain the potentially explosive hazardous area combined motor/cable certification. Where protection cables are part of an intrinsically safe circuit the outer sheath shall be coloured blue.


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D.


Jointing of cables is not acceptable.

3.1.17Bearings A. B.

C.

D. E. F.

The motors shall run in ball and/or roller bearings and the weight of the motor shall be carried by thrust bearings incorporated in the motor body. Maximum life bearings with oil seals shall be fitted to both drive end and non-drive end bearing housings to prevent ingress of solid particles and liquids. Bearings shall be in accordance with BS 292 or equivalent. Bearings shall be grease lubricated and shall be fitted with a means for replenishing the grease and a relief device for disposal of excess grease. Hydraulic button head grease nipples in accordance with BS 1486 Part 2 or equivalent shall be provided and shall be extended, where necessary, such that they are located at the top of the frame. Re-greasing points shall be located for ease of access. Bearing temperature monitoring facilities shall be provided on submersible motors over 100kW and on non-submersible motors over 250kW. “Sealed for Life” bearings shall not be used except for small motors. Where required, large machines shall be provided with insulated bearings to prevent bearing failure due to circulating rotor currents.

3.1.18Noise Levels Unless otherwise required by the Contract, the noise levels (Sound Power Levels dB(A)) of the motors shall be in accordance with BS EN 60034-9.

3.1.19 Paint Finish The paint finish shall be entirely compatible with the environment to which the motors will be subjected. This shall consist of an anti-corrosion primer/undercoat with a 2 part heavy duty epoxy resin paint or such other paint finish determined by the application, and as detailed in the specification for Corrosion Protection.

3.1.20Electr o – Magnetic Compatibi lit y 3.1.21 Regulations A.

B.

C.

Ensuring electrical component, equipment and systems supplied are safe and does not interfere with the normal operation of other equipment is the basis for Electromagnetic Compatibility regulation. Low Voltage Directive 73/23/EEC; shall apply to electrical equipment designed for use at a rated voltage of 50 to 1000 V for alternating current and 75 to 1500 V for direct current. Rated voltage shall refer to the input or output voltage of the equipment and not voltages which are generated internally. The electro-technical product shall also meet the requirements of other applicable directives in addition to the Low Voltage Directives. The compliance of individual components with the requirements of appropriate European Norms (EN) does not imply compliance of the end product. End product testing ensures that interconnections as well as manufactured CE marked components are performing to what is formally stated in their declaration of conformity.

3.1.22 EMC: Electrom agnetic Compatibil ity A.

B.

C.

EMC is the ability of different items of electrical equipment to work together without suffering the effects of interference. All equipment shall operate without interfering with broadcast and communications signals and be immune to normal levels of such signals. EMC implies that equipment shall not generate unacceptable levels of interference, which affect the performance of other products designed to operate in the same environment. Also, equipment shall have sufficient immunity to electrical interference, such that the equipment continues to operate in an acceptable manner. The contractor shall submit a certificate issued by the manufacturer that the electrical equipment's supplied against the contract under execution complies with the requirements of the EMC Directive.


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3.1.23 The CE Marking A.

All electrical products shall have CE Marking as an EU recognised certification mark that confirms the product has been tested and complies with the European Union Electromagnetic Compatibility Directive and other relevant directives, standards or norms.

3.1.24 EMC Direct ive and Standards A.

B. a. b. c. d.

The electro technical products shall be designed and constructed that do not cause excessive electromagnetic interference and are not duly affected by electromagnetic interference. Electrical products shall carry a CE mark and manufacturers 'Declaration of Conformity'. There are four generic standards: EN 50081-1 1992 EMC - Generic emission standard - Part 1. Residential commercial and light industry. EN 50081-2 1993 EMC - Generic emission standard - Part 2. Industrial environment. EN 50082-1 1997 EMC - Generic immunity standard - Part 1. Residential commercial and light industry. EN 61000-6-2 1999 EMC - Part 6-2: Generic standards - Immunity for Industrial Environments.

3.1.25 Recom mendation s For Reducing Interference A.

a. b. c. d. e. f. g.

The Contractor shall exercise the manufacturer's recommendation for reducing interference. Following is basic guidelines for ready reference that helps reduce radiated interference by screening of the equipment and cables. The conducted interference can be reduced by filtering the main supply. Keep all cables as short as possible Separate power cables and signal cables from each other and from different equipment Shield the mains cable to the welding equipment if any Apply earthing and equipotent bonding to the welding installation Connect the equipment to a separate mains supply spur or using a different phase Physically separate welding equipment from other equipment Weld at times, which cause minimum disruption.

3.1.26 EU Product Direct ives A.

B. a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. C.

The EU product directives deal with large families of products or horizontal risks such as those addressed in the Electromagnetic Compatibility Directive. The manufacturer and exporter are responsible for ensuring the product meets the requirements for all applicable directives. The following directives (with the reference between brackets) have been adopted: Low Voltage (73/23/EEC) Simple Pressure Vessels (87/404/EEC) Safety of Toys (87/378/EEC) Construction Products (89/106/EEC) Electromagnetic Compatibility (EMC) (89/336/EEC) Machine Safety (89/392/EEC) Personal Protection Equipment (89/686/EEC) New Hot-water Boilers (92/42/EEC) Gas Appliances (90/396/EEC) Explosives for Civil Uses (93/15/EEC) Recreational Craft (94/25/EC) Non-automatic Weighing machines (90/384/EEC) Active Implantable Medical Devices (90/385/EEC) Equipment for Explosive Atmospheres (94/9/EEC) Telecommunications Terminal Equipment (91/263/EEC) Most of the above-mentioned directives are amended by Directive 93/68/EEC, "Rules for the Affixing and Use of the CE Conformity Marking."

3.1.27MCC, LV Switch boards and Contro l Panels 3.1.28 Design And Cons truction A.

The term FBA used in the following means Factory Built Assembly


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B.

C. D.


The LV Assemblies shall be Totally Type Tested, conforming to the requirements of BS EN 60439 (IEC 439), designed in the form of floor standing Multi-cubicle-type containing modularized Incoming and outgoing units. There shall be a separate section for Busbars and cables. All functional units’ incoming and outgoing shall be housed in a separate compartment. All FBA’s shall consist of number of cubicles of equal height and depth mounted side by side to form a composite board of uniform appearance. Assemblies shall be front access only, unless specified otherwise constructed such that doors and covers are flush with one another and aligned to a common vertical plane; manufactured out of mild steel coated with Alu Zinc having the following thickness:

Plinth/bed frame Frames Covers and Doors Mounting plate Gland Plate

- 3.00 mm - 2.00 mm - 2.00 mm - 3.00 mm - 3.00 mm

E.

All except mounting plates shall be Epoxy Polyester Powder coated to BS 4800 shade 18E51 Blue. With a minimum thickness of 0.075 mm. The mounting plate shall be white.

F.

All plastic parts used within the assembly shall be of flame-retardant and self extinguish type and halogen free.

3.1.29 Test Specifi cation s and Certifi cation s A.

B.       

C. D.

E.             

F.

Type Tests : The LV Assemblies shall be Totally Type Tested by INDEPENDENT and Internationally recognized testing authority such as ASTA/KEMA in accordance with clause 8.2 in BS EN 60439-1. Following tests must be conducted and supported by the relevant certifications. Verification of temperature rise limits. Verification of dielectric properties. Verification of short-circuit withstand strength. Verification of effectiveness of the protective circuit. Verification of clearances and creepage distances. Mechanical operations test. Verifications of the degree of protection (IP Code) Should there be modification to any components of the LV Assembly, NEW Type Tests have to be carried out and supported by relevant Type Test Certificate. Routine Tests : The LV Assemblies shall be Routine Tested at a place of assembly in accordance with clause 8.3 in BS EN 60439 to ensure all material and workmanship free from faults. Tests to be carried out on all new as delivered Assemblies and their transport/shipping sections. Following tests must be conducted and supported by the relevant Factory Tests certifications. All mechanical parts, lifting arrangement Wiring, cabling and termination details Dimensional details Components specification Internal and external supports and structure Engineered drawings, documentation and application development software. Operational test and sequence of operation. Primary and secondary current injection test on all protective devices. Checking of electrical continuity of all protective circuits Dielectric test Insulation resistance test All other tests as recommended by the manufacturer Additional tests as instructed by the engineer The performance of routine tests so conducted at the manufacturer’s works shall not relieve the supplier/manufacturer of LV Assembly of the obligation of repeating all tests at site upon completion of the installation.


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3.1.30Park Ligh ting 3.1.31 General Reference shall be made to ADM Lighting Specifications for parks, public realm and architectural st lighting. Rev 0, 1 Nov 2011. All control cabinets, cables, lighting masts including holding down bolts with nuts and washers, brackets, luminares, flood lights, lamps, service cut-outs and appurtenances will be supplied, delivered, installed, tested and commissioned by the contractor. The Contractor shall be responsible for the complete Park lighting installation, including liaising with the ADM to ensure that the control cabinets are energized and lighting fittings made operational. This should include engineer approval of shop drawings and obtaining clearance and inspection certificates from ADM. The Contractor shall supply and install all cabling and warning tapes required for the park lighting starting from the lighting control cabinet to the end of the lighting circuit. The Contractor shall be responsible for the civil works of the park lighting system (except as otherwise specified) the layout for which is shown on the drawings. The works include also the provision and installation of duct crossings for service cables. The installation of ducts to the required diameter shall be according to site requirements and engineer’s approval. The Contractor shall liaise with the Abu Dhabi Municipality Engineer and co-ordinate his activities where appropriate, with the Abu Dhabi Distribution Company. Materials and equipment shall be suitable for use under the prevailing conditions of a harsh environment as per the requirements of the ADM Lighting Specification. In calculating the rating of electrical cables, switch-gear and all items of equipment, the necessary derating factors shall be determined and applied to ensure that the equipment will operate satisfactorily and meet its design criteria. All quantities shall be confirmed after the approval of shop drawings. The incoming electrical supply shall be 400 volts, 3-phase, 4 wire, 50 Hz. The distribution shall be 400V 3-phase or 230V single phase as per the requirement. Lighting study for different cases shall be submitted with the proposed luminaires for approval.

3.1.32 Design Requierements As part of the design process for the park lighting installation, the Contractor shall carry out the following duties:• submit details of all materials required for the contract for review by the Consultant and Client approval. • investigate the Contract site, survey, trial pits, liaison with utility authorities to verify all site conditions and location of existing utilities services. • prepare lighting case studies for all conditions on the Contract , all types of layout, different options for pole height, luminaires types, luminaires layout, angle of tilt etc to meet the international standards, contract specifications, ADM Lighting Specification and Estidama. • prepare working drawings in digital format showing pole locations, types, luminaires arrays, cable routes, control cabinet locations, power supply routes, ducts and standard details etc.


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• prepare of single line wiring diagrams, pole and foundation structural calculations, voltage drop calculations, load schedules for all approved installations. • revise and update designs and drawings as necessary due to obstructions which shall be subjected to client approval and instructions.

3.1.33 Reference Standards The installation shall comply with: Relevant British Standards and Codes of Practice, or equivalent as approved by the Engineer. Standards and Recommendations issued by the International Electro-Technical Committee. ADWEA Electricity and Water latest Regulations and the general requirements of the local supply authority. Chartered Institution of Building Services Guide Book (IES) for external lighting. CEI , VDE. International Commission of Illumination (CIE) recommendations on lighting. In particular, the street lighting installation and equipment shall be in accordance with the standard Abu Dhabi Municipality/ADWEA Specifications: All Standards and Codes referred to shall be the latest issue at the time of invitation to Tender.

3.1.34 Main Power Supply Power supply to control cabinet shall be supplied from MDB/SMDB/Feeder Pillar / Service turret, covered by other section of Contract. Contractor shall make necessary survey to decide closer place to the power source before proceeding with shop drawing. The work will not be considered as completed unless the power supply to the system is provided. The maximum permissible voltage drop from substation to control cabinet is shall be as per the latest ADWEA’S wiring regulation, edition 2007. Power supply cables to the Control cabinet shall be provided with protection tiles and warning tape. For each Park lighting cabinet the required number of circuits of 6, 10, 16and 25 sq.mm 4 core CU/XLPE/SWA/PVC cables shall run as per the approved scheme. Cables shall be provided with warning tape.

3.1.35 Check of Third-party Equip ment The Contractor shall ensure that all equipment supplied by others forming part of his installation shall be new and in accordance with the standards required. Any defect must be reported in writing within seven days of receipt of the equipment in order to allow changes to be made or replacements instructed by the Engineer and agreed with the client.

3.1.36Cables 3.1.37 Distribution Cables All cables accessories and materials shall be of the best quality and most suitable for local climatic conditions and shall be such that the cable shall withstand without damage, any conditions arising from short circuits, switching operations and sudden variations of load and voltage as may be met under normal working conditions. The cable shall be suitable to be buried directly in saline soil. The Contractor shall submit for approval a sample cutpiece of each type of cable and one metre length of any cable size with the required embossment or with non erasable print. The materials are to be Contract 106, Volume II

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accompanied by manufacturers’ installation instructions. This specification provides for manufacturing, testing of four core power stranded copper conductor XLPE/SWA/PVC cable, rated service voltage 600/1000 volts. ADM approval shall be submitted for any cable used in this contract. Priority will be for the local cable then for GCC cables.

3.1.38 Conductors The conductors shall be stranded plain annealed copper in accordance with IEC Publication 228: Conductors of Insulated Cables or BS 6360:1981. The conductors shall comply with the test requirements mentioned at Clause 9 of BS 6360:1981 and test certificates from independent authorities / labs shall be submitted.

3.1.39 Insulation The insulation shall be XLPE (GP8) complying with table 16 of BS 5467:1989 and BS 6899 in addition to IEC Publication: 502:1983 Table III. Test Certificates from independent approved bodies / authorities to be submitted prior to delivery to site. The insulation thickness shall comply with BS 5467:1989 Clause 6, Table 16. Core insulation colors shall be Red-Yellow-Blue-Black. The insulation shall meet the Test Requirements mentioned in the following standards:Clause 20 of BS 5467:1989 relating to compatibility. Clause 5, Table 5 of BS 5467:1989 relating to insulation.

3.1.40 Bedding The inner sheath shall be black extruded PVC bedding complying with the requirements of BS 5467:1989 and BS 6746:1984 for type 9 compound or IEC Publication: 502:1983.

3.1.41 Fillers And Binders Non hygroscopic synthetic fillers to be applied integrally with the bedding in accordance with BS 5467:1989 Clause 8 and IEC Publication: 502:1983 to form a compact and circular cable. The fillers and binders shall comply with the compatibility test given in Clause 20.1 of BS 5467:1989.

3.1.42 Wire Armour The armour shall consist of a single layer galvanised steel round wires of appropriate size mentioned in Table 16 of BS 5467:1989. The armour wires must cover the entire periphery of the inner sheath as per BS 5467:1989.

3.1.43 Armour Tests Samples of galvanised steel armour wires shall be tested for mechanical strength and electrical conductivity and resistance in accordance with BS 5467:1989, and BS 1442:1969, respectively. Testing requirements for zinc coatings on steel wire and for quality requirements shall comply with BS 443:1982. Test Certificates from independent approved authorities/laboratories shall be submitted prior to delivery to site.


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3.1.44 Over sheath The over sheath shall be PVC complying with BS 6234:1987. Thickness of over sheath should comply with BS 5467:1989, table 16 or IEC Publication 502:1983.

3.1.45 Testing Of Cables Tests on the complete cable shall be carried out according to the schedules given in Table 5 under Clause 15 of BS 5467:1989. Test Certificates from independent approved authorities / laboratories shall be submitted prior to delivery to site.

3.1.46 Earth Cable This specification provides for manufacturing and testing of single core stranded copper conductor PVC cable (non-armored). The cable, in general, shall comply with BS 6004:1984.

3.1.47Low Voltage Flexibl e Power Cables for Conventio nal Lighti ng Columns and Luminaires 3.1.48 General The following specifications are for manufacturing, and testing of circular, flexible, copper conductor, confirming to harmonized code H05 VV-F, 300/500 Volts grade, PVC insulated, sheathed cable rated for 85 deg. C. as per BS 6500 and BS 6746, which is to be used inside the lighting columns between luminaires and service Cut-out. An extra loop of at least 200 mm length shall be provided near the service cut-out for future use. The Priority will be for local made then GCC made

3.1.49 Conductors The conductors shall be stranded plain/tinned annealed copper in accordance with BS 6360:1981 class 5 flexible conductor. The conductor shall comply with the test requirements mentioned in BS 6500:1990 and test certificates from independent authorities/labs shall be submitted.

3.1.50 Insulation The insulation shall be PVC insulation complying with BS 6500: 1990 suitable for 105 deg. C. Test Certificates from independent approved bodies/authorities to be submitted with the offer as evidence. The insulation thickness shall comply with BS 6500:1990 Table 16. Core insulation colours of each core shall be as per Table 16 of BS 6500:1990. The insulation shall meet the Test Requirements mentioned in BS 6500.

3.1.51 Sheath Type : The sheath shall be PVC type TM2 complying with the latest edition of BS 6500. Thickness: Thickness of sheath should comply with Table 16 of BS 6500:1990.


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3.1.52 Testing Tests on the complete cable shall be carried out according to BS 6500: 1990.Test Certificates from independent approved authorities/laboratories shall be submitted with the offer as evidence.

3.1.53 Cable Identif icatio n Cable identification shall be according to BS 6500:1990.

3.1.54 Protection Where the flexible cables pass through metallic hole openings, an approved rubber/plastic gasket shall be provided, securely attached to the metal work to ensure adequate cable protection.

3.1.55Street Ligh tin g Service Cutout 3.1.56 Application The street lighting service cutout are required to be installed at the base of columns (poles) for protecting the luminaires fixed at the top of the columns against short circuits.

3.1.57 Rating The service cut-out shall be rated at 400V/240V, 50 Hz. operations, at 50 deg.C amb. temp. and 95% relative humidity.

3.1.58 Standard The street lighting service cutout shall conform to the provisions of BS: 5486 (Part I) - 1977 or IEC 439.

3.1.59 Construction The general arrangement of the street lighting services cutout along-with dimensions and materials of construction shall be indicated on the Contractor’s shop drawings. The street lighting service cut-out shall consist of: - Housing with cover - Protection MCBs of required rating between 6A to 16A and with a minimum breaking capacity of 10kA for 230V - Terminal Blocks, R, Y, B, N - 2 Brass cable glands with shrouds, for sizes mentioned in the BOQ 2 earth tag - 20-10Amps, 230 volts contactor – 3 Nos for Poles feeding tennis court,Basket ball court and play area. Each cable terminal assembly shall be capable of accepting 2 Nos. sector shaped copper cables of not less than 35 mm² each. All terminal parts shall be made from materials which are not subject to develop corrosion when used in combination with each other. A high quality flexible phase insulating barrier shall be provided between all terminals as well as on both sides of the end terminals. The phase barrier shall protrude sufficiently on all sides of the terminal to ensure electrical safety. Brass cable glands shall conform to B.S. 6121 and shall be type BW, complete with lock nut. They shall be mounted together with a 1 mm thick tinned copper plate, linking them together. The copper plate shall be bonded to an external earth stud and to the earth bar.


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3.1.60 Housing The housing shall consist of a base plate, holding all components and glands, and a removable cover. The material shall be hot dipped galvanized, as detailed in Clause 11.3. The plate shall be 2.5 mm thick and the cover 1.5 mm thick. Protection class shall be IP 44. The base plate shall have 2 Nos. rear fixing holes of 7 mm diameter. The cover fixing screws shall be captive.

3.1.61 Testing The cutout shall be tested as per the provisions of BS: 5486 Part 1: 1986 and IEC 439-1: 1985 Clause 8, and routine test certificates shall be submitted for Engineer's approval.

3.1.62 Materials to be subm itt ed wit h the off er Each contractor shall submit with his offer three numbers of each type of cutout required for, and fully assembled. The materials shall be accompanied by manufacturers operating instructions.

3.1.63Ligh tin g Contro l Cabinet 3.1.64 General This section contains a description and the specifications for the lighting control panels as indicated on the drawings, described in the Bill of Quantity and as specified herein: The cabinet shall contain all the electrical components necessary for automatic lighting of luminaires in night hours or poor light conditions. All components should be high quality and shall come from original country with certificate of origin. All ratings specified for bus bars, circuit breakers and components are the continuous currents at an enclosure temperature of 60°C. Lighting control cabinet shall be two types as required on site

3.1.65 Type A Incommer, 100A MCCB fixed type, more than 50 KA sort circuit with adjustable thermal protection from 0.8 to 1 Outgoing contactors for each outgoing –AC1 30 Amps. Outgoing MCCB 30A, TP, 400V, 15KA, Each going circuit shall be protected with ELCB 40 Amp, 100 mA Dropper busbar as 10x5mm Size of busbar shall be as per type test certificate for fault level of 46 KA for one second Other mentioned specifications will be considered as type B.

3.1.66 Equipment Housing Control cabinets shall be manufactured from hot moulded, glass fiber reinforced, self extinguishing polyester and UV stabilized for outdoor applications. They shall be free standing and be protected to IP55 according to IEC Publication No. 529. The cabinets shall be mounted on reinforced steel concrete bases with provision for cable entry through the bottom of the panel. The external side of the cabinet shall be protected from weather agent by adequate gel coat layer containing the colour pigment (light gray) unless different colour is required for the contract. The wall thickness shall not be less than 4.5mm on side and more than 6.0mm at load bearing points. All metallic parts used in the cabinet, including but not limited to bolts, nuts, latches and glanding plates shall be totally non-corrosive in the environmental conditions prevailing at Emirate of Abu Dhabi. The cabinet shall be installed directly on the leveled concrete foundation with anchor bolts, if installed Contract 106, Volume II

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outside or on steel frame if inside in the room with galvanized/stainless steel nuts.


extra wide flat washers, spring washer and

Double doors shall be provided which can be securely locked. Access shall be from the front only. Components shall be mounted on a rear mounting plate with ample room for maintenance. No components or projections will be permitted on the cabinet or the doors except for the installation of a photoelectric cell. All non-current carrying metal work shall be properly bonded to earth. At no point in the system shall the resistance to earth exceed 1.0 Ohm. This excludes the actual resistance to earth of any earth rods which are outside the scope of this project. The armouring of the cable shall be bonded to brass lugs and solidly earthed. The armouring shall be earthed at both ends of the cable. The cabinet shall be certified to withstand 46KA r.m.s. for one second and a Short Circuit Test Certificate shall be submitted with the shop drawings. The enclosure shall have 8 louvers (ears) for diagonal ventilation. Prevention of the ingress of dust through louvers shall be provided to maintain the degree of protection of IP55 of IEC 529. The colour of the enclosure shall be beige (RAL 7032). A pre-fabricated sloped canopy of suitable dimensions shall be provided to protect the cabinet from water and direct vertical sunlight shall be provided. An air gap not less than 1.5 cm shall be present between the canopy and the cabinet for ventilation. The cabinet doors shall be pad lockable. The pad lock and master key shall be supplied. In addition to pad locks two separate latches shall also be provided with the doors, one (with right panel) lockable with key and another (with left door panel) internally lockable sliding bolts. The door locks shall be stainless steel Grade AISI 316 or gun metal and the key entry shall be dusttight. The enclosure shall have toughened glass window for photo cell. A metal pocket for the schematic diagram and the "As-Built" diagram shall be provided in the enclosure door. The diagram shall not be stuck to the enclosure. The doors shall be designed in a manner that opening of 120 degree (with stopper) can be attained to allow maximum access for cabling and maintenance. An anodized aluminum long life label 30x30cm with danger logo, preferably dual colour, bearing "ADDC" in both Arabic and English, and "SLCC" shall be attached to the door in a proper location and firmly attached with rivets. The circuit numbers shall be fixed firmly with rivets or other acceptable system. The sticked one with glue is not acceptable. All hinges are to be gun metal or stainless steel and three hinges shall be provided for each door. The enclosure shall be provided with a door switch-operated internal illumination lamp circuit complete with 26 watt, self-contained control gear, compact fluorescent lamp suitably protected from accidental damage and located in the top side of the panel. Six numbers of openings in the bottom plate anchoring the control cabinet to the concrete foundation shall be provided. Dimension, location and size of anchor bolts to be used is to be specified. The controller housing panel shall allow building up equipment complying with IEC 439 and BS 5486 Part1:1990. All devices and equipment shall be accessible from the front of the panel. All hinges and locks are to be stainless steel and easily removable / replaceable. The panel shall be provided with a removable 3 pieces of gland plate at the bottom to fix compression type brass glands along with earth tag. All incoming and outgoing cables shall enter and leave the cabinet at the bottom.


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Cable gland entry holes are to be factory punched and are to be the knockout type or sealed with appropriate rubber cover. The number of cable entry holes shall be one for incoming, for outgoing as per requirement and shall be according to the cable size. Two lugs of appropriate dimensions shall be fixed on the top/sides of the cabinet for easy handling. ASTA Test certificate should be available.

3.1.67 Type B Circuit Breaker (Incoming MCCB) There shall be one moulded case circuit breaker for the incoming feeder to each control panel. The MCCB shall be rated at 225 amp (100A for type A) for three phases, 400V A.C., 50 Hz. to IEC 157-I and BS EN60947-2:1992 specifications as indicated on the drawings. The MCCB shall be adjustable between 0.7 to 1.0 times of rated current. Moulded case circuit breakers shall be suitable to accommodate auxiliaries and under-voltage release. They shall be of the thermal magnetic type with a short circuit capacity withstand of not less than 50 KA for one second at 400V, and shall be suitable for 50-55 degree C. ambient temperature operation with the prevailing enclosure condition. The exposed incoming terminals shall be provided with a suitable insulated cover up to the equipment mounting plate in order to allow no access to the live incoming terminals. There shall be minimum clearance of 300 mm between the incoming glanded cable and input terminals of the MCCB. The capacity of the terminal sockets for MCCB shall be 240 sq.mm maximum stranded Cu cables through suitable terminal tin plated copper bars.

3.1.68 Outgoing MCCBs/MCBs The outgoing MCCBs shall be provided, rated at 63 amp, TP, 400V, 25kA for one second. Four, six or eight or ten numbers outgoing circuit MCCB’s shall be provided as directed by the Engineer. The control cabinets shall have suitably rated MCBs for the protection of control circuits and the cabinet internal lamp circuit. Each control cabinet shall have one number single phase 20 Amps ELCB, and appropriate corrosion resistant switched socket outlet (3 pin square British type with box patters) as per BS 1363 (1984) appropriately located and neatly and tightly fitted inside the enclosure.

3.1.69 Bus bars The fault level for busbars shall be 50KA for one second and the busbars shall be of hard drawn copper and size as per short circuit fault requirement as per type test certificates and rated for 50-55 C. All the busbar (phase and neutral) shall be of same size and half the size for earth of hard drawn, high conductivity, tinned copper and rigidly supported. The bars to be positioned to give maximum access and covered with PVC covering for identification and protection against accidental contact. The size of the droppers shall be - Cross Sectional Area 75 sq.mm, as 15 x 5mm. All droppers for branch circuits shall be bus bar type of rating not less than 100 amperes. Earth bus shall be provided at the bottom and secured with stainless steel bolts of grade AISI 316 so as to give a positive electrical connection. In addition a 12mm terminal shall be provided on the cabinet body and connected to the earth bar. Provision shall be made in the enclosure to terminate the earth bus bar with the earth electrode outside the panel. All cable glands, shall be connected directly to the earth bar.

3.1.70 Contactor/AC1 A 100 amp, 400V Contactor shall be provided to control each of the four, six, eight, ten outgoing circuits.


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The remote control contactor shall be of the single coil actuated, electrically operated, suitable to carry not less than the rated current of the main circuit breaker at 50-55 degree C. ambient and shall be obtained without the use of latches or semi-permanent magnets. The contactor shall comply with BS 5424: Part 1:1977 and shall be for AC 1 class duty. Rated insulation voltage for 660 V AC. The contactor shall have minimum making and breaking capacity in accordance with utilization category AC 1 of IEC 158-I and shall be suitable for minimum class II intermittent duty. Ambient operation temperature shall be in the range of -10°C to 70°C. The contactor components must be suitable for continuous duty and for repetitive load switching. The contactor selected shall be such that all current carrying and live parts shall be properly shielded and it shall not be possible to come into accidental contact with them. All contact assemblies shall be dust protected, and an arrangement for easy removal of the coil shall be provided (preferably slide in type). The coils of all contactors shall be suitable for operation at a voltage of 240 +/- 10 to 15% and frequency of 50 Hz. operation. The pick up of the coil shall be from 0.85 to 1.1 of the voltage. The operation of the contactor shall be by means of a photocell. Each outgoing circuit shall be provided with 63 Amps, 100 mA ELCB.

3.1.71 Wiring and Cablin g All secondary internal wiring within the control cabinet shall be with heat resisting, 1000V hard grade PVC/XLPE Insulated copper cables, colour coded or sleeved for easy phase identification suitable for the circuit rating, arranged neatly and firmly attached. All the wiring leads shall be so arranged to allow current reading with a clip-on ammeter on each phase of main incoming and all outgoing circuits. All wiring shall be housed in wiring trunking forming an integral part of the enclosure whenever possible. All wire terminals into connectors shall have wire ends or straight lugs. All the wires selected should have the amperage rating at 60 degree ambient and sufficient allowance for enclosure derating. The suppliers' attention is drawn to the fact that: All incoming cable feeders to the panel shall be armoured, stranded copper conductors, 4 core, XLPE insulated and PVC over-sheathed. The incoming terminals shall be suitable for cables of 70mm², 120mm² and 240mm² (special cases) All outgoing cable feeders from the panel shall be armoured, stranded copper conductors, 4 Core, XLPE insulated and PVC over-sheathed. The outgoing terminals shall be suitable for cables of 1 6 - 25 mm². Therefore, all the connectors must be suitable to receive these types of cable. All output cables shall be connected through rugged terminals. All terminals shall be designed for sector shaped stranded copper conductors. All incoming and outgoing cables are to enter from the bottom of the enclosure and hence all the connections must be done at the bottom and not at the sides. All cables and wires must be colour coded as per the following detail. Blue, Red and yellow for phases Black for neutral Green/Yellow for the earth wherever required.

3.1.72 Cable Glands All cable glands shall be brass compression type cable glands complying to BS 6121 with earth tags and lock buds for XLPE/SWA/PVC cables 4 core. All cable glands to be supplied with matching cable sleeves. Glands shall be fitted with PVC shrouds filled with waterproof plastic compound and made fast to the cable with PVC tape.


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Glands shall be fitted with earthing rings to allow connection of protective conductors. The contractor shall carry out all work involved in terminating the cables, supplying weatherproof plastic compound, PVC shrouds, tape, etc.,all subject to the approval of the Engineer.

3.1.73 Control System The switching of the lighting luminaires shall be through an automatic control arrangement comprising of a photocell and selector switch assembly. An adjustable (0-2000 lux) photo electric controller shall be provided for normal operation and in the event of an unusual low lighting situation occurring during day light hours. Suitably auxiliary relay if required shall also be applied.

3.1.74 Photo Electr ic Swit ch The cabinet shall be equipped with a photo electric switch of the following specification: The photo-electric control switch or cell for the control cabinet shall operate from a supply voltage of 240 Volts and be rated for a load of 1000 Watts. They shall be adjustable for turning on and turning off within a range of 0- 2000 lux. It shall be suitable for operation within 0 degree C. to +60 degree C. temperature range. It shall have a fail-safe feature so that the lighting remains energized in the event of component failure. The photo-electric control switch shall be housed and mounted inside the control cabinet. An onoff auto switch of 5 amp rating shall be provided and properly labelled for controlling and by-passing the photo-electric cell. A resistor type surge protection shall be provided in parallel to the photocell switch. Photocell to be fitted inside the cabinet in the front, right hand side of the panel behind a factory made transparent ultra violet resistant window of typical size 10 cm x 10 cm. The photo electric cell shall be fully electronically operated type complying with BS 5972 and shall operate at the preset levels. The photocell controls shall have a preset switch “ON” and “OFF” point and have a time delay incorporated in the circuit to prevent accidental operation by intermittent stray light i.e. car head lamps. The photocell shall be located to ensure clear unobstructed view to the sunlight.

3.1.75 Selector Switc h An auto/manual selector switch for performing the following functions shall be provided in the cabinet. - Auto ON/OFF; - ON - OFF

3.1.76 Phase Selector Switch A phase selector switch shall be provided to select the control phase in case of any faulty phases in the main supply.

3.1.77 Identifi cation of Cont rol Cabinets The control cabinets shall be identified as per instruction of site Engineer.

3.1.78 Documents and Info rmatio n to be Submit tedfor the Control Cabinets The Contractor shall submit the relevant design calculations, drawings and data for approval prior to the fabrication of any panels, which is to include but shall not be limited to the following: ASTA Test certificate should be available. General dimensions of the panel anchor bolts, opening locations and gland plate openings. Contract 106, Volume II

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Detailed scaled drawings for the fixed components in the panel, including important maintenance and operating instructions of the manufacturer. General description for the material, manufacturing, fabrication, coating and treatment of control cabinets. Door hinges, locks and flaps drawings (including materials). Internal cabinet ventilation (circulations and air flow design). Detailed general arrangement drawing. Single line diagram Chart showing yearly on/off times. All components, catalogues, manufacturer's ratings, cable glands calculations and detailed drawings are to be attached with the control cabinet material submittals, for the Engineer’s approval. However, the approval of Engineer does not absolve the contractor of the contractual obligations as to the performance compliance to the specification requirements.

3.1.79 Testing The cabinets and internal main circuitry shall be manufactured and tested in accordance to the testing specifications of BS 5486 Part 1: 1990 and IEC 439-1: 1985 clause 8 The contractor shall submit ASTA or KEMA tests certificates for routine and type test from independent approved laboratories/bodies to show the compliance of his product.

3.1.80 Meteorol ogic al and Amb ient Condi tio ns Prevailing in the AbuDhabi Emirate The equipment shall be suitable for use in the climatic conditions pertaining to Abu Dhabi. In particular the following parameters shall be taken into consideration. max. recorded ambient temperature min. exposed ambient temperature max. exposed metal temperature (black body) max. relative humidity (Winter) max. relative humidity (Summer) wind velocity max. gust velocity

55°C 0°C 80°C 100% 80% 160 km/hr 208 km/hr.

Under certain combinations of these climatic conditions, condensation can occur. The average rainfall is generally low but is erratic. Sudden thunderstorms with intense precipitation accompanied by high winds may occur any time, but are usually of short duration.

3.1.81 Handin g-Over of Compl eted Work s Preliminary or final handover to Abu Dhabi Municipality shall be the responsibility of the conttactor on completion and testing of installation. The Contractor has to provide suitable generators to energise control panels if power supply is not available during testing.


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3.1.82 Monthly Maintenance: Testi ng and Reports During the Maintenance Period (12 months duration), the Contractor's approved street lighting engineer shall carry out a monthly inspection and maintenance of all the works and shall compile a monthly report for submission to the Engineer and Client. Maintenance shall include all works to keep the lighting installations in full operative condition. Testing and recording of illumination levels shall be with the supervision of the Engineer. The report shall include as a minimum:a) List of all items of equipment requiring maintenance, detailed in sequence by material type. b) Details of any repeated material failures, such as early burn-out of lamps, with reasons for failure and proposed rectification, photographs where necessary for clarification. c) Date and time of inspection. The Reports shall be comb-bound, signed by the Contractor's engineer and three copies shall be submitted to the Engineer for review and submission to the Client

3.1.83Form of Construction A. B. C.

D.

E. F.

G.

H.   

I.

The LV Assemblies shall be manufactured in fixed execution providing FORM 4b Type 6 and/or Type 7 segregation unless specified elsewhere in the specification/contract documents. LV Assemblies shall have internal separation by means of metallic or non-metallic partitions or barriers. Components within the compartment /cubicle shall be provided with the degree of protections to IP 2X as minimum whereas the degree of Protection to IP4X shall be provided to adjacent functional units preventing contact with live parts. Electrical continuity between the exposed conductive parts of LV Assembly and protective circuits of the installation shall be ensured to provide protection against indirect contact by using protective circuits. The protective circuits throughout the installation shall be so designed that makes it impossible to break the protective path with the removal of any component from the LV Assembly. All outgoing circuit’s protective conductor shall have a separate terminal of adequate size duly identified in accordance with the Identification Section explained elsewhere in this specification document. LV Assemblies must be designed by giving highest importance to the accessibility specially when in service/fully powered, allowing easy viewing for inspection and operation, replacement of fuses and extension of additional functional units etc. The LV Assemblies shall be designed, manufactured and tested to IP54 in compliance with the requirements of IEC 60529 which ensures: Unintentional contact with hazardous live parts Ingress of water or moisture Ingress of solid foreign bodies and dusts. Equipment such as Variable Frequency Drives (VFD), UPS and others with large watt loss if specifically mentioned in the particular requirements to be included in the FBA that require forced ventilation by employing external fan and louvers as recommended by the manufacturer, the degree of protection (IP rating) shall be reduced to IP43 from IP54.

3.1.84 Fault Level (Short-Circui t Ratin g) A.

B.

The LV Assemblies shall be designed and type tested to withstand a fault current of 50 KA for 1 second symmetrical. Additionally the LV assemblies shall be type tested for safe containment of an internal arcing fault, which will check the capability of the steel structure to withstand the forces associated with the arc, and ensure safety and integrity of the assembly for continuous use. This is to establish that the enclosure of LV Assembly together with internal partitions and/or barriers withstands the pressure and temperature arising from internal arcing with short circuit current and thus provides protection for persons in front of or within the close proximity of the LV Assembly in the event of internal arcing.


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C.


The LV Assemblies shall be designed and equipped with properly sized circuit breaker and or fused disconnect switch as specified to provide selective short-circuit co-ordination so that faults are cleared without disturbing other circuits’

3.1.85 Service Conditions A. B. C.

D.

The LV Assemblies shall be designed for indoor installation except where specified specifically for outdoor installation. The LV Assemblies shall be designed to operate satisfactorily in an ambient air temperature of +50 degree C and RH exceeding 90%. Unless otherwise specified temperature up to +70 degree C and RH up to 100% shall apply during transport, storage and installation. Equipment subjected to these extreme service conditions without being operated shall not suffer irreversible damage when operated under normal specified conditions. The altitude of the site installation shall not exceed 2000 meters.

3.1.86 Environmental Conditions A.

The LV Assembly shall normally be located indoors in service conditions as specified above. However some parts of the LV assembly such as sensors field instruments and pilot devices may require installation in highly corrosive gaseous environments such as Hydrogen sulphide and methane may adversely affect the functions of the components and devices. In such application environments special measure shall be adopted to prevent corrosion and the subsequent rise in resistance leading to temporary or permanent interruption in control circuit.

3.1.87 Temperature Rise A.

B.

The temperature rise in LV Assemblies shall not be allowed to damage the components, connectors, wires, terminals etc. The equipment in normal service condition, no live part shall become subjected to high temperature causing overheating that increases the Risk of internal arcing accidents. The extreme care shall be taken while designing the equipment’s to ensure external surface temperature is maintained within the specified limits without causing burning of the skin when making contact with the external surface of the enclosures.

3.1.88 Clearance and Creepage Distances A.

B.

The clearances and creepage distances in the LV Assemblies shall be based on rated Impulse withstand voltage in accordance with BS EN 60439-1 to ensure that the equipment designed is capable of withstanding without failure under specified test conditions. The equipped LV Assemblies must confirm to the clearance & creepage distances and withstand voltages explicitly by taking into account the specified service conditions.

3.1.89 Site Consid erations A. B. a. b.

c. d. e.

The maximum height of assemblies shall be 2400 mm above the finished floor level. Site consideration including safety and maintenance shall be taken into account in the design of assemblies. These considerations shall include: Clear floor space of at least 1000 mm shall be provided in front and rear of all assembles. In order to provide an unobstructed exit route a clear path of not less than 500 mm shall be provided in front of assemblies when cubicle doors are opened at right angles. Cubicle doors shall close towards the exit from the building enclosing the assembly. Provision of sufficient space to allow for doors to open fully without fouling other items of equipment or other open doors. Limiting the size and weight of assembly sections to those imposed by transportation, site access and permitted levels of site floor loading. Clear floor space of at least 1000 mm shall be provided from the sides of all assembles those are designed for future extensions in order to allow possible future extension with ease.

3.1.90Mounting A.

Floor mounted assembles shall either be provided with an integral plinth or a separate rolled mild steel channel bed frame, at least 50 mm high.


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B.

C.


Fixing shall be by not less than four holding down bolts per assembly section, located around the periphery of the section. The fixing shall not be visible from outside the section, but shall be readily accessible from within. Fixings for post, respectively column mounting shall be provided outside the enclosure. The back of the enclosure shall not be drilled to accept fixings.

3.1.91Cubic le A. B. C.

D.

The type of cubicle construction shall be multi-compartment type unless specified otherwise. Multi-cubicle assemblies shall be designed to provide fully segregated self-contained compartments. Each cubicle/compartment shall have its own door. Power Factor Correction capacitor Panels, skid mounted panels and other wall/floor mounted panels and distribution boards shall be constructed to FORM 2 segregation as described in the relevant sections. All cubicles especially FORM 2, shall be provided with a means of ensuring that equipment can be adequately isolated for maintenance purposes without interrupting essential loads which may continue to operate whilst maintenance is being undertaken.

3.1.92Doors and Covers A.

B. C. D. E. F.

G. H. I.

J. K.

Doors shall be adequately sized to accommodate readily and neatly all mounted equipment, open at least 120 degrees, be rigidly constructed, suitably braced and provided with at least two substantial hinges which shall be captive when the door is closed Each door shall be provided with chromium plated ‘T’ type catches at least one of, which shall be lockable. The doors shall be fixed to the frame by continuous stainless steel hinges over their entire height. Locking combinations shall be provided as specified. Three keys for each key type shall be provided on individual key rings having a nametag showing identify details. Where the need of padlocking facilities is identified by the engineer/employer, the padlocks will be supplied and fitted. Equipment shall not be mounted on covers. Covers shall not weigh more than 30 kg, and any cover over 7.5 kg shall be provided with a means of supporting the lower edge when its securing bolts are being inserted or removed. Removable back covers shall be provided. Each door shall be provided with an internal welded earthling stud, and shall be bonded to the assembly main earth bar. Neoprene gasket used for sealing panel door covers and for door mounted instruments shall be of highest quality not to get deteriorating when equipment installed in H2S and Methane gas environments. Doors and covers giving access to potentially live conductors shall be provided with prominent warning labels, in English and Arabic. Doors on outdoor assemblies shall be retained in the open position by the provision of adequately fixed stays.

3.1.93Components Mounti ng A. B.

C. D.

Each cubicle/compartment shall be provided with removable steel components mounting plate located clear of the cubicle rear panel. All components, other than door mounted, shall be located on the component mounting plate by bolting into tapped holes or by using self-tapping screws. Nuts used for securing components shall be captive. Rail type fixings may be used where appropriate. Components shall not be mounted on any other surface. No components shall be located within the assembly at a height greater than 2000 mm or less than 500 mm above finished floor level. It shall be possible to replace and maintain any component without first removing other components.

3.1.94Bolt s, Nuts And Screws A.

All bolts, nuts, screws and washers used in the construction of the assembly shall be stainless steel Grade 316L.


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B. C.


Bolts and nuts for cover fixing shall be captive and provided with protective washers to prevent damage to paintwork. Floor fixing bolts shall be manufactured from stainless steel Grade 316L.

3.1.95Contro l Supply A.

B.

Unless specified otherwise control supplies shall be 110V arc. derived from a transformer within each cubicle/compartment of the assembly, fused on its primary and secondary windings with a removable neutral link in the secondary circuit. Auxiliary supplies such as 24 V AC/DC, 240 V AC etc. are specified in the relevant individual component’s specifications.

3.1.96Cubicle Heater A.

Each compartment shall be provided with a separately fixed compartment heater rated 240 Volts AC. Apart from those in motor starter compartments the heaters shall be controlled by means of individual “OFF/AUTO” switches. Auto operation shall be by means of adjustable panel mounted humidistat covering the range of humidity envisaged. Each circuit shall be fused and powered from common supply tapped from the main bus in main Incomer section.

3.1.97Future Extension s A.

LV Assemblies shall be designed for ready extension at each end.

3.1.98Bus bars A. B. C.

D. E. F. G. H. I.

Electro tinned high conductivity 99.9% Copper, with a continuous current rating of specified amperes plus 20% at specified service conditions The mechanical and dielectric strength of bus bars and supports shall be capable of withstanding the worst conditions of electrical surge, which can occur in the installation Bus bars shall be fully insulated by using high temperature grade heat shrinkable Red/Yellow/Blue/Black colour PVC sleeve throughout its length or by means of providing secondary insulation. Moulded PVC shrouds shall be provided over joints. All three phases and a neutral busbars shall be of same size enclosed in a separate chamber. Earth busbar shall be of half the size of phase busbar running throughout its length. The mains horizontal busbars unless specified otherwise shall be located on the top of the assembly. Vertical busbars shall be fully encapsulated enclosed in a separate chamber located approximately 350 – 400 mm from the front of the column. Bus bars connections shall be identified by phase colour marking and adequately supported by suitable supports designed to withstand the full fault capacity as specified herein. Connections from the main bus bars to MCCB’s controlling main motor starters and outgoing distribution feeder shall be via solid copper bus bars and NOT cables. Bolted copper bus bar links shall be provided where specified and shall be used for maintenance purposes only. The link section shall be easily accessible from the front or top of the board and shall have a lockable cover. Provision for storing the links nuts and bolts shall be made in the switchboard.

3.1.99Cable Termin ations A. All terminals for outgoing connections shall be located at a low level in the compartment adjacent to the cable gland trays. Direct termination on equipment such as Distribution Board Fuses or Miniature Circuit Breakers (MCB’s) is not acceptable B. All live terminals shall be fully shrouded by using high-grade high temperature material. C. All cable entries shall be affected using copper cable glands to IP rating as specified. D. Cables shall enter assemblies through detachable steel or aluminium/brass (for single core cables); gland plates fitted at least 200 mm above finished floor level. E. Gland plates shall be rust-proofed and provided with a welded and bonded earthling stud, and adequately sized to accommodate present and known future cabling requirements. Access to both sides of each gland plate when it is in position shall be possible from within the assembly. Cables shall enter at the top or bottom of assemblies as specified. F. Cableways shall be provided to ensure that apart from inter -connections no cable routed to one cubicle shall pass through any other cubicle. Contract 106, Volume II

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Electro Mechanical Specifications 2

G. For cable sizes above 300m and above insulated glands shall be fitted. H. Provision for accommodation of rising armoured cables shall be provided with adequate cable supports and a form of cable entry via approved cable glands secured to a steel glanding plate. I. Space shall be provided to accommodate cable glands of appropriate size for incoming and outgoing circuits. All gland plates and trays shall be adequately earthen. J. Cable disconnecting links shall be provided where specified and shall be used for maintenance purposes only. The links shall be fitted to the bus bar risers immediately before the cable terminations and shall be easily accessible. The links shall be labelled ‘ISOLATING LINK’ and the circuit or cable reference shall be quoted.

3.1.100 A.

B. a. b. c. d. e. f. g. h.

Within each assembly, all metal parts of equipment’s’ supplied, other than those forming part of an electric circuit, shall be bonded to the earth bar. Metalwork may be used for this purpose provided that earth continuity conductors are fitted at all joints and other discontinuities, and those connections to metal work are made using welded or bolted stud. The following metal parts must be provided with Equipotential Bonding connected to earth busbar system by using yellow/green earth cable of at least 6.0 mm square. Gland plates & covers Side sheets Top- & intermediate Barriers Top- & End covers Rear & Front Covers Cable Boxes Doors and bolted front covers Horizontal busbar barriers.

3.1.101 A.

Small Wiring and Terminal Blocks

Wiring shall generally be of the multi-stranded high temperature to minimum 105 C flexible PVC insulated, 600/1000V single core stranded copper type cable to BS EN 6231, with a minimum cross sectional area of 1.5 mm Sq. for control and 2.5 mm sq. for power.

3.1.102 A. a. b. c. d. e. f. g. h. i. B.

Panel Earthi ng

Colour Coding

Colour-coding shall be: Red - Red phase Yellow - Yellow phase Blue - Blue phase Black - Neutral Green and Yellow - Earth/Protective conductors Grey - 110V a.c White - 60 D.C. Purple - <50V a.c Brown -Current Transformers Identification of conductors and auxiliary circuit shall be in accordance with BS EN 60445 and BS EN 60446

3.1.103

Termination

A.

All wiring shall have crimped terminations, only one wire being held by any one crimp. Crimped lugs shall be of the insulated type without conductor exposure between the crimp and wire insulation. B. The type of crimp used shall be appropriate for the type of terminal to which it connects. C. Terminations shall be neatly arranged leaving adequate length for one termination. D. All terminal blocks for the connection of small wiring shall comprise shrouded anti-tracking moulding of melamine phenolic or comparable material with provision for securing conductors. E. Either by high tensile screws and clamps or alternatively in the case of small telephone type conductors by solder tag connection. F. Terminal blocks shall be arranged to facilitate easy access to both terminals and wiring ends. Connections for outgoing circuits to auxiliary pilot cables shall be provided with test links.


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G. Removable rail terminals shall be provided for all wiring, mounted at an angle to provide ease of access. Centre-disconnecting link type terminals shall be provided for analogue signal circuits, external control devices and all alarm/telemetry signals. Sufficient, suitably sized earth terminals and end stops shall also be provided. H. The gap between gland plates and associated terminals shall be such that conductors can be safely manipulated and connected without damage. Terminals shall face the door of a cubicle for ease of connection. I. Barriers shall be provided on on all all terminal banks, to group terminals into logical divisions. Power terminals of different phases shall be seperated from each other and separated from control terminals. J. In all cases care shall be taken to ensure that terminals are easily accessible after all wiring and plant cabling has been installed and terminated. All connections shall be made on the front of terminal blocks. K. No more than two conductors shall be connected to one side of a terminal. Outgoing cables shall be wired so that all assembly wiring is connected to one side only. L. The terminal numbers, voltage grouping and and terminal block layout shall correspond precisely with wiring diagrams so that quick and accurate identification of wiring can be made. M. All terminals shall show the circuit wire number reference. N. A separate dedicated telemetry/RTU section shall be provided in the MCC cubicle equipped equipped with all terminals duly wired and located in the side or on the top of the compartment interior leaving maximum room for free issued fully wired and tagged RTU complete with all associated hardware’s on a mounting plate. O. MCC vendor to co-ordinate with RTU vendor through the contractor to confirm the size of free issued duly wired RTU on a backplane. MCC vendor shall install and complete interconnection wiring between the RTU and the MCC accordingly.

3.1.104

Installation

A.

Wiring shall be neatly laid and run in limited compression compression insulated insulated cleats, insulated insulated straps or, where more than ten wires follow the same route, in plastic slotted-sided trunking with clip-on covers. Where trunking is used, the effective overall cross-sectional area of cables shall not be greater than 70% of the trunk cross sectional area. B. Wiring to items of equipment mounted on hinged doors or subject to movement shall run in helical binding or flexible conduit, being securely anchored at both ends; leaving ample slack to prevent wiring strain. C. Holes in steelwork through which cables pass shall be protected using grommets or bushes, suitable for the size of hole. D. Cables used for control, extra low voltage and instrument signal transmission, likely to be affected by interference, shall be screened and/or spaced from each other and from heavy current power cables. The separation distance shall ensure that the resultant electrical noise is insufficient to cause any form of malfunction of associated equipment or give false readings.

3.1.10 3.1.105 5 A.

Ferrul ing in g and Markin g

All wiring shall be identified identified at each end by means of glossy plastic ferrules showing the wire number as on the schematic diagrams. Ferrules shall be colour coded, ‘Z’ type and indelibly marked.

3.1.10 3.1.106 6

Cable Connecti Conn ecti ons on s

A.

Where single single core cable cable is to be accommo accommodated dated a non-mag non-magnetic netic gland gland plate shall shall be provided. provided. For For cable size 400 mm Sq. and above insulated glands shall be fitted. B. Undrilled gland plates shall be provided for the reception of conduits conduits and threaded glands. Boxes and glands shall be within the cubicles except where otherwise approved. C. Prior to manufacture the Contractor shall confirm cabling termination requirements with the Engineer.

3.1.107 A.

Interlocking

Mechanical Mechanical interlocking interlocking shall be provided provided where possible. All electrical electrical interlocking shall be of the double interlocked type having separate permissive and prohibitive interlocks. Thus to allow a


Page 517 of 589

Section 015000

B.

device to operate there must be an absence of prohibitive signals and a presence of permissive signals from the remaining devices in the interlocked system i.e. fail safe. Suitable equipment shall be provided mechanically to prevent a device being manually operated when a prohibitive signal from another part of the interlocked system is present.

3.1.10 3.1.108 8 A. B.


Prot ecti on Relays

Protection Protection relays and associated associated devices shall be provided provided as described in the relevant relevant section. All switchboard switchboard relays shall shall comply comply with BS BS 142 or or other approve approved d equal equal standard. standard. Secondary injection tests shall be easily possible by means of purpose-made voltage and/or current plug-in type test terminal blocks which automatically open circuit or short circuit the integral voltage transformers or current transformers respectively and provide terminations for the test supply. Disconnection of any permanent wiring will not be acceptable.

3.1. 3.1.10 109 9

Marki Marki ngs And Identifi cation s

A.

All components, components, devices, devices, switches etc. mounted mounted inside the LV Assemblies Assemblies must be clearly clearly marked identifying the circuits and their protective devices. B. The material used for making internal labels shall be white trifoliate. These labels shall be engraved and fixed on a separate dedicated rail screwed on to the components mounting plate. C. All external labels/name plates shall be clear Perspex rear engraved in English and and Arabic fixed with stainless steel screws. D. Labels fixed or glued directly on to the component component mounting plate or PVC trunking or on top of the component shall not be permitted under any circumstance. E. Abbreviation used for the designation of of the components components must be identical with those in the wiring schematic drawings prepared in accordance with BS EN 60750. F. All relevant drawings and related documents must be kept in the drawing pocket in one one of the compartment and supplied together with the LV Assembly. G. The neutral conductor in the main circuit and protective earth (PE) shall be be readily distinguishable by shape, colour, marking and location.

3.1.110 A. a. b.

c. d. e. f.

For each switchboard switchboard the Contractor Contractor shall supply supply the following following equipment: equipment: 1 No. Electrical grade 1000 Volts, rated for 15 KV for 1 minute dielectric strength rubber mat, 1000 mm wide extending the full length of the MCC/switchboard. The rubber mats shall be specifically manufactured for electrical purpose purpose to BS 921. The mats shall be made of Solid natural or synthetic rubber insulating materials. The mat shall be solid and not perforated having a minimum thickness of 10 mm. 1 No. Pair of electrical grades rubber gloves to BS EN 60903. 1 No. Notice in English and Arabic advising treatment for a person suffering from electric shock. A wall mountable lockable key box complete with tags and numbering. S.L.D in A1 size picture fram.

3.1.11 3.1.111 1 A. B.

C. D.

Accessories

Source Sour ce Tests

Provide testing of Factory Factory Built Assembli Assemblies es The whole Assembly shall be witness tested as integral units for a complete sequence of operation and as laid down in BS EN 60439 and based on the completeness of the circuits in the final manufacturer’s works. The Assembly shall not leave the manufacturer’s works until the same have been duly approved and stamped by the Engineer and written permission is obtained for their dispatch to site. The following is a list of important tests shall be carried out: Primary injection tests to ensure correct operation of the current operated protection  relays and direct acting coils, over their full range settings. Balanced Earth fault stability tests by primary current injection. Care must be taken to  reproduce accurately the burdens of inter-connecting cables. A further test to ensure correct polarity must be made after assembly. Tests on auxiliary relays at normal operating voltage by operation of associated remote  relays.


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Section 015000




Correct operation of sequencing and control circuits at normal operating voltage by operation of local control switches, and simulation of operation from remote control positions

3.1.11 3.1.112 2 A.

B.

D.

The Motor Control Centre and the Main Distribution Distribution Boards shall be considered considered as the key elements of an electrical installation in pumping stations in lieu of satisfactorily functioning of the entire installation of pumping station that is largely dependent on the Motor Control centre and power distribution. The motor Control Centre specification to be read in conjunction with the following drawings, Section “FBA” and other relevant product sections. a. Single Line Diagram of MCC b. Legend and Load Schedule c. General Notes C. The Motor Control Centre shall be designed to perform in harsh conditions providing high level of reliability that attribute to: a. Minimal failure b. No dangerous fault c. All time availability d. Easy accessibility e. Local/Remote control and monitoring f. Improved periodic maintenance and check The Motor Controls, Contactors, Power Monitors, Transformer, Control & Monitoring Devices, Instruments and Electrical Connections etc. that guarantees overall dependability.

3.1.11 3.1.113 3 A.

C.

ATS and MTS Panel

A separate standalone standalone ATS and MTS MTS panel located within the MCC room shall be provided as specified. The MCC in this case shall have one Incomer Circuit breaker only and the same shall be powered by a common feed coming from the ATS & MTS panel. Refer to section for switches for more technical details. Otherwise the mcc’s two incomers shall work as an ATS.

3.1. 3.1.11 115 5 A. B.

Inco mer Sectio ns

Each Incomer Section Section shall consist, as as minimum, of: a. 4 Pole motorized ACB/MCCB with accessories b. 3X Voltmeter 96X96, 240 degree scales for mains bus voltage live indication. c. Power Monitor d. Phase failure/phase sequence for sensing mains bus voltage. The trip contact wiring to be carried out to isolate all motive loads excluding main pumps (dedicated control as part of EMPR protection device) in the event of phase failure or phase reversal condition. e. Lightning and surge protection (for Mains only) f. Auto/manual changeover for MCC MCC with two or more Incomers (See Metering Section below) g. Trip circuit healthy test facility in case of a circuit breaker is logically designed to trip on fault through externally mounted protection devices e.g. IDMT (Inverse Definite Minimum Time relay), UV relay etc). h. Control fuses i. Open/close/trip indicating lamps, terminals etc.

3.1.114 3.1.114 A.

Moto r Cont rol Centre (MCC) (MCC)

Metering Metering Contro l Secti Secti on for Incomers

All meters meters shall be of the the door mounte mounted d type. A separate metering section shall be included in order to accommodate analogue meters, Power Monitor, control relays, timers, PLC, selector switches, push buttons, indicating lamps etc. as necessary for interlocking scheme for the incomers. Auto/manual changeover scheme shall be included unless specified otherwise, as a definite requirement for two or more incomers, provided generator for alternate supply is included for permanent and fixed installation as part of the contract .


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Section 015000

D.

Detailed drawings shall be be prepared during the design stage and and the same to be be submitted to the engineer for approval prior to the manufacturing.

3.1.11 3.1.116 6 A. B.

C.

B.

C. D. E.

a. b. c. d. F.

G.

B. C. D.

200/5 A 300/5 A 1000/5 A 2000/5A The Contractor shall ensure that in case of requirement of CT operated analogue meters wherever specified shall be provided with calibrated meter scale matched with the primary amperes of the current transformer. Where specified sparate KWh panel shall be provided

B.

Small Lighti Lig hti ng And Power Distr ibutio ibu tion. n.

Wall mounting mounting type distribution distribution board, board, fed from MCC, with MCCB, MCB, ELCB, RCBO combinations for Lighting and small power shall be provided in the MCC room. The specifications, selection and sizing of breakers shall be in accordance with particular requirements, load schedule and relevant specification sections.

3.1. 3.1.12 120 0 A.

Outgoi ng Secti Secti ons

Each outgoing starter, feeder or other Functional Unit shall be enclosed enclosed within its own section providing Form 4b /Type 6 segregation. Component selection and sizing shall be in accordance with the Section “FBA” and other relevant sections wherever applicable. One spare equipped feeder section (MCCB only) with earth leakage protection per MCC shall be provided as minimum. The rating shall be subject to the approval of the engineer. One spare unequipped feeder section per MCC shall be provided as minimum.

3.1. 3.1.11 119 9 A.

kWh Meter Sectio n

A separate section section shall be provided to house Authority Authority (ADWEA/ADDC) calibrated calibrated kWh meter. The contractor shall ensure that the kWh meter is calibrated and properly sealed before installing and wiring. The kWh meter shall be direct reading type for load up to and including 100 A powered through a separate 100 A (Maximum Rating) 3 Pole with solid neutral link, fixed type manually operated MCCB housed within the kWh meter section. The kWh meter section door shall have the facility to pad lock the door by the authority. The contractor shall provide the padlock and three keys as approved by the engineer. ATS and MTS standalone panel where specified shall be provided with Authority kWh meter on the panel. No kWh meter shall be installed in the MCC in this application.. The kWh meter shall be CT operated for loads exceeding 100A. Following are the approved ratings of the current transformers (CTs) as approved by ADWEA and their associate company ADDC.

3.1. 3.1.11 118 8 A.

Generator Hook -Up

Pumping Pumping stations requiring requiring mobile generator generator shall be provided provided with Appliance Appliance Inlet socket outlet outlet as described under Section Industrial plugs and sockets. The appliance inlet shall be used for generator generator up to 125 125 A and be housed in a weather weather proof junction unction box fixed and located outside the MCC Room as shown on plant and equipment equipment drawing. The junction box shall have detachable gland plate at the bottom facilitating easy connection and disconnection of generator cable. Higher capacity generator rating above 125 A shall be provided with solid copper links.

3.1.11 3.1.117 7 A.


Common Contro l Secti Secti on

The Common Control section shall consist of the following controls and instruments as minimum for guidance purpose only subject to the approval of the engineer: a. Non door interlock MCCB b. 24 V DC regulated power supply c. 24 V DC Ni Cd battery


Page 520 of 589

Section 015000

d. e. f. g. h. i. j. k. l. m. n. o. p. q. r.

24 V DC Ni Cd battery charger Power distribution MCBs for field instruments Programmable Logic Controller (PLC) Pressure, flow, conductivity & Level Indicators Local/Remote selector switch Float/Level selector switch Pumps Duty-Selec Duty-Selection, tion, selector selector switch switch Push buttons for lamp test, fault-reset etc. Status Indicating Lamps Control Relays, Timers and Control Fuses as required according to the logic + 20% as spares wired to the terminals. Zener barriers Signal isolator Hygrostatically controlled Anti-condensation heater Standard and special terminals to suit the applications requirement Terminal Kiosk (A separate partitioned terminals arrangement clearly labelled identifying IN/OUT). [All wires to field devices and telemetry section must be routed through terminal kiosk].

3.1.12 3.1.121 1 A.

B.

C.

Telemetry Sectio n

The telemetry section shall consist of the following controls as minimum for guidance purpose only subject to the approval of the engineer: a. Non door interlock MCCB b. 24 V DC Ni Cd battery c. 24 V DC Ni Cd battery charger d. Remote Terminal Unit (RTU) – Refer to ICA manual for specifications e. Modem - Refer to ICA manual for specifications f. Interposing relays g. Hygrostatically controlled Anti-condensation heater h. Terminals, control fuses and surge protection etc. i. Signal isolators. All starter compartments, compartments, common control compartment, compartment, and other compartments compartments equipped equipped with controls and monitoring devices within the Motor Control Centre, standalone control panels, separate terminal kiosks and unit mounted control panels shall be provided with Hygrostatically controlled Anti-condensation heater. Selection and sizing of of the component shall be in accordance with the requirements laid down in the particular specification, “FBA” and other relevant specification sections.

3.1. 3.1.12 122 2 A.


Drawings And Documentati on

Following is a List of related drawings and documentation’s to be submitted together with the MCC drawings or separately by the contractor for Engineer’s review and approval prior to the manufacturing and commencement commencement of any work at site. a. Short circuit and Voltage Drop calculations b. Power Factor Correction Capacitors (PFCC) Calculations c. Load Schedules d. Lighting and Small Power Socket Layout e. Cables, conduits and ducting layout f. Cable trenches and earth pits g. Fire detection and fire alarm h. Telephone sockets, JN Box, conduits, duct, duct, manhole manhole etc. i. Field instruments, sensors and other devices mounting detail and location j. Instruments Instruments loop loop diagrams diagrams k. Terminals interconnection drawing l. Detailed drawings drawings and and supporting documentation’s for other other vendors if any supply panels and devices e.g. Macerators, Odour control systems, telemetry RTU etc. m. Testing and calibration records and procedures n. Installation, Operation and Maintenance procedures


Page 521 of 589

Section 015000

3.1.123 A.

B. C.

D.

E. F.

B.

C.

D.

E.

Low Voltage Circui t Breakers

All low voltage Circuit Breakers shall be suitable for controlling loads as indicated and shall confirm to BS EN 60947-2 utilization category B or other approved equivalent standard for 415 V 3 phase 50 Hz 4 wire operation for use on specified fault level and for service and site climatic conditions as described in clause 3.11. All low voltage circuit breakers shall be housed in control boards/cubicles, which comply with the requirements of Clause 3.11. Unless specified otherwise all Incoming(s) Circuit Breakers shall be sized based on the current ratings as follows:a. 800 Amps. and above shall be 3 Pole or 4 Pole as applicable draw out electrically operated motor driven type Air Circuit Breaker (ACB) b. Above 160 Amps but below 800 Amps. shall be 3 Pole or 4 Pole as applicable draw out, electrically operated motor driven type Moulded Case Circuit Breaker (MCCB). c. Up to and including 160 Amps. Shall be 3 Pole or 4 Pole as applicable Plug-in type manually operated Moulded Case Circuit Breaker (MCCB). d. MCCB rated up to and including 125 amps. 3 pole with neutral link when used as a means of KWH metering cut-out for ADDC shall be manually operated fixed type. Unless specified otherwise all Outgoing(s) Circuit Breakers shall be sized based on the current ratings as follows:a. Above 800 Amps. shall be 3 Pole draw out electrically operated motor driven type Air Circuit Breaker (ACB) b. Above 250 Amps but less than or equal to 800 Amps. Shall be 3 draw out, manually operated Moulded Case Circuit Breaker (MCCB). c. Up to and including 250 Amps. Shall be 3 Pole Plug-in type manually operated Moulded Case Circuit Breaker (MCCB). All low voltage ACB/MCCBs shall be rated for continuous duty at 415 V 3 Phase 50 Hz with minimum short circuit capacity 50 KA for 1 second. All low voltage Circuit Breakers shall have utilization category B so as to provide selective discrimination with other series devices.

3.1.124 A.


Low Voltage Air Circui t Breaker (ACB)

Air Circuit breakers shall be provided as stated above, fully withdraw able electrically operated motor driven type with electrical and mechanical ON/OFF/TRIP indications. Electrically operated air circuit breakers shall be provided with manually operated handle for charging spring mechanism allowing the breaker to operate manually in the event of failure of motor mechanism. The air circuit breaker shall be provided with built-in over current, short circuit and earth fault protection having the following characteristics:a. Adjustable long time delay current setting between 50 – 200% with variable tripping time characteristics. b. Adjustable short time delay current setting 200 – 800% with variable tripping time characteristics. c. Instantaneous tripping for heavier over current applications adjustable from 400 – 1600% of the base current. d. Adjustable earth fault trip current setting 20 – 80% with variable tripping time characteristics. The air circuit breaker shall provide three positions:a. Service position – for opening and closing main and auxiliary contacts. b. Test position – for opening main contacts but closing auxiliary contacts. c. Isolated position – for opening all main and auxiliary contacts. d. An indicator shall clearly show these positions and a mechanism to allow locking of the air circuit breaker in any position. All circuit breakers shall be provided with interlocks to ensure that:a. Circuit breaker cannot be plugged in or isolated when it is closed b. The circuit breaker cannot be closed until it is fully plugged in or completely isolated c. The circuit breaker cannot be, closed in the service position without completing the auxiliary circuits between the fixed and moving positions d. Only one incoming supply can be energized at any one time where more than one supply is available.


Page 522 of 589

Section 015000


e.

F. G.

H.

I.

J.

K. L.

M. N. O.

Mechanical interlocking shall be provided to prevent withdrawing or inserting of the circuit breaker when it is in ON position. Any attempt to do so shall automatically trip the circuit breaker. The withdraw able part of the circuit breaker shall be effectively connected to earth through scraping contacts that shall make before and break after the main and auxiliary contacts. The moving contacts comprising of main and arcing contacts shall be of the spring loaded selfaligning type. These contacts shall be so arranged that arcing contacts make before and break after the main contacts. Individual shutters, which automatically operate as the truck, are racked in and out shall be provided for busbar and circuit spouts. When closed the shutters shall effectively prevent any contact with either the busbar or the circuit connections and also seal the spouts against the ingress of dust. The shutters are to be coloured and painted in bold characters with “BUSBARS (red) or “CIRCUIT” (yellow) as appropriate in Arabic and English. Provision shall be made to lock each shutter in the closed position A purpose designed, separate earthling device shall be provided to earth either the cable box or the busbar side of the circuit breaker. Single function earthing shall be arranged so that it shall only be possible to earth non-current carrying conductors. The air circuit breaker shall include but not limited to the following as minimum:a. 8NO/8NC auxiliary contacts b. Arc chutes c. Folding extension rail d. Charging handle e. Open and close push buttons f. Trip indicator g. Spring charge motor h. Spring charge indicator i. Breaker position indicator mechanically and electrically. j. Micro-processor based protection and management unit that provides the following control and monitoring features: 1. Over current protection 2. Short circuit protection 3. Earth fault protection 4. Neutral protection 5. Thermal memory 6. Alarm logging 7. Field selectable Manual or Auto reset 8. Microprocessor malfunction watch dog 9. Programmable input/outputs 10. Load monitoring 11. Operation counter 12. Serial communication by employing Modbus protocol. a. Carriage/Lifting Truck for ACB exceeding 25 Kg in weight [ One carriage for each site/project regardless of number of breakers provided b. Shunt trip and under voltage release. The air circuit breaker shall include facility to test the trip circuit healthy mechanism. Air Circuit breakers shall be designed and constructed such that inspection, maintenance and replacement of the main fixed and moving contacts shall be easily possible on site. Manufacturer's detailed instructions shall be incorporated in the maintenance manuals. Circuit Breakers requiring their complete return to the manufacturers for service will not be acceptable. The air circuit breaker when equipped with transformer protection relays shall be provided with, an intertrip relay to trip the H.V. circuit breaker on operation of transformer protection device. The air circuit breaker shall trip every time it’s associated HV circuit breaker trips. Association of Short-circuit Testing Authorities (A.S.T.A.) or Keuring van Electrotechnische Materialien, Arnhem (K.E.M.A) test Certificates shall be submitted for all circuit breakers


Page 523 of 589

Section 015000


3.1.125 Low Voltage Moulded Case Circuit Breakers (MCCB) A.

a. b. c. d. e.

f. B.

C. D. E.

Moulded Case Circuit Breaker shall be provided as stated above with electrical and mechanical ON/OFF/TRIP indication when used as an Incomer and be certified to at least the same fault level (Icu) as that of the busbar systems. MCCBs shall have the following minimum features: Mechanical indication of the circuit breaker when opened closed and tripped. The circuit breaker shall have quick break and quick make trip-free switching mechanism so as not to withhold the contacts closed against short circuits and abnormal currents. Facility for padlocking without the use of loose components. At least one unused volt free changeover auxiliary contact, wired down to outgoing terminals, for remote indication. Adjustable Magnetic and thermal inverse time delay protective device to protect against sustained overloads and instantaneous tripping under heavy overloads and short circuits. An additional facility shall be provided to prevent unauthorized adjustment of thermal and magnetic settings. Shunt trip and/or under voltage release as applicable. Each MCCB shall be housed in a separate Compartment with the operating handle door interlocked when used as an Incomer, feeder or starter, so that access can only be gained to the Compartment with the MCCB in the OFF position. Padlocking shall be provided in the OFF position only. When the MCCB is used for control transformers, distribution or ICA compartments the handle shall be internally mounted with appropriate shrouding and warning labels. Each MCCB shall be complete with 2 N/O and 2 N/C spare auxiliary contacts (10A, 240v rating) in addition to those required for the Contract. Each MCCB used as an Incomer or feeder shall have facilities for electrical as well as mechanical interlock. All incoming circuit breakers shall be provided with electrical & mechanical interlocking scheme to ensure that only one incoming supply can be energized at any one time where more than one supply is available.

3.1.126 A. a. b. B.

These shall be suitable for the type of load they feed. Mcb’s shall comply with Type B, of BS EN 60898. They shall include the following minimum features: Magnetic and thermal trip elements Trip-free mechanisms The minimum short circuit rating of the Mcb shall be 10 KA, unless shown otherwise on the relevant single line diagrams.

3.1.127 A.

B.

C. D.

E.

Earth Leakage Circuit Breakers (ELCB)

Earth Leakage Circuit Breakers (ELCB) or Residual Current Circuit Breaker (RCCB) shall have tripping characteristics appropriate to the application and provide discrimination with other series devices. ELCB/RCCB shall comply with BS EN 61008-1. Current operated earth leakage circuit breakers shall provide accidental protection by interrupting dangerous contact with the voltage that may be present in the faulty electrical equipment’s and/or wiring as a result of frame faults, weaker insulation resistance or misuse. The ELCB shall also provide a high degree of protection against earth leakage, fires and electric shock The ELCB protecting socket outlet shall have a rated residual operating current of 30 mA with an operating time not exceeding 40 m sec. All other areas protected by ELCB shall have operating current as indicated on the relevant drawings. The ELCB shall isolate all live conductors. Switching and isolation devices incorporating RCDs shall be selected to provide current and time discrimination with upstream and downstream protective devices.

3.1.128 A. B. C.

Miniature Circuit Breakers (MCB)

Combined MCB/RCCB

Residual Current Circuit Breaker with Over current Protection (RCBO) RCBO shall comply with BS EN 61008-1 & BS EN 61009-1 RCBO units shall be provided for final circuits supplying socket outlets, outdoor lighting, heating circuits and other small loads.


Page 524 of 589

Section 015000

D.

The units shall have trip sensitivity of 30 mA or as indicated on the relevant drawings.

3.1.129 A. a. b. c. d. e. f.

3.1.131

B.

C.

D.

E. F.

G.

H. I. J.

B. C. D.

Discon nect Switches Fuse Swit ches

Fuse switches, where specified, shall comprise flush/surface mounted heavy duty composite air break switches and fuse units complying with BS EN 60947-3 and fitted with fuses to BS EN 60269 and shall be rated and equipped as detailed. Composite units shall be contained within an enclosure of metal and shall be fitted with an earthing terminal or equivalent to enable the enclosures to be earthed irrespective of any means of connection such as provided for attaching armouring or other metallic covering of the cable supplying the composite unit. Fuse switch shall be capable of making, carrying and breaking current under normal circuit condition, which may include specified operating overload conditions and also carrying for specified time currents under specified circuit conditions such as those of short circuit. The switch breaking capacity shall be related to AC 23 utilization category or other approved equivalent standard for 415 V 3 phase 50 Hz 4 wire operation for use on specified fault level and for service and site climatic conditions as described in clause 3.11 BS EN 60269 complied HRC fuses shall be provided as a mean of over current/overload protective device to protect the switch. The maximum rated current of the fuse with regard to the prospective short circuit current in the actual circuit shall be mentioned. The fuse shall be connected after the switch so that a short circuit will not occur in the fusecombination, thus for an expected fault to take place after the combination fuse switch unit In the event of a fault this combination shall provide protection, permitting switching without, for example contact welding and preventing separation of main contacts in case of fault occurring during running. The combination fuse switch unit shall be housed in an enclosure so constructed that the cover cannot be opened until the switch is fully opened and the construction shall be such that when the cover is opened a competent examiner can override the interlock and operate the switch. After such operation the cover shall be prevented from closing with the switch position indicator in a false position. Switches shall be provided with mechanical ON/OFF indicators and operating handles. Means shall be provided for locking the switch in the OFF position only. The combination fuse switch unit shall be fitted with 2NO + 2 NC auxiliary contacts wired to the terminals.

3.1.132 A.

Source Test

All circuit breakers shall be subject to the following witness tests to BS EN 60947 or other approved equivalent standard for voltages up to and including 1000 Volts. Routine tests including H.V. pressure test, Millie-volt drop tests and mechanical tests. Operation of D.C. closing coil and satisfactory closing of the circuit breaker with the voltage on the coil between 85 per cent of it’s rated voltage and 110 per cent of it’s rated voltage. Satisfactory shunt opening and shunt closing of the circuit breaker with the trip coil energized Interchange ability of identically equipped withdraw able circuit breakers and checking of all mechanical and electrical interlocks. Current injection tests as described under section 16480 FBA Type Test Certificates giving records of performance for identical circuit breakers shall be made available.

3.1.130 A.


Isolator

The switch when used alone as explained above as an Isolator shall confirm to the utilization category AC23 and shall fully comply with the requirement specified for isolating functions specially the isolating distance in accordance with the applicable standard. An Isolator shall be capable of opening and closing the circuit ON-LOAD with full voltage applied across the terminals. The Isolator shall be capable of carrying currents under normal circuit conditions and carrying for specified time currents under abnormal conditions such as those of short-circuit. All other features of the Isolator shall be same as specified above for combination fuse switch unit.


Page 525 of 589

Section 015000

3.1.133 A.

B.

C.

D. E.

F. G.

H. I.

B.

C.

C. D.

E.

F. G. H. I.

J. K.

Change-Over-Switch

Change-over-switch where specified shall be provided in accordance with BS EN 60947-3. The Change over switches shall be manually operated multi pole type suitable to provide changeover and safety isolation between two low voltage power supplies rated 415 Volts 3 phase 4 wire 50 Hz under load conditions. The switch breaking capacity shall be related to AC 23 utilization category or other approved equivalent standard for 415 Volts 3 phase 4 wire 50 Hz operation for use on specified fault level and for service and site climatic conditions as described in clause 3.11 The changeover switch shall be periodically maintained to ensure proper operation and system reliability.

3.1.135 A. B.

Fuses

These shall be selected according to the application and be suitable for the type of load they feed, for example motor starting, cable protection, protection for the semi conductor devices, control transformer protection etc. Fuses shall be sized according to the condition under which they will operate such as normal, small sustained overload, heavy overload etc. in order to consider the operating characteristics accordingly. The fuse shall either include a suitable fuse carrier or it shall be capable of isolation. If the fuse carrier is included it shall be such that when it is being withdrawn normally or when it is completely withdrawn the operator is completely protected from accidental contact with any live metal of its fuse link, fuse contacts and fixed contacts. Fuse/links shall be fixed inside cubicles with sufficient spacing to facilitate easy fuse/link withdrawal. If the fuse is capable of isolation it shall be so interlocked with the switch that isolation is complete before the fuse enclosure can be opened further. The switch shall be prevented from closing while the fuse-cover is open. All fuses shall be of HBC/HRC cartridge type to BS 88/BS EN 60269. Fuse holders and fittings shall be made of moulded plastic insulating material of an approved make. Ceramic materials will not be accepted. Fuse fittings shall be fully shrouded and it shall be possible to change the fuses without danger of contact with live metal. Fuse fittings shall have basic sizes of 16, 32, 63, 100 and 200A and the fuse holders shall be able to accept fuse links of that rating on any BS rating down to the next basic size. A mechanical indication device shall be built into the fuse to indicate operation/fail status.

3.1.134 A.


Transf er Swit ch ATS/MTS/Byp ass

Transfer switch where specified shall be provided in accordance with BS EN 60947-6. Transfer switch shall be Withdraw able type allowing easy removal of the switch for maintenance and without disconnecting the power cables. ATS/MTS functions shall be mechanically and electrically interlocked to ensure proper sequence of operation. Bypass switch contacts to close only during the bypass isolation operation. Bypass of the load to either normal or emergency power source with complete isolation of the ATS shall be possible regardless of the status of the ATS. The switch breaking capacity shall be related to AC 23 utilization category or other approved equivalent standard for 415 Volts 3 phase 4 wire 50 Hz operation for use on specified fault level and for service and site climatic conditions as described in clause 3.11 The ATS, MTS and Bypass Isolation switch shall be provided from a single manufacturer. A visual indication shall be provided to indicate ATS/MTS/Bypass position. The ATS shall incorporate adjustable 3 Phase under & over voltage and frequency sensing on normal and emergency source. Whenever there is a voltage dip of 80% or below in any phase of the normal source or frequency displacement of 2 Hz from the nominal for a maximum period of 10 seconds (field adjustable) a contact shall close to initiate starting of the engine generator. Upon emergency source reaching required power supply of 415 Volts 3 Phase 50 Hz +/- 5%, the load shall be transferred to the emergency source after a programmable set time delay. When the normal source has been restored to 90% or more of the rated voltage on all phases, the load shall be retransferred to the normal source after a programmable set time delay.


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Section 015000

L.

M.

N. O. P.

Upon restoration of the normal source to full voltage and frequency, the generator will continue to run unloaded for about 5 to 10 minutes programmable and then shutdown. The generator shall now be ready for next operation automatically in case of failure of a normal source. It may be possible that the generator fails during running on load, retransfer under such condition to normal source shall be made instantaneously upon restoration of proper voltage and frequency. The transfer function shall be achieved through purpose designed microprocessor based controller equipped with LCD digital display and a keypad/touch pad for Para metering. Auxiliary contacts wired to terminal shall be provided to indicate normal and emergency source availability. A periodic NO-LOAD test on Transfer switches shall be conducted and logged.

3.1.136 A. B. C. D. E.

B. C. D. E. F.

Source Quality Contro l And Tests

All Switches shall be subject to the following witness tests to BS EN 60947 or other approved equivalent standard for voltages up to and including 1000 Volts. Routine tests including H.V. pressure test, Millie-volt drop tests and mechanical tests. Functional tests Current injection tests as described under clause 3.11. Type Test Certificates giving records of performance for identical circuit breakers shall be made available.

3.1.137 A.


Low Voltage Starters

The starter components as required are to form part of a Motor Control Centre described under section “FBA” and as such circuit connections; protection devices and the like shall comply with BS EN 60439. The starters shall be in accordance with BS EN 60947-4. The starter compartments shall be so arranged to provide easy access to the component’s mounting for maintenance purposes and shall be damp-proof and dust-proof with a minimum Ingress Protection (IP) rating to IP 54. The motor starter shall be rated to carry full load current of its rated duty at its most severe load conditions and shall also meet service and site climatic conditions specified in the section “FBA”. All starters shall be selected for Utilization category AC3 duty and be capable of at least 20 starts per hour at 100% full load torque. The components of the starter shall have been type tested and ASTA certified to achieve Type 2 co-ordination in accordance with BS EN 60947. The following method shall be employed to start the motors unless specified otherwise on relevant contract drawings:-

3.1.138 Direct on Line (DOL) Full Voltage Motor Starter Up to 4.0 KW inclusive The Direct on Line starters shall be designed to start and accelerate the motor to normal speed and provide protection to the motor and its associated control and power circuits against operating overloads and switching off the motor by disconnecting the supply to the motor from the mains. The reversing full voltage Direct on Line starter if to be used shall be designed in the similar manners.

3.1.139 Star - Delta (S-D) Reduced Volt age Motor Starter A.

B.

C.

5.5 KW – 11.0 KW inclusive The Star Delta starters shall be designed to start and accelerate 3 phase motor only in such a way that in the starting position the stator windings are connected in star and with a recommended time delay they are connected in delta for final running position. To provide protection to the motor and it’s associated control and power circuits against operating overloads and switching off the motor by disconnecting the supply to the motor from the mains. The transition from star to delta connection must occur when the motor has run up to its full speed. The transition time between star and delta contactor to be controlled through adjustable timing device by ensuring that the star contactor is opened before closing the delta contactor.


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Section 015000

D.


The motor shall have 6 terminals in the junction box of the motor with a shorting strip to facilitate star delta starting. It shall be studied properly prior to employing this method of starting in order to ensure that rd resisting torque during starting is less than 1/3 of the motor torque. Closed transition type starters where specified shall include wire wound porcelain core resistor banks of sufficient thermal rating to allow three consecutive starts of 30 seconds starting period followed by a 15 minutes rest and another 30 seconds starting period. Resistance value shall be chosen to give high starting current with low transients current. Starter compartment incorporating resistor banks shall be ventilated by providing louvers if necessary.

E. F.

3.1.140

Soft Starters

11.0 KW and Above J. A solid state, microprocessor based, reduced voltage soft starter shall consist of six silicon controlled full wave rectifiers, two rectifiers per phase connected back to back in reverse configuration. K. The soft starter shall be employed to reduce the voltage across the motor terminals during the starting process resulting in reduced torque from the motor. The voltages across the motor to be increased and decreased progressively in such a way that facilitate step less start and stop of a motor. L. The soft starter shall be provided with one isolation contactor to provide positive isolation from the mains and one bypass contactor to bypass the soft starter power section when motor reaches to its full speed. M. The starter shall be equipped with metal oxide arrestor type surge suppressors across the SCR to protect against voltage transients and resistor/capacitor Snubber network to protect against false firing of SCR. N. A temperature sensor shall be embedded to the heat sink of each SCR to protect the soft starter from over-temperature condition. O. Any failure in the soft starter shall be indicated on the cubicle door through LCD display or LED indicator without requiring to open the door. P. The soft starter shall be supplied factory configured ready to commission, without requiring any Para metering or reconfiguration at site. Q. The soft starter shall have the following protective feature as minimum: a. Over temperature / Overload / Jam / Stall / Phase Loss / Phase reversal / Shorted SCR R. The soft starter shall have the following control feature as minimum:a. Kick start 0-85% locked rotor torque – 0 to 2 seconds b. Ramp start 0-85% locked rotor torque – 1 to 60 seconds c. Current limit start 0-85% locked rotor current – 1 to 60 S d. Soft stop 0 to 60 seconds S. The soft starter shall be provided with high speed fuses as recommended.

3.1.141 3.1.142

Varaible frequency dri ve Appl icable Standards

Unless otherwise specified, VFDs shall conform in design, material, equipment, construction and performance to the latest editions of the IEC standards:           

Rotating electrical machines IEC 60034 Classification of degrees of protection provided by enclosures of rotating machines IEC 600345 Starting performance of single speed three phase induction motors IEC 60034-12 Semi-conductor converters-Specification for basic requirements IEC 60146-1-1 Semi-conductor converters - Application guide IEC 60146-1-2 Semi-conductor converters - Transformers and Reactors IEC 60146-1-3 Terminal markings for power converter equipment IEC 61148 Semiconductor self-commutated converters IEC 60146-2 Methods of test for winding wires IEC 60851-1 Classification of degrees of protection provided by enclosures IEC 60529 Low voltage switchgear and control gear IEC 60947


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Section 015000

3.1.143 A.

B. C. D.

E. F. G.

H. I. J.

B.

C. D.

E. F.

Design

Design and construction shall be simple and well laid-out providing good accessibility to components and parts. Even under extreme conditions of major short circuit there shall be no danger to persons in the vicinity of the assembly. Each pump/motor shall be provided with an independent frequency converter system as shown on the single line diagram. Harmonic suppression equipment shall be supplied to ensure harmonics do not exceed specified limits. All electronic cards shall be mounted away from the semiconductors and shall be in drawout modules. Test pins shall be provided on the front face of the cards to facilitate checking signals in running mode. All IGBT modules shall be drawout pattern for easy replacement of semiconductors. Communication port shall have standard protocol. The frequency converters shall be IGBT type with zero harmonics and near unity power factor. The EVSDS shall be designed to have a site rating at least 15% above the required pump power at the duty point of the pumps. The EVSDS shall have at least: a. 120% Max. rated torque for 10 sec. for starting and re-starting. b. 110% Max. rated torque for 60 sec. for starting, re-starting and acceleration. During continuous operation, the VFD shall be capable of developing sufficient torque under load conditions to respond to 20% alteration in set point within a time of not more than 30 sec. The minimum time interval between set point changes will be not less than 30 sec. The operation speed range of the VFD shall be 20-100% of the rated maximum speed.

3.1.144 A.


Speed cont rol and prot ection

The deviation between set point value and measured value shall normally be less than 2% of the set point value. When the measured value deviates by more than 5% of the set point value, a 20-second time delayed alarm will be raised. A thermal overload of the motor shall trip the VFD. The overload condition should be detected by built-in RTDs in the motor windings and also an electronic-type overload relay built into the converter. The FVD shall be suitable for continuous repeated start/stop operations without any adverse effect on the motor or frequency converter. The estimated total running up time shall be stated by the manufacturer at rated voltage at the line terminals of the frequency converters. The pump & motor inertia shall be estimated or be based on data given in IEC 60034-12, Critical Speeds The VFD and related motor shall be designed to run through the critical speeds of the whole system in the shortest time possible.

3.1.145

Harmon ics at the Line Side

The manufacturer shall design the frequency converters such that the total levels for current and voltage distortion do not exceed 1.0% at the supply side of the VFD with all the duty pumps running.

3.1.146

Radio Interferenc e

All frequency converters shall meet the requirements of the relevant IEC Standards (or in draft version for the same) regarding the emission of radio frequencies. Radio frequencies emitted by other equipment shall not hamper the correct operation of the frequency converters.

3.1.147

System Contro l

The frequency converters shall be controlled by the following signals: a) 4-20 mA reference signal from the speed controller in the control panel. b) Ready to start signal (interposing "ON" signal). This signal is a potential free contact which will be given by the control panel if the VFD is allowed to start. c) STOP signal (interposing "OFF" signal). This signal is a potential free contact which will be given by the control panel to stop the VFD. d) Loss of the 4-20mA signal shall result in operation at the lowest speed. e) ON/OFF and manual lowering and raising control shall be provided at local as wells as at remote. Alpha numeric keyboard and display to be available in the drive (door mounted) for read out and local control along with fault diagnosis display. Contract 106, Volume II

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Section 015000

3.1.148


CONSTRUCTION REQUIREMENTS

Each converter should basically consist of: a) isolation switch (padlockable in `off' position) b) main fuses c) contactor d) electronic relay for comprehensive motor protection e) earth fault protection relay f) harmonic filter and power factor correction equipment g) control and auxiliary equipment for supply and distribution system h) control, triggering and system control equipment i) protection, supervision and alarm equipment and measuring/ testing facilities j) rectifier k) DC link l) inverter m) converter

3.1.149

Noise

The converter sound pressure shall not exceed 81 dB(A), at any location 1 m distant from the converter under any load and/or frequency condition within the operational speed range of the VFD.

3.1.150 A.

B.

C. D.

E. F.

Enclos ure of Converter

The converter cabinet shall be self-supporting and suitable for floor mounting. The maximum height of the cabinet shall not exceed 2350 mm excluding fans, fan hoods or ducts and the maximum door width shall be 800 mm. The enclosure class of the converter panel with the doors closed shall be not less than IP42. Converter components should be accessible from the front. A design which makes use of modular plug-in/draw-out assemblies for both the system control electronic equipment and power electronic equipment is preferred. The converter elements shall be arranged in a logical segregated manner to allow easy recognition of components and safe maintenance work. Exposed parts within the LV compartments of the converter which have to be accessible during normal operation of the EVSDS for measuring, adjusting, resetting etc. shall, when the door is open, have an enclosure to a degree of protection of at least IP 20. All components of LV converters should have a degree of protection of at least IP 20 with open compartment doors. The converter panel(s) shall form an integral part of the complete L.V. Board as far as possible especially for smaller size converters. It shall be accessible during normal operation without opening compartment’s door. Also refer to specification for LV switchboard/motor control centers.

3.1.151

Cooling of the Converter

The cooling of the converter shall be natural cooling or fan ventilating with fans on the top of the frequency converter panels. Fans shall be low noise type. They should shut down upon stopping of the motor to get increased life for the ventilators.

3.1.152 System Contro l, Protecti on And Alarm Equipment A. B. C. D. E.

The manufacturer shall provide all the system control, protection and alarm equipment for the entire drive system and its auxiliary equipment. The system build-up shall be subject to approval of the OWNER/ENGINEER. Printed circuit boards should be installed in standardised electronic equipment frames with easily accessible front and rear. Assembled cubicles shall be factory-wired to terminal strips and shall be functionally tested before dispatch. The system should be provided with LOCAL/REMOTE-PC MODE, ON/OFF control by key switch for local and remote/AUTO operation. All data shall be kept in non volatile memory to save them upon power failure conditions. Battery backed up memory is not preferable. All drive parameters read out values shall be selectable on the alphanumeric keyboard. Parameter setting should also be made possible on the panel with password protection facility.


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Section 015000

3.1.153 A. B. C. D.

E.

F.

G. H.

Protecti on and Alarm Equipment

A fully electronic protection system is preferred obviating the need for special ultra-rapid semiconductor fuses. For essential protection functions of the VFD, a separate backup protection shall be provided to accommodate for a failure of the electronic protection system. The backup protection shall comprise a standard fuse and electronic type overload relay. All earth potential connections shall be connected to earth via one common connection to allow for checking the insulation resistance to earth. The sensitivity of the main circuit earth fault protection shall be better than 2 A with a maximum time delay of 1 second. The protection and alarm system shall provide sufficient detailed information to enable maintenance personnel familiar with this type of equipment to troubleshoot the frequency converters system down to the printed circuit board or power semiconductor level. The following indications shall be available on the converter as a minimum: a) output frequency b) output current c) output power d) output voltage e) motor speed f) torque g) DC bus voltage h) operating hours i) heat sink temperature j) input power k) input current l) input voltage m) input frequency n) kilowatts hours o) indication lights for the following signals: p) .. ready for operation q) .. running r) .. alarm s) .. trip The use of filament lamps is not allowed. The minimum protection should include a) Inverter: DC bus over voltage, DC bus under voltage, over temperature, over current, short circuit at start up, electronic circuit fault, suppression of frequency band, flying restart, automatic reset. b) Motor: short circuit, Earth fault, motor stall, motor overload, under current, output phase loss, unbalance, motor RTD protection.

3.1.154 A.


Starter Compartment

Each starter (D.O.L / Start Delta / Soft Starter shall be housed in a separate compartment equipped with the following: a. 1 No. Triple pole MCCB externally operated through door mounted handle interlocked with the cubicle door, with built in shunt trip coil b. 1 No. Thermal Overload Relay or Digital Electronics Motor Protection Relay (EMPR) to provide protection of motors against under voltage, over voltage, undercurrent, over current, phase sequence, phase imbalance, phase loss, earth leakage etc. c. Digital electronics motor protection relays (EMPR) shall be provided to a motor having a capacity more than 4.00 kW or driving sewage pumps or macerators or process pump irrespective of motor capacity. d. 1 No. Set of AC3 duty contactors as required according to starter type and configuration. e. 1 No. Set of auxiliary relays required for providing the necessary indication and control logic sequence. f. 1 No. Set of timers required to providing the necessary delayed action to meet specific functional requirements. g. 1 No. 240/110V 50 Hz double wound single phase centre tap transformer with earth screen of suitable capacity to supply all control circuit and pilot devices requirements. h. 1 No current transducer.


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Section 015000

i.

j. k. l. m. n.

o. p.

q. r. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

13. 14. 15.

1 No. Anti-condensation heater (off when starter contactor is closed). The heater shall be separately fused, controlled by a hygrostat having setting range (50-100%) which operates when the preset value of %RH exceeds above the due point. Thermistor relays and continuous monitoring of temperature of winding of motor shall be included in the starter compartment as per electric motor specifications. Provision for connection of cooling fan motor where applicable Moisture protections relay as recommended by the plant manufacturer or where specified separately. Bearing temperature, seal leakage for motor/ pump monitoring and protection. 1 No. Door operated TEST/NORMAL push button located inside the starter compartment wired through auxiliary contact of the MCCB for the purpose of conducting live functional tests to the control circuit whilst the main MCCB is isolated. 1 No. Set of main motor terminals and auxiliary terminals as required for remote controls and indications wherever applicable. 1 No. Set of volt free terminals (digital and analogues) as required for telemetry RTU located in a separate MCC section sized enough to accommodate RTU together with associated hardware’s Zener barrier shall be provided for Analogue signals wired to terminals for field mounted Instruments located in non safe area such as H2S and Methane gas. The following equipment as minimum unless specified elsewhere shall be mounted on the door of each starter cubicle: 1 No. Ammeter fitted with suppressed scale and RED pointer to read and monitor motor running and starting current. 1 No. Green pilot lamp to indicate "SUPPLY ON" 1 No. Red pilot lamp to indicate "MOTOR RUNNING” 1 No. Amber pilot lamp to indicate "MOTOR FAILED” 1 No. "HAND/OFF/AUTO" selector switch. 1 set "START/STOP" push buttons ( stop button latch type ). 1 No. Lamp test push button. 1 No. Externally operated reset push button. 1 No. 6 digit hour run meter to count total operating time of motor non-reset table type. 1 No. Start / Stop counter . A separate indication lamp shall be provided to indicate each motor fault condition. A common fault indication shall be provided for all fault conditions. The indication lamp shall be provided on the door of dedicated common control compartment. Additionally a set of wired terminals shall be provided to hook-up flashing light on the building roof. All pilot devices for control and indications . The wiring of the starters shall be carried out in accordance with the Sequence of Operation and Control Philosophy Components not described herein but necessary to meet the requirement of Functional Design Specification (FDS)

3.1.155 A. B. C. D. E. F.

Contactors

The Contactors shall confirms to standard BS EN 60947-4-1 Utilisation category AC-3, type tested and ASTA certified to achieve Type 2 co-ordination. All power and control wires terminated on the contactor terminals shall be easily accessible from the front. The contactor design shall allow inspecting main contacts and operating mechanism for servicing and maintenance without disconnecting the power cables. Terminals used for power and control circuit wiring must provide IP2X protection as minimum with starter compartment door opened. The contactor shall be 3 pole or 4 pole according to the application requirements. When selecting Contactors for Power Factor Correction Capacitors and Lighting duty, these must confirm and tested to the duty in accordance with the standard.

3.1.156 A.


Protection

The Contractor shall provide for the Engineer's approval circuit protection drawings, which shall include the types and setting ranges of each protective device, the ratio and classification of associated current and voltage transformers and each trip and alarm function.


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Section 015000

B.

C. D. E. F.

G.

All protective relays shall be the product of an approved international manufacturer. They shall be suitable for the climate and site conditions and fully sealed against the moisture or dirt and shall be tropicalised. The relay shall have an automatic thermal compensation for variation in temperature between 0 O O C and 60 C. Relays shall be suitable for operation between + 10 % and - 25 % of their nominal rated voltage. Each relay shall be complete with panel mounting facilities and terminals for external circuit connection. Secondary injection shall be easily possible by means of purpose-made voltage and/or current plug-in type test terminal blocks which automatically open circuit or short circuit the integral voltage transformers or current transformer respectively and provide terminations for the test supply. Disconnection of any permanent wiring will not be acceptable. Each individual element of the relay shall initiate a flag to indicate that the element has operated. The element and flag shall be reset by operating an external reset button mounted on the front of the relay case / panel door as approved by site engineer.

3.1.157 A. B. C. D. E. F. G. H. I.

J. K. L. M.

N. O. P. Q. R.

S. T.


Relays

All auxiliary relays shall mainly comply with BS EN 116000 and BS EN 116205-7 Where similar relays have different operating voltages and/or different contact configurations, they shall be non-interchangeable. Voltage at nominal operating temperature and shall not ‘drop-out’ at greater than 60 % of the nominal coil voltage. Relays shall be continuously rated and capable of sustaining a voltage 10 % in excess of the nominal coil voltage Relays shall be fully encapsulated and be of the plug-in type, with terminals protected to a minimum of IP2X. Plug-in relays shall be fitted with transparent dust-proof covers. External connections shall be screw clamp terminals, which are easily accessible with the relay in position. Relays shall include the provision for manual operation. The pin configuration of the relay shall be printed on the casing and on the bases in order to ensure correct pin alignment. Relays shall be suitable for operation on a nominal 240 V AC, 110V AC/DC, 24 V AC/DC or other voltage as specified or deemed necessary for the safe operation of the devices connected using auxiliary relays. Relays shall be suitable for operation at plus 10% and minus 25% of their nominal rated voltage. The contacts configuration shall be either normally open/normally closed or changeover contact combinations. The contact material shall be suitable for its specific application. It will not be permitted to use mixed voltages on the different contacts of a particular relay. If necessary additional relays shall be used by employing good engineering practices such as operation of add-on relay through auxiliary contact of main relay. Relays Coil shall be vacuum impregnated ensuring satisfactorily operation for the adverse climatic conditions as specified. The relays shall be mounted on DIN Rail. Relays shall be secured to their bases by retaining bar or clip to prevent malfunction due to the relay being loosened in its base. Care shall be taken to ensure that relay contacts and associated wiring are suitably fused protected. All type of relays shall have a means of visual indication e.g. light emitting diode (LED) or neon bulb mounted within their clear covers connected directly across the relay coil to indicate when the relay is energized. These indicators shall be easily seen when the relay compartment door is opened. A permanent means of identification shall be affixed to both relay and base in line with the circuit diagram reference. Where remote supply voltages are used, a warning label engraved in English and Arabic shall be fitted, clearly identifying the source of supply.


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Section 015000

3.1.158 A. B. C. D. E. F. G. H. a. b. c. d. e. f. g. h. i. j. k. l. m. I a. b. c. d. e. f. g. h. i. j. k. l. J.

B. C.

D.

Electroni c Motor Protecti on Relay

The Motor Protection shall be provided by an intelligent electronic device that is user friendly and user configurable, capable of controlling the motor manually or automatic. EMPR shall be CE marked and confirm to BSEN 60947-1 EMPR with LCD display shall be provided in the MCC for each pump motor starter regardless of the rating of the pump and non-sewage pump drives above 11.0 KW. Non sewage pump drives up to 11.0 KW inclusive may be provided with ambient compensated bi-metal type thermal overload relay. EMPR shall have built – in RS485 communication port utilizing Modbus RTU protocol for serial communication with other devices on the network EMPR shall be supplied with software, user manual and interconnecting cables EMPR shall be provided with user friendly software windows based communication program allowing easy access to all features with pull down menus The protection features shall include the following as minimum: Over load protection Over current protection Over voltage protection Under voltage protection Under current protection Phase sequence Phase imbalance Phase loss Earth leakage Earth fault Thermistor broken Open contactor Locked rotor Motor current sensing shall be through external 5 A or 1 A current transformer. The following measured values shall be displayed on the LCD mounted on the starter compartment door. RMS current of each phase RMS voltage Earth Leakage current Continuous monitoring of thermal capacity of the motor Thermal capacity used during start Power factor of the motor Motor KW Phase unbalance Parameter settings Percentage of FLC of the motor Adjustable delayed start/stop Maintenance Log EMPR shall be capable of registering all trip commands and log trip and pre-trip metering values for reporting and printing purposes.

3.1.159 A.


Programmable Ranges

Overload – shall be based on the calculation of accumulated I²t value and selected thermal capacity curve. The tripping time shall be 0-10 Sec. Adjustable. Locked Rotor – To trip the motor within 1 to 5 Sec. when the running current exceeds the stalled rotor trip level of 1.5 to 5.0 x FLC. Phase unbalance – Should there be a phase current unbalance of greater than 15% lasting for 5 seconds an alarm shall be generated. If the condition prolonged for 10 seconds or more a trip shall occurs. Ground fault – The ground fault shall be measured as a percentage of primary range of current transformer. The setting range for the ground current shall be 300mA to 5 Amps current. An adjustable delay time of 0-30 seconds shall allow preventing nuisance alarm from momentary surges. It should be possible to make the alarm setting below the trip level to indicate early warning insulation breakdown.


Page 534 of 589

Section 015000

E.

F.

Thermistor/Over temperature – EMPR shall be capable of accepting PTC and NTC sensors. Thermistor level shall be selectable for both alarm and trip conditions with an adjustable time delay of 0-5 seconds. Under current – 10 – 100% of motor FLC with a time delay of 0-30 seconds.

3.1.160 A.

B. C.

D.

E.  

F.

G.

H.


Thermal Overload Relay

Thermal overload relay where specified shall be of Bi-metallic inverse time-lag type, which shall be used with a contactor in the starter circuit enabling switching device to open both control and power circuit (fully isolating the power to the motor terminal box) when the current in the relay exceeds a predetermined value. The thermal overload relay shall fully comply with the requirement of BS EN 60255-8 The thermal overload relay shall be simple and robust suitable for direct contactor mounting or if to be mounted separately shall be used with manufacturer supplied links and associated attachment. The thermal overload relay shall be designed to include ambient temperature compensation feature from – 20 Deg C to + 65 Deg C eliminating the need of any calibration in the field during operation. The thermal overload relay shall provide the following protections:Over-current/Overload Single phasing/Phase failure The thermal overload relay shall have MAN/AUTO field convertible Reset button located on top of the relay for resetting of the relay after trip. Additionally a facility shall be provided on the door of starter compartment to reset the relay. The thermal overload relay shall have two characteristics, the one when the relay bi-metals are in cold state that will break the contacts of the relay within 8-10 seconds and the other when in hot state the contacts breaking shall be reduced to approximately one third of the tripping time as indicated for the cold characteristics. The tripping time may be allowed to vary depending upon the starting of the motor such as normal/heavy-duty. The thermal overload relay shall have been type tested and ASTA certified to achieve Type 2 co-ordination in accordance with BS EN 60947.

3.1.161

Thermi stor Relay

A.

All motors where provided by the manufacturer as per requirements of motor specifications, shall be protected against excessive temperature, poor cooling, high ambient temperature, high starting frequency etc. by providing thermistors. B. Thermistors shall be of PTC (Positive Temperature Coefficient) type made of platinum wire Pt100 having resistance of 100 ohms at 0 degree C. These shall be embedded in the stator winding/slot and the leads of the elements shall be brought out to a separate terminal block located within the junction box of the motor. C. Thermistors shall have a tamper proof pre-set point and fast response time. D. Thermistors shall be designed to include the following features:a. Tamperproof b. Rapid responding c. UL/CSA recognized component d. Eliminates nuisance trips e. Field-proven Klixon design f. Requiring no field adjustment g. Allows full use of motor rating h. Directly senses winding over-heating i. Thermistors shall protect the motor against the following conditions: j. Locked rotor k. Running overload l. Single phasing m. Voltage unbalance n. High motor ambient temperature o. Blocked ventilation E. Thermistors have to be connected to a separate control unit that enables tripping of the motor through the starter contactor upon change of resistance of elements in the thermistor circuit beyond pre-determined value. Contract 106, Volume II

Page 535 of 589

Section 015000


F.

The wiring of the relay module shall be so done, that inhibit the starting of the pumps automatically even after the temperature limit sensors have cooled and re closed the circuit. The facility shall be provided in the motor control centre to reset the control circuit manually, ensuring that a proper cause of overheating has been determined and corrected prior to the restart of the pumps in auto mode. G. Additional to the sensing of winding temperature by the thermostat, means shall be provided to monitor the bearing temperature wherever provided by manufacturer as per requirements of motor specifications

3.1.162 Moisture and Mechanic al Seal Leakage Protection Relay A.

All pumps, shall be provided with dedicated moisture and mechanical seal leakage protection relay as recommended by the manufacturer and/or as indicated in the particular specification. B. The moisture sensing probes detect the presence of moisture in case of failure of outer seal of the pump. C. The probes shall also detects water in the motor chamber and provide a warning prior to the water reaching the bearing or wound stator assemblies. The sensor leads must be connected to a moisture relay equipped with alarm contacts for indication. D. The moisture detection relay shall be either supplied by the pump motor manufacturer or by the Motor Control Centre Vendor. The pump manufacturer shall provide schematic diagrams and work instructions pertaining to the mounting and location of the relay. E. The Motor Control Centre vendor shall strictly adhere to the wiring practices and works instructions as provided by the manufacturer.

3.1.163 A. B. a. b. C. D.

E. F. G. H. a. b. c. d. e. f.

Earth Leakage Protection Relay as shown on the drawings wherever in the specification shall be provided so as to measure the earth leakage current of the circuit it is connected. This protection system shall be comprises of two components: Core Balanced Current Transformer (CBCT) Earth Leakage Relay (ELR) The CBCT may be designed in ring or rectangular shape to suit mounting on conductors/cables or busbars as appropriate. The information from the CBCT shall be first registered in the amplifier circuit and continuously monitored thereby. Whenever the leakage exceeds the preset value this will operate a relay and through which trip the main circuit breaker of the circuit as per the designed logic. The ELR shall confirm to BS EN 60947-2. The ELR shall be adjustable type and suitable for mounting on compartment door. Residual operating current range: 0.03 to 2 A, Time delay: 0-1 S The ELR shall have the following main features as minimum:Immunity to nuisance tripping Protection against direct and indirect contact Continuous monitoring of the leakage current. Capable of operating under all unbalanced phase conditions. Alarm contact with fail safe operation LED Status indications

3.1.164 A. B. C. D. E.

Earth Leakage Relay

Source Tests

Provide type test certificate. All Motor Protection Relays shall be witness tested as integral units forming part of the “FBA” for a complete sequence of operation and as laid down in BS EN 60439. Secondary injection tests to ensure correct operation of the current and voltage operated protections over their full range of settings. Software simulation test where applicable shall be demonstrated to prove the satisfactorily operation of the protection devices. The complete assembly shall not leave the manufacturer’s works until the same have been duly approved and stamped by the Engineer and written permission is obtained for their dispatch to site.


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Section 015000

3.1.165 A.

B. C. a. b. c. D. E.

F. a. b. c. G. a. b. c. H. I.

J. K.


Lightning & Over Voltage Protecti on Unit

Mains Incomers’ of all Factory Built Assemblies – “Motor Control Centre, LV Distribution Boards and Control Panels etc.) as described under Section “FBA” shall be provided with Lightning and Over Voltage protection unit to protect the equipment’s against over-voltage generated by spikes and electrical switching events. The protection device shall confirm to BS 2914 and shall be rated for High Exposure Level as defined in BS 6651. The protector shall be so designed and field proven that neither interfere nor restrict the system’s normal operation. It shall not: corrupt the normal mains power supply break or shutdown the power supply during operation Have an executive earth leakage current. The protection shall be rated for a peak discharge current of no less than 10KA (8/20microsecond waveform). The protector shall limit the transient voltage to below equipment susceptibility levels. Unless stated otherwise, the peak transients let-through voltage shall not exceed 600 V, for protectors with a nominal working voltage of 240 V, when tested in accordance with BS 6651 Category B – High (6KV 1.2/50 microsecond open circuit voltage, 3KA 8/20 microseconds short circuit current) The peak transient let-through voltage shall not be exceeded for all combinations of conductors: Phase to neutral Phase to earth Neutral to earth The protector shall have continuous indication of its protection status. Following conditions shall be monitored:Full protection present Reduced protection –replacement required No protection – failure of protector Remote indication of status shall be possible via a volt free contact. The status indication shall provide warning of protection failure between all combinations of conductors, including neutral to earth. This shall prevent a potentially dangerous short circuit between neutral and earth going undetected for some time. The protector shall be supplied with detailed installation instructions. The installer shall comply with the installation practice detailed by the protector manufacturer. The minimum rating of 63 A MCCB/MCB or as recommended by the manufacturer shall be provided as Isolation means to disconnect the device from the power source.

3.1.166

Power Monitor

A.

Power Monitor (PM) shall be a true RMS digital instrument, with LCD display mounted locally on the Incomers’ cubicle door, capable of controlling and measurement highly non-linear loads accurately and able to detect voltage based disturbances. B. PM shall be CE marked and confirm to BSEN 61010-1 C. The Power Monitor shall register all measured values and log current and previous measured values for reporting and printing purposes. D. The Power Monitor shall be supplied with software, user manual and associated interconnecting cables.

3.1.167 A.

Features

The Power Monitor shall include the following features as minimum but not be limited to: a. True RMS measurement of current and voltage b. Control and measurement of highly nonlinear loads c. Capable to detects voltage based disturbances d. Interface capability with PLC/RTU/Circuit breaker e. Provide load shading capabilities f. Provide interface with Power Factor Correction Control equipment g. RS-485 port h. Modbus communication protocol i. DNP3.0 Communication protocol j. Web enabled Ethernet capability k. Measurement of Harmonics


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l. Monitoring of disturbances in the power supply network m. Continuous sampling at 128 times per cycle n. Trending analysis for historical data collection o. Sequence of events

3.1.168 A.

The following parameters shall be displayed on the LCD: a. RMS current of each phase b. RMS voltage L1-L2-L3-N c. Average System voltage (Vav) d. Average system current (Iav) e. Real Power (KW) f. Accumulated energy consumption KWH reading g. Reactive Power (KVAr) h. Apparent Power (KVA) i. Power Factor (cos phi) j. Peak demand k. Frequency (HZ) l. Temperature (T) m. THD current (%Ithd) n. THD Voltage (%Vthd) o. K-factor

3.1.169 3.1.170 A. B.

C. D. E. F.

G. H. I. J. K. L. M. N. O. P.

Measurements

Power Facto r Correcti on Capacito rs Unit Capacitor

The Power Factor Correction Capacitors (PFCC) shall be provided to improve the overall power factor of the plant/equipment to 0.93 or more lagging to meet ADWEA / ADDC regulations. PFCC shall be designed and manufactured for automatic centralised operation as global compensation employing multiple steps, “ standalone” IP 54 Factory Built Assembly (FBA) as described under section “FBA” and as such circuit connections; protection devices and the like shall comply with BS EN 60439. Power Factor Correction Capacitors shall be self-healing type confirming to BS EN 60831. PFCC and all other components that form part of the power factor correction equipment’s shall be housed in a minimum FORM 2 enclosure with no other exception, as described in section “FBA” The enclosure shall be of equal height of MCC and located adjacent to the MCC or at other suitable location within the MCC room. Power factor correction capacitors shall be modular in design, highly reliable, dry, self -healing metalized polypropylene film element or equivalent as approved by engineer, fully encapsulated in plastic housing. Capacitors shall have low losses (typically less than 0.5 watts per KVAr), Capacitor shall be fitted with overpressure disconnect device and a wire wound discharge resistor sized to automatically discharge the capacitor to less than 50 volts in less than one minutes. Capacitors shall be used with capacitor rated duty contactors specifically designed for switching of capactive current. Each capacitor step shall be protected by quick disconnect type fused disconnect switch fitted with recommended HRC fuses disconnecting all the 3 phases simultaneously. HRC fuses shall have built-in blown fuse indicator feature. PFCC enclosure shall be fitted with forced ventilation fan and louvers if necessitated. IP rating in the case of forced ventilation shall be maintained to IP43 minimum. It shall be ensured to isolate the PFCC equipment completely in case alternate source of power supply using generator set is employed. PFCC enclosure shall be sized to accommodate an additional step of equal rating in the future if so necessitated. Capacitor shall be designed to carry 135% of rated current and 110% of rated voltages continuously at 50 degree C. Internal wiring within the PFCC enclosure shall be fire-retardant to 105 degree C.


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Section 015000

3.1.171 A. B.

B.

C.

D. E.

Power Factor Regulato r

The minimum number of capacitor switching steps shall be four (4) as far as practically possible for smaller rating capacitor banks and between 6 to 12 steps for others. The capacitors’ KVAr shall be so chosen to provide maximum programming flexibility such as switching sequence 1:2:2:2, 1:1:1:1 etc. in order to maintain the power factor within the set limits for most of the operating time. An alphanumerical LCD, micro-processor based automatic power factor correction regulator shall be provided to control steps and display measurement of the following:a. Power Factor b. No. of steps connected c. Step connection and disconnection time d. Actual current e. Reactive current f. Active power g. Reactive power h. THD voltage i. Alarm conditions as listed below The regulator shall have built-in alarm relay for remote indication and following alarm conditions locally: a. Low power factor b. Abnormal power factor c. Leading power factor d. Over current e. Over temperature f. Over voltage g. THD high h. Capacitor overload etc. The regulator shall provide facility to manually energize/de-energise capacitor steps for the purpose of testing and verification of required/set power factor. The regulator shall provide facility to change manual mode of operation to auto operation after preset (programmable) time for manual mode of operation has elapsed

3.1.173 A. B.

Detun ed Reactors /Harmon ic Filters

Anti-resonance reactor detuned or filters deemed necessary to reduce the harmonic content shall be provided in accordance with the regulation of the ADWEA/ADDC. Total Harmonic Distortion (THD) of voltage at point of common couplings shall adhere to IEEE Harmonic Standard 519-1992 and ER G5/4.

3.1.172 A.


Field Tests

PFCC assembly shall be tested at site during commissioning The results so obtained shall be verified with the actual requirements and ADWEA / ADDC regulations, modification, if any, shall be carried at no extra cost.

3.1.174

Instruments

A.

All indicating instruments e.g. Ammeters, Voltmeters, KW Meter, Frequency Meter, Power Factor Meter etc. wherever specified shall be of 240 Degree scale, flush mounted and of the same appearance throughout. B. They shall comply with BS 89 and built to industrial grade accuracy not exceeding 0.5%. They shall be sealed against ingress of moisture and dirt and shall be hermetically sealed or tropicalised. C. Instruments shall have an external zero adjustment and have black bezels. They shall be positioned at easily readable height not exceeding 2000 mm above finished floor level. D. Meters shall be fitted with an adjustable RED pointer indicating the normal circuit rating of the associated plant, equipment and drive. E. Instruments shall have a square front appearance, dimensions of 96 mm x 96 mm for measuring the parameters of a plant or equipment’s total connected load. Dimension 72 mm x 72 mm size meters shall be permitted to use for individual loads. F. Ammeters used to measure current in the motor circuit shall have suppressed scale (minimum 5 times the full load current. of the motor) to indicate the maximum starting current. Ammeters shall


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Section 015000


be selected such that the ampere reading under normal running load is approximately 70 to 80 percent of their rated scale. G. All meters shall have factory calibrated scale to match the connected load. It will not be permitted to use any label whereby the operator needs to recalculate the actual measured parameter by computing the value from the label. H. Motors rated full load current 10 amperes and below shall be provided with direct reading type Ammeter and rated current exceeding 10 amperes, the ammeters shall be connected via current transformers. I. Kilowatt-hour meters shall be arranged to register 3 phase 4 wire unbalanced loads. The Kwh meter shall be provided in accordance with the requirement of ADWEA or their associated companies.

3.1.175 A.

B.

The control power transformer shall be double wound, isolating type, with screen between the windings; designed and manufactured to BS EN 60742, centre tapped and earthed via a removable bolted earth link, minimum capacity 100VA/50Hz, 415/110 Volts, 240/110 Volts and/or 240/24 V as per applications requirement. The control transformer shall have the following features: a. Vacuum impregnated windings. b. Low Inrush Current c. Torch proof termination. d. Easy access to fixing holes e. Legible and easily accessible rating label/plate

3.1.176 A.

B. C. D.

E. F. G.

B. C. D. E.

B. C.

Voltage Transf orm ers

Voltage transformers used in conjunction with instrumentation where specified shall be of the isolatable type with a secondary 3 -Phase 110 volts. The transformers shall be epoxy resin and comply with BS. 7625. The primary and secondary windings shall be protected by H.R.C. fuses. The connections between the fuses and the primary conductors shall be adequately rated to withstand the short circuit rating of the Switchgear In the case of HV, automatically operating shutters shall be provided to conceal the HV orifices when the transformer is withdrawn. A padlock with non-interchangeable key shall be provided for the shutter.

3.1.178 A.

Current Transform ers

Current transformers shall comply with BS 7626 and shall be suitably rated and designed to carry out appropriate function viz. metering and protection as specified in particular requirements. The secondary current of current transformer shall be 5 A unless specified otherwise The minimum Short Time Current Rating shall be 3 seconds. Identification labels giving type, ratios, accuracy, limit factor, rating, output and serial numbers shall be fitted. Duplicate rating labels are to be fitted on the exterior of the mounting chambers suitably located to enable reading without removal of any cover. Only Bar primary type current transformers shall be used. One secondary terminal of each current transformer shall be earthed through a removable link at the Switchgear. Secondary wiring of the current transformer shall be terminated on shorting type terminal block. The supplier of equipment (FBA) shall ensure shorting of CT secondary wiring through the terminals prior to the shipment of the equipments.

3.1.177 A.

Contro l Power Transform er

Timers

Timers shall be plug-in or surface-mounting types; solid state microprocessor based employing CMOS IC technology. Timers shall be suitable for operation on a nominal 240 V AC, 110V AC, 24 V AC/DC or other voltage as specified or deemed necessary for the safe operation. Timers shall have linearly calibrated scales, in units of time, each scale division being a maximum of 5% of full scale. Repeat accuracy shall be within 0.5% of full scale.


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Section 015000

D. E. F. G. H. I. J.

Timers shall be provided with “energized” and “timed out” indicators. Plug-in timers shall be fitted with transparent dust-proof covers. External connections shall be screw clamp terminals which are easily accessible with the timer in position Timers shall be secured to their bases by retaining bar or clip to prevent malfunction due to the relay being loosened in its base. The pin configuration shall be printed on the casing of the timer and on its associated bases in order to ensure correct pin alignment. Timer shall be provided with 10 Amps. Rated output relay with DPDT contacts. Unless specified otherwise, timers shall be provided for circuits that require delay on operate, delay on release, and star-delta starting of a 3-phase induction motor. Multifunction timing relay programmable where specified shall be provided to the satisfaction of the engineer.

3.1.179 A.

B.


Hour Run Meter

There shall be two counters provided for each motor. The one counter shall be non-reset table hour run meter, rotating disc type for measuring total operating period (accumulative) of a motor. The minimum size shall be 48 x 48 mm. The counting capacity shall be 99,999.99 hours. The colour of the decimal digits shall be red while the colour of other digits shall be white. The second counter shall be provided for counting TOTAL (accumulative) number of start of a motor. This shall be non-resettable, electronic type with permanent memory retention arrangement and LCD display to indicate Number of start of a motor.

3.1.180

Digital indi cators

Digital indicators shall have 4 digits display with floating decimal point. Digits shall be 14 mm high. The entire display shall be of standard DIN format 96 x 48 mm

3.1.181

Fuses

All fuses shall be HRC ( High rupture capacity). One spare fuse shall be clipped close to the position in which it would be in service. All small wiring for controls, voltmeters, supplies, etc. that originate from the main and sub-main busbars, shall be protected by busbars mounted fuses, suitable rated for the purpose intended. Installation of fuses shall be such to enable easy and safety access for replacing.

3.1.182

Protective Devices

The application specific protective devices where provided shall generally comply with BS 142. The contractor shall submit detailed engineering calculations and co-ordination study for the protective devices so proposed for engineer’s review and approval prior to the commencement of any work undertaken.

3.1.183

Pilot Devices

A. Pilot devices shall confirm to BS EN 60947-5.1. B. Pilot devices shall be round in shape having 22 mm Dia suitable for mounting on the cubicle door. C. The pilot devices shall have two main parts the operator and the Snap-On contact block. The mounting between the cubicle door and the operator shall be done through Snap-On flange. D. Pilot devices shall be designed to provide IP65 as a minimum protection when installed in the enclosures. Terminals shall be protected to IP2X.

3.1.184

Push Buttons

Push buttons shall comply with the following specifications unless specified otherwise in particular requirements: a. Standard design b. Mushroom type where specified c. Non Illuminated d. Anodized Aluminium Bezel e. 1NO+1NC configuration minimum f. RED button for STOP function g. GREEN button for START function [Recessed type] Contract 106, Volume II

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Section 015000

h. i. j. k.


Mushroom RED for Emergency STOP function BLACK button for manual RESET GREY button for lamp test Push buttons for other functions where applicable shall be subjected to the approval of engineer.

3.1.185

Selector Swit ches

Selector switches shall comply with the following specifications unless specified otherwise in particular requirements: a. Standard design b. Lever type cam operated c. Twist Release/Push-Pull/KEY type where specified and/or approved by engineer. d. Non Illuminated e. Anodized Aluminium Bezel f. No. of positions as per logic diagram g. BLACK colour h. 1NO+1NC configuration minimum

3.1.186

Pilot Lig hts (Indic ators)

Indicators shall comply with the following specifications unless specified otherwise in particular requirements: a. Low voltage transformer latch type 110V/50Hz primary b. Bulbs shall be long life neon types rated at least 10% higher than the rating of the bulb provided. c. RED colour for RUN/ON indication d. GREEN colour for STOP/OFF indication e. AMBER colour for TRIP/FAULT indications f. WHITE colour for SUPPLY AVAILABLE indication g. BLUE colour for SUPPLY ON indication h. Indicators for other conditions where applicable shall be subjected to the approval of engineer. i. The pilot light operator shall be designed to facilitate removal of bulb from the front of the unit without requiring any tool. j. LEDs shall not be permitted unless forming built-in feature of stand-alone product/controller to indicate operation status.

3.1.187

Light Emitting Diods (Led)

LEDs shall be allowed only when forming built-in feature of stand-alone product/controller to indicate operation status.

3.1.188

Remot e Push Button Stations

Remote push button station where specified shall comply with the following specifications: a. IP66 metal/thermoplastic enclosure for standard applications b. IP68 metal/thermoplastic enclosure when submerged in the water suitable for installation in nonsafe areas involving Methane and H2S gases. c. Suitable for panel and base mounting d. Pilot devices used shall be of the specifications described above and confirm to the degree of protection of the enclosure.

3.1.189

Enclos ed Emergency and Safety Switc hes

A. Emergency and safety switches where specified shall confirm to BS EN 60947-3, Utilization Category AC23 and comply with the following specifications: a. IP65 metal/thermoplastic enclosure suitable for installation in non-safe areas involving Methane and H2S gases. b. Visible operating handle with marking OFF/ON position c. Lockable in Off position by using padlocks d. Suitable for base/wall mounting e. The breaking capacity shall be more than the largest circuit it breaks f. The emergency switch shall have red handle on a yellow background


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Section 015000

3.1.190


Control System

Manual control: Operators at pump station observe the process and implement control action manually. Remote manual control: A comprehensive set of measurements is transmitted via RTU unit to the operator employing a SCADA system. The necessary action is taken by the operator, directed from the control console Automatic control: Signals from field measurements are processed by a suitable RTU for remote control and PLC for local control with adequate programs for the control; control actions are determined by algorithms. Remote automatic control : A comprehensive numbers of measurements, transmitted via RTU unit to the SCADA system, will be processed by computer programs and control actions are determined by algorithms. A. Though the SCADA system is not part of this contract, the Contractor shall provide facilities required for the communication with the existing telemetry / SCADA system via RTU. One panel compartment in the MCC shall be provided with local power supply with battery back-up for RTU. RTU, with enough terminals, shall be provided and wired for all input and output connections. The list of I / O shall be in accordance to the latest list issued by the telemetry section of PGD plus 25% spare capacity. A copy of I/O requirements is shown under control Philosophy (subject to revisions in future if required). B. A selector switch, having two positions "Local/Remote", shall be provided to enable controlling and operating the entire plant either locally, through PLC mounted in control compartment in local mode. Or remotely, through RTU when remote mode is selected. C. Pump selection, selector switch with the following selections a. Duty pump No1 b. Duty pump No2 c. Duty pumps No3,etc. d. Cyclic duty e. Manually through selector switch provided for each pump (Hand / Off / Auto) E. A selector switch for selection of operation through level controller or through float switches shall be provided in addition to automatic change-over from level control to float switches control in case of failure of level control. Normally this switch shall be kept at level control position. F. The controls of the Plant shall be arranged in a logical order. Any failure or warning signal shall activate the annunciator. Whenever a fault occurs an indicator lamp shall illuminate the annunciator window to indicate the fault and a buzzer shall sound to give warning. It shall be possible to deactivate the buzzer but the visual signal shall remain until the fault is cleared or accepted. The control system shall be, accordingly, provided to enable executing the following tasks: a. Full automatic control by RTU, in remote position selection b. Enable local manual operation and control during maintenance or repair c. Enable auto through PLC in local position selection d. Safety devices can not be overridden e. Process programs can not be changed without proper authorization f. Set points can not be changed without proper authorisation G. In case of unauthorised manipulation of control systems a remote and local alarm signal shall be given. This alarm can only be deactivated by resetting controls to their original operation points or by an authorised change. Any change of set-points shall be recorded in detail in the "event list". H. For reference and guidance the control philosophy for the operation of pumps is attached as Appendix.

3.1.191 3.1.192

Programmable Logic Contro l (PLC) Scope

The programmable logic controller (PLC) shall be provided as described herein which will receive discrete and analogue inputs. Through the use of relay ladder logic and other languages i.e. FBA, IL, Sequential Function Chart (SFC) etc., it will control discrete and analogue output functions, perform data handling operations and communicate with external devices.


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Section 015000

3.1.193 A.

B.

C.

D.

B.

Design And Manufact ure

The programmable logic controller and all of the corresponding components together with accessories, interconnecting cables and associated connectors used within the contract shall be supplied by the same manufactures. All products shall be designed, manufactured, and tested in accordance with recognized UL, CSA, IEC and CE mark industrial standards. The system shall be operational during and after testing. See tables on the following page for standards requirements.

3.1.195 A.

Manuf acturer’s Standards

The manufacturer shall have fully operational ISO9001 certification issued by an internationally recognised agency for "Quality Systems- Model for Quality Assurance in Design/Development, Production, Installation, and Servicing." The manufacturer shall submit properly documented record of supply of similar equipment working satisfactorily in the similar climatic and service conditions for the last 10 years. This shall be the minimum prerequisite to propose such equipments. The manufacture in addition to above shall also submit a written authenticated statement to provide after sale support services including that of availability of spares for a minimum period of 10 years from the date of completion of commissioning of entire project. The system shall comply with current EEC Directives for compliance to EMC immunity and elimination as indicated by IEC 1000 and associated sections of the machinery directive BS EN 60204.

3.1.194 A.


Training

The manufacturer or its authorized representative shall provide complete technical training during the project execution phase and after completion of the project, as directed by the department. This shall include headquarters or local training, regional application centres, and local or headquarters technical assistance.

3.1.196

Reference Standard s

A. a. b. c. d. e. f.

The PLC equipment shall confirm to the requirement of the following standards: BS 7671 16th Edition of the IEE Regulations for Electrical Installations BS EN 60204 Safety of machinery BS EN 61000 Electro-magnetic compatibility BS EN 61131 Programmable Controllers BS EN 50170 General purpose field communication system ISBN 0 86341 233 5 IEE Guidelines for the documentation of computer software for real time and interactive systems g. ISBN 0 11 883906 3 HSE Programmable Electronic Systems in safety related applications

3.1.197 A. a. b. c.

All components of the PLC system, except CRT terminals and programming workstations, shall confirms to the following environmental specifications Storage Conditions Temperature -40 To 85 Degrees Celsius Operating Conditions Temperature 0 To 55 Degrees Celsius Humidity 5 to 100% relative humidity, non-condensing

3.1.198 A.

B. C.

Enviro nmental Conditi ons

PLC Hardware

PLC system shall comprise of a central processing unit, input/output modules, serial interface modules and programming units. The PLC shall be of modular construction and as required and approved by the engineer with plug in I/O cards and facility to install expansion racks when necessary. The system shall include 25% spare capacity in hardware and memory for future modifications. The PLC shall be supplied complete with a laptop programming and diagnostic device plus all necessary leads and programming software & manuals. The PLC control equipment shall be housed in the common controls section of MCC and shall be fed by Non door interlocked MCCB. A separate signal marshalling section shall be provided to accommodate all input and output signals to the Control and Telemetry section.


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Section 015000

D.

E.

F. G. H. I.

J.

The equipment shall accept status and analogue (4-20mA) signals from both field and panel mounted instruments. Analogue inputs shall be scanned into a 12 bit binary (minimum) analogue to digital converter with buffered inputs. The PLC power supply shall be 24Vdc, 110V ac as specified. The equipment shall be maintained in operation during a period of mains failure drawing power from the battery or UPS system for a minimum back-up time of 8 hours. The battery/UPS system shall include diagnostic and automatic self-test routines with volt-free contacts to initiate an alarm in the event of malfunction. If required by the particular specification a HMI/Text Display Unit as specified will be provided as a permanently connected means of accessing set points and timer settings. The HMI shall be pre-programmed to provide a basic graphical display of the process. Real-time numeric display of process variables and alarm messages shall be available. All process control functions shall be accessible for the operator from the HMI. The application program shall be stored in "Non Volatile Memory". A schematic block diagrams for an overview of the PLC system and general arrangement in the MCC section indicating the location and proposed placement shall be submitted for Engineer's review. The contractor shall ensure while submitting his proposal that the PLC systems selected provides high availability and high level of integrity.

3.1.199 A.

B. C. D.

E.

B. C.

D. E.

B. a. b. c. d. e. f.

Power Supply

The power supply unit shall be modular in design, compatible with main CPU and expansion racks allowing easy on-site replacement in the unlikely event of failure. The power supply shall contain an isolated, internal 24VDC power source for I/O modules requiring 24VDC power. The power supply unit shall contain a battery compartment for installing a long life Lithium battery to protect programming CMOS RAM memory. The battery power transfer shall be bump less. The battery shall be capable of supporting the memory for a period of minimum one year without having power applied to the system. The low battery condition shall be alarmed. This battery shall be replaceable while power is applied to the PLC.

3.1.201 A.

Parts Interchange

The PLC controller family shall have a high degree of interchange capability. The power supply, battery, EEPROM Chips, Hand-held programmer should all operate equally well regardless of the CPU being used. The system shall incorporate a modular design using plug-in assemblies with pin and socket connectors. It should be possible that all assemblies and sub-assemblies performing similar functions shall be interchangeable. The system design shall accommodate the replacement of assemblies without having to disconnect field wiring, removable connectors shall be used to connect field wiring to the individual circuit board assemblies. All major assemblies and sub-assemblies, circuit boards, and devices shall be identified using permanent labels or markings each of which indicates the manufacturer’s catalogue number, product manufacturing date code, UL and CSA certifications together with CE marked symbol.

3.1.200 A.


Central Proc essi ng Unit (CPU)

The Central Processing Unit shall be a modular type capable to solve application logic, store the application program, store numerical values related to the application processes and logic, and interface to the I/O systems. The CPU shall need no additional modules to provide at least the following advanced programming features: PID Math Double Precision math Logical functions Subroutines High Speed Counter function


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Section 015000

g. h. C.

D.

E.

F.

Data Array Move and Indirect Addressing The user application program shall be stored in Random Access Memory (RAM) or a combination of RAM and Electronically Erasable and Programmable Read Only Memory (EEPROM). The user application program scan time, on average, shall be no greater than 50ms for logic and integer processing. Where three terms control (PID) and Floating point data processing is required, the application scan time shall be no greater than 100ms. The Central Processing Unit shall contain a minimum Intel 80188 or Intel 80386EX microprocessor operating at speeds no less than 10 MHz up to 25MHz as the main processing element, memory. The CPU shall contain a built-in Ethernet (IEEE802.4) port, 10BaseT. The port shall support simultaneous communications for programming, PLC-to-PLC exchanges through programming, and Host/SCADA communications from PCs.

3.1.202 A. B. C. D. E.

B. C.

B. C. D. E. F. G.

B. C.

Visual Diagnosti cs

Status of low or dead battery and the diagnostic status of the discrete I/O modules containing fuses shall be indicated. The red LED shall be illuminated (fail safe) to indicate fuse healthy condition. LED should extinguish to show presence of a blown fuse condition. The diagnostics shall provide information on the configuration and CPU, memory, communications and I/O status. The processor shall maintain the states of up to 128 discrete system diagnostic bits to be read by a host or incorporated as contacts into the ladder program for customized diagnostic routines. Faults may be cleared by the user by way of a programmer. Provision shall be made by way of passwords to protect these faults from unauthorized clearing When an I/O fault occurs, the processor shall report the location of the fault, the condition the address and the circuit number if appropriate. The processor function shall have the capability to time-stamp system faults for future references.

3.1.205 A.

Real Time Clock

All PLC’s, shall be additionally programmed to perform, alarm and event logging incorporating a real-time clock (RTC). The RTC shall have stability better than 1 Second Per Day. The RTC shall be protected against power failure for a minimum of 200 hours. Timing shall continue throughout any power failure. The use pf RTC functions within the PLC other than time dependent control and logging shall be kept to a minimum. The use of constant frequency bits, reserved within the PLC data areas, shall be used for general timing applications.

3.1.204 A.

Serial Communi cation Port

Serial communication ports shall be provided to facilitate the following: Connect the programmer for PC compatible programming software Connect the Hand-Held Programmer to the PLC Connect to one of the wide variety of third-party operator interfaces utilizing an open architecture software protocol. Provide RS-422 signals with RS-485 compatibility. The characteristics of this port shall be software configurable and shall be modem compatible

3.1.203 A.


Input Modules

Digital input modules shall be 16-point (maximum per Card), 24 VDC, signal source type, with individual screw terminal connections. Where space restrictions or high-density signal requirements are apparent 32-point 24VDC digital input modules may be permitted with the approval of the engineer. All digital input units shall be capable of accepting, a volt-free contact signal, and the source voltage shall be regulated 24VDC and shall be derived from the PLC panel. Where the input from an external source is not volt-free then suitable isolation devices shall be provided in order to prevent cross-connection of different supplies. This device may be e.g. interposing relay or optical-isolator. For frequencies of operation greater than 30


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Section 015000

D.

E. F. G. H. I.

operations/hour, the use of electromechanical devices shall not be permitted. All interface/isolation devices shall provide visual indication of Signal State. All Input modules shall be segregated into groups, which relate to 24VDC supply commons. Where different supplies are apparent in input connections, these shall be segregated in accordance with supply common grouping. Inputs signals from 'DUTY' equipment shall not be allocated to the same input module as signals from 'STANDBY' equipment performing the same function. The analogue current input module shall be capable of converting 4, 8 or 16 channels of inputs in the range of 4 to 20 mA. Resolution of the converted analogue current input signal shall be 12 bits binary All analogue signals shall be updated each scan into a dedicated area of data registers. The conversion speed for all analogue current input channels shall be within 2 - 10 milliseconds

3.1.206 A. B. C. D. E. F. G. H. I. J. K. L. M. N.

B. C. D.

E. F. a. b. c. d. e. f.

Outp ut Modules

Discrete AC output modules shall have separate and independent commons allowing each group to be used on different voltages. Discrete AC output where used shall be provided with an RC snubber circuit to protect against transient electrical noise on the power line. Discrete AC outputs shall be suitable for controlling a wide range of inductive and resistive loads by providing a high degree of inrush current (10x the rated current). Discrete DC output modules shall be available with positive and negative logic characteristics in compliance with the IEC industry standard. Discrete DC output modules shall be provided with a maximum of eight output points in two groups. with a common power input terminal per group. Discrete DC output modules shall be compatible with a wide range of load devices, e.g. motor starters, valves, and indicators etc. The current rating of the relay output shall be capable of supplying the load according to the applications. The analogue voltage output module shall be capable of converting digital data to analogue outputs in the range of -10 to +10 volts. Resolution of the converted output signal shall be minimum 12 bits. All analogue signals shall be updated each scan into a dedicated area of data registers. The analogue voltage outputs shall be configurable to default to 0 mA, 4 mA or hold-last-state in the event of a CPU failure. Output signals to 'DUTY' equipment shall not be derived from the same output module as 'STANDBY' equipment performing the same function. Digital outputs used for AC inductive loads shall be fitted with arc suppression devices as close to the load as is practicable. Means shall be provided to allow the disconnection of outputs causing unsafe movements or actions without removing power from the PLC Processor or inhibiting program execution

3.1.207 A.


PLC Syst em Failur e

Provide hardware Watchdog relays driven by digital outputs from the PLC to detect major PLC processor fault, I/O error and low battery fault. Make provision to hard-wire the relay contact to the RTU. PLC's to include facilities to retain the last state of the output modules at the time of the PLC failure. This shall be achieved by means of hardware or software. Failure of an extension or remote rack, sub-system or remote PLC, or communications between units, shall set each bit of the input memory image at a safe state such that failure will not cause unwanted movements or actions to occur. If required by the contract, a ‘Hot-Standby’ processor shall be provided to automatically and bump less take over processor functions in case of primary processor failure. The power (AC and DC) for I/O shall be distributed by the use of suitably rated MCB's. Separate MCB shall be provided for the followings: PLC and I/O rack power supplies. External networking or communication etc. if any Analogue DC power supplies. Digital 24VDC power supplies. Digital 110VAC input modules. Digital 110VAC output Modules


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Section 015000

3.1.208 A.

B. C. a. b. c. d. e. f. D.

E. F.

G. H.

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

B. C. D.

E. F. G.

Hand-Held Prog rammer

The Hand-Held Programmer shall provide 4 modes of operation, Program, Data, Configuration, and Protect. The Hand-Held Programmer shall be powered by the connected PLC, without the need of any external auxiliary power. The Program mode shall provide the capability to enter an application program, monitor an existing program, or make on-line changes. The Data mode shall provide the capability to monitor all of the reference tables, and make word changes to this data. The Configuration mode shall provide the capability to configure and monitor the connected Input/Outputs. The Protect mode shall provide the capability to select password protection options. The Hand-Held Programmer shall be capable for online connectivity. The Hand-Held Programmer shall be capable of reading, writing and comparing the contents of RAM and EEPROM.

3.1.210 A.

PLC Soft ware

PLC Software shall be developed within the BS EN 61131-3 environment. Application program shall be developed by using software package that only conform to BS EN 61131-3 requirements. Standard IEC libraries of Functions and Function Blocks shall be used when writing application software. All software shall be suitably documented to include the following as a minimum: Suitable commands Function description Symbolic addressing local data areas Symbolic addressing global data areas Descriptions of all constants List of cross-references Minimum two programming devices shall be available for development of application programs, a small hand-held device with back-lit LCD readout and a Software programming package running on a PC compatible laptop or desktop computer. On-line and off-line, CPU and I/O configuration and application program development shall be achieved with a PC compatible computer and programming and documentation software. Both the PC compatible computer and the hand-held programmer shall be connectable to the PLC via a built-in serial communication port. The serial communication port shall provide RS-422 signals with RS-485 compatibility. In addition to the serial communications, the PC compatible computer shall be connectable to the PLC via Ethernet TCPIP supporting the SRTP application protocol. The programming devices shall have access to the application program, the CPU and I/O system configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O override capabilities

3.1.209 A.


Window s Compatible Softw are

The WINDOWS/ Windows NT Platform compatible software shall provide the capability of reading, writing, and verifying the configuration and program with a diskette backup. The software shall provide on-line help information throughout its execution paths. The software shall allow development of programming, storing the program to the PLC, monitor program and reference address status while the PLC is in Run or Stop mode. The software shall be user friendly to generate printout of the program for documentation purposes selectable to print various options e.g. printing of complete program with instruction for each rung, the reference list, reference description, reference address & tables etc. The software shall have built-in modem connection capabilities. The programming software shall support bump less run mode storage of the program to the CPU. The software shall have provisions for importing and exporting tag names, comments and descriptions in an .xls format


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Section 015000

3.1.211 A. B.

C. D.

E. F.

G. H.

B.

C. D.

Display Unit

The stand-alone panel mounted Display Unit where specified, shall be serially interfaced with PLC within the MCC for local control and monitoring function that meets and/or exceeds the requirement as stated below: The display unit shall be back-lit with touch screen LCD coloured, high performance pixel graphics flat panel capable of providing process information by using variety of communication protocols via Modbus, Profibus, DH-485, Device net, DH+ etc. to name few. Following are the minimum features the display unit must be capable of supporting. Remote downloads (via network, gateway etc.) a. Screen Security b. Built-in alarm functionality with enhanced alarming capability c. Floating point file support d. Touch pad buttons e. Universal Language Support f. Bar and trend graph g. Real-time clock h. ASCII input and display i. Ethernet/IP Communication j. Expandable Application Memory k. Window based configuration software l. Serial com port for PLC communication m. Serial com port for Printer n. Minimum resolution 240 x 128 pixel o. Suitable for 240 V AC/24 V DC p. Operating temperature 0 to 50 degree centigrade q. Humidity up to 95% non condensing r. UL Listed s. CE marked

3.1.214 A.

Syst em Securi ty

The CPU shall have a memory protect key switch together with passwords to provide different levels of access privilege for the PLC when the programmer is in On-line.

3.1.213 A.

Instr uct ion Set

The programming language shall be BS EN 61131-3 compliant. The CPU shall be capable of solving an application program whose source format shall be relay ladder diagram. The language shall support relay, timers and counters, arithmetic, relational, bit operation, data move, conversion, and control functions etc. The CPU shall be capable of solving an application program whose main program format is in Sequential Function Chart (SFC) with underlying code in relay ladder diagram. Control functions shall be provided to limit program execution, an immediate I/O update of all or a portion of the inputs or outputs for one scan while the program is running, or to update I/O during the program in addition to the normal I/O scan. Additionally, the function shall provide a mean to read inputs into memory auxiliary to the true input table, and execute outputs from discrete memory alternate to the true output table. A method for structuring the ladder program shall be provided with the use of a JUMP Function. This will cause the program execution to jump to a specified location in the logic targeted by the location of the LABEL function. Diagnostic and fault detection requirements shall typically include I/O data corruption, single bit RAM failures, power supply failures, processor failures, and I/O bus failures. Hot standby systems where specified shall detect and report failures of all critical components so that appropriate control actions may be taken. All components that acquire or distribute I/O data or that are involved in execution of the control logic solution are considered critical components. A fault in the active unit shall cause a switch of control to the backup unit. Refer to the particular section for detailed specification pertaining to Hot-Standby systems if specified.

3.1.212 A.


PLC System Documentatio n

The following documentation shall be submitted to the engineer for approval prior to the application software development:


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Section 015000

B.

C. D. E.

a. Functional Specification including PID and flow charts b. I/O configuration drawing c. Field Interface d. Communication if any e. Software Specification The following documentation shall be submitted to the engineer for approval after completion of software development, design and commissioning of the system. a. Overview of the system software b. Updated Software specification. c. Full software listing with descriptive comments and synonymous. d. A written description of the function of each section of the PLC programme. A full written description or listing of local and global variables, including all internal flags and calculation data areas with description of use. I/O and Communications configuration table, highlighting all switch or configuration settings for all processor modules, I/O modules, racks or base-plates, operator interfaces, printers etc. Operation and maintenance manual to include but not limited to PLC start-up, power failure, PLC systems failure, battery low, communication, field instruments etc.

3.1.215 A. B.

C.

B.

C.

B.

C. D. E.

F. G.

H.

Factory Accept ance Tests (FAT)

The FAT shall demonstrate compliance with specified requirements and duly approved Functional Design Specifications (FDS). The FAT shall ensure compatibility of interconnected equipment, the proving of their interconnections and the interchange ability of modular items, plus operational/failure mode testing and recovery from failure. The FAT shall be conducted using suitable and duly approved simulation equipment to ensure satisfactorily operation of the PLC.

3.1.217 A.

Pre-inst allation tests

All equipment shall be subjected to a pre-installation test. All equipment shall be visually inspected before installation to ensure that no obvious damage has occurred during transit and storage. Where relevant ranges, duty, labelling etc., shall also be checked. Pre-Installation tests do not require detailed test procedures or documentation unless equipment is designed for installation on an existing and functioning site. Witness/ approval of preInstallation tests shall be at the discretion of the Engineer.

3.1.216 A.


Installation

Input/output modules shall be provided with adequate cabling support to avoid strain on the termination headers. The I/O wiring shall be loomed to allow for the removal of the individual I/O card header complete with the attached wiring. For each I/O module, the header shall be clearly identified as to which module it relates. PLC I/O wiring shall be wired directly to terminal blocks. Terminal blocks shall be installed to display a logical physical order coinciding with the associated PLC input identification order. Each wiring termination between I/O modules and incoming/outgoing terminals shall be identified with the relevant alphanumeric I/O address. Provide protection against lightning and/or power surges to protect electronic devices and telecommunication links against surges induced in signal and power lines. The protection device shall be such that the limiting-level shall not interfere with the normal operation of the system and shall be below the electronic device's surge withstanding rating. Provide Zener barrier in the panel wired to the low voltage/low current signals (level, pressure transmitters etc.) present in the in the non-safe area (classified areas - Methane and H2S). 2 I/O wiring shall be minimum 0.75 mm stranded copper conductors (24/0.2mm), PVC insulated to withstand 300/450V, and BASEC approved and manufactured to BS 6500 Table 19 or equivalent. Where high-density modules are used then suitably rated multi-core cables may be used. Where 110VAC signal switching is utilised Input/output ‘Source’ switching characteristics shall be maintained.


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Section 015000

I. J. K.

L. M. N.

10% spare capacity or one spare module of each type utilised, whichever is the greater, shall be provided for each PLC system. Sufficient chassis slots (rack mounted PLC system) with empty I/O module shall be provided to allow for a 10% future expansion. The plastic trunking used for I/O wring shall have sufficient capacity to allow the spare I/O slots to be fully wired. The trunking shall not be filled to greater than 70% before the spare slots have been wired. Sufficient spare terminal mounting rail shall be installed to allow the future wiring of the spare I/O modules to outgoing terminals. All unused I/O on installed modules shall be terminated. I/O modules shall be designed for 1500 volt isolation between the field wiring and the system backplane.

3.1.218 A. B. C. a. b. c. d. D. E.

F.

G. H. I.

B. C. D. E. F. G.

Field Tests

The tests conducted at works shall be repeated upon completion of installation of the hardware including all cables, operator interfaces if any and peripherals devices, field instruments and before any plant is connected. The performance of the system under test shall be compared with test reports, technical schedule and tables to ensure that it meets the requirement of the specifications in full. The first time test at site if possible if possible shall be conducted whilst the plant remains in a 'dry' state, i.e. without any process media - water, , sludge, chemicals etc. being present. After satisfactory completion of the 'dry run test’, the system shall be tested after the introduction of the process media and with all plant equipment available. An up to date copy of each system diskette and the system documentation shall be available at site for the duration of the site-testing program. An operational and Hardware/Software log shall be maintained. Emergency-stop and safety circuits shall be hard-wired and shall be tested to ensure that safety circuits are non dependent on the PLC software developed logic for the protection of the equipments.

3.1.220 3.1.221 A.

Source Tests

Provide system acceptance testing as detailed in the technical submittal already approved and covered under provisions of Section xxxxxxx - General Requirements. Test the complete PLC system that includes the full control scheme. Operational/failure modes shall be demonstrated using the following simulation devices: Digital inputs make/break switches Digital outputs indicator lights or relays Analogue inputs potentiometers/voltage and current sources Analogue outputs analogue or digital meters Where other method of simulation or signal forcing is proposed this shall be approved by the Engineer prior to conducting the tests. Interfaces to other equipment where applicable, e.g. as data links to other PLC systems, communication links, variable speed drives, electronic motor protection systems, power monitor and RTU telemetry systems etc. shall be tested using equipment of the same type. If the interface equipment are supplied by other vendors then arrangements shall be made, by the contractor, to conducts an integrated test at one of the manufacturer's works in the presence of both suppliers. Testing of software and communications diagnostics as applicable. The Assembly shall not leave the manufacturer’s works until the same have been duly approved and stamped by the Engineer and written permission is obtained for their dispatch to site Submit test report incorporating a change in control system, faults found, solutions provided and software and documentation changed.

3.1.219 A.


Remote Terminal Unit General

Each RTU shall be microprocessor based equipment having a proven track record within the wastewater industry, having a robust modular construction, and constructed for ease of maintenance and repair.


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Section 015000

B. C.

Functional Requirements RTU’s shall be provided with following functions, as a minimum, but not be limited to: a. Support for DNP-3 protocol. b. Data acquisition from plant equipment (digital and analogue inputs). c. Data recording and time stamping (time and date). d. Sequence of events recording. e. Alarm management (prioritise) including report by exception. f. Handling data received from control centres. g. Data processing (including math functions). h. Initiating commands (digital and/or analogue outputs) & software routines (pump sequence control). i. Self diagnostics j. Communications control including route selection. k. Programming and diagnostics via control centre, & RTU configuration and maintenance units. l. On-line and off-line RTU configurations.

3.1.222 A.

B.

C.

D.

E.

F.

G. H. I. J.

K.

L. M. N. O.

P.


RTU Hardware

RTU will be the main device used to control loops in each RTU process area. Each RTU shall be able to receive analogue and digital inputs from the field, perform input signal processing and alarm checking, perform algorithms control, and output to valves and other actuators. Each RTU controller together with its associated control and accessories e.g. back-up power, interposing relays, surge suppressors, barriers, fuse/MCB, terminals etc.shall be mounted and wired on a back plate. The assembly shall be tagged and fully factory tested by the RTU Vendor. The fully factory tested, passed and tagged RTU sub-assembly shall be free issued to the MCC vendor for mounting in the MCC's dedicated and designated as RTU/Telemetry control section. All dimensions and wiring requirements shall be co-ordinated by the contractor, MCC vendor and RTU vendor accordingly. While installing the RTU sub-assembly in the RTU section of the MCC, it shall be ensured that all parts of the sub-assembly have easy access and ability to do maintenance of the modules/cards. The circumstances where the RTU is to be retrofitted to MCC or if due to size restrictions within the MCC, it is unfeasible then the RTU as a complete sub-assembly shall be mounted within a stand-alone IP65 enclosure. The specification and guidelines pertaining to the design, construction, installation, testing and commissioning of standalone RTU as provided in the relevant sections "Factory Built Assembly", "Motor Control Centres" and "General Requirements" shall be followed. The RTU shall be an intelligent device capable of handling data collection, logging, report by exception, current data retrieval and pump sequence control programs. Each RTU shall be sized for controlling the specified input/outputs and future expansion. The program and data held within memory shall remain intact and error free if all external power is removed from the RTU for a minimum period of one year. The contractor shall supply batteries for each RTU with sufficient capacity to maintain full power to the RTU for 8 hours, after a power failure. The UPS system shall be integral to the RTU. The batteries shall be of a sealed NiCad maintenance free type. All field connections shall be made in terminal strips located for easy access. These terminals shall be clearly marked and identified. Terminals carrying voltages in excess of 24V shall be fully shrouded to IP2X. All terminals shall be of the ‘flip up’ isolator type with test points. A configuration and diagnostic device shall be provided for local display of signals, programming and fault diagnosis. RTU’s shall be capable of being equipped with RS232/485 links for interconnection to standalone control systems, standard equipment packages and PLCs. A dedicated serial port shall be provided for connecting a hand held programming unit or the PC. Connection to other devices will use Modbus ASCII or RTU protocol as standard. The SCADA system communication has been standardised on the DNP3 protocol, which being an objectbased application layer protocol, has the flexibility to support multiple operating modes such as poll-response, polled report-by-exception, unsolicited responses and peer-to-peer. RTU’s shall be configured such that a single RTU failure will not interrupt or degrade equipment monitoring and control functions of other RTU’s. RTU failure shall be alerted to the operator at the highest alarm priority.


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Section 015000

Q. R. a. b. c. d. S. T.

The modem used for PSTN communications shall be of a type approved by Etisalat and be fitted with a surge diverter. The RTU shall include input / outputs circuits as per site requirements but as a minimum the following input/output circuits: 32 digital inputs 16 digital outputs 12 analogue inputs 4 analogue outputs The RTU shall be modular in design and expandable allowing plugging a wide range of modules on to a backplane of an RTU rack without aid of any tool. All components of the RTU assembly shall be capable of operating satisfactorily in an ambient temperature of 65 Degree C and up to 100 % non-condensing RH.

3.1.223 A. B. C. D.

B.

D. E. F.

G.

B. C.

B.

Analogu e Inputs

A minimum of 12-bit analogue to digital conversion shall be used providing a minimum resolution of 1 in 4,096. The overall conversion accuracy measured from the RTU terminals shall be linear and better than 0.15% of full scale under operating conditions specified elsewhere in this specification. The analogue inputs shall be configurable to 4-20 mA dc.

3.1.227 A.

Digital Output s

The digital output shall consist of volt-free relay contact outputs configurable for either normally open or closed in the de-energised state. The rating of the relay contact shall be minimum 200 mA at 24 V dc for an inductive load, or 2A at 240V, 50 Hz ac for a resistive load. 6 The relays shall be rated for a minimum of 10 operations. The RTU shall monitor the relay driver circuit and check for the correct operation of the relay. Each digital output shall be configurable between continuous and pulse modes. In continuous mode, the digital output shall be set to a particular state and remain there until set to the opposite state. In pulse mode, the digital output is set to the energised state for a preprogrammed time, which shall be a minimum of 2 s. The time shall be user configurable for each pulse mode output. The mode and time information shall be downloadable from the LCC. All outputs shall be wired to an interposing relay for driving the logic

3.1.226 A.

Digit al Inputs

The digital inputs shall be voltage-free and earth-free contacts. Changes of state in the digital inputs shall be reported to the main processing module for further processing. The inputs shall be configurable from a downloadable database. Digital inputs may be either single point, double point or multi-point. The interpretation of states for single or double point inputs shall be configurable

3.1.225 A. B. C.

Central Processi ng Unit (CPU)

The CPU shall be Intel 32 bit CMOS microprocessor with 16 MHz clock speed and 2MB RAM. The RTU shall be equipped with two PROMs, one EPROM for storing the system parameters and program and the second Flash EEPROM for storing application programs. The RTU shall be embedded with RISK chip and have real time clock function. Watch-dog, diagnostic LEDs and power monitoring shall be some of the monitoring features of the RTUs as a minimum

3.1.224 A.


Analogu e Output s

The analogue outputs shall be 4-20 mA, 12-bit resolution. The integrity of loop signal shall be continuously monitored and if the loop impedance exceeds the drive capability, the fault shall be reported to the corresponding control centre. Each analogue output shall be capable of withstanding indefinitely short-circuiting or open circuiting, and provided with transient protection. Isolation between outputs and incoming power supply, and outputs and all other RTU interfaces shall be as for analogue inputs specified above.


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Section 015000

3.1.228 A. B. C.

B. C.

D.

E. F.

G.

H. I.

J.

Future Expansion

It shall be possible to add any input/output type plug-in module with a geographical addressing facility. The system hardware, application software and database shall be sized to accommodate a total of 10% increase in signal capacity overall and up to 25% increase in an individual RTU. Sufficient plug in or add on modules shall be provided and wired to terminals ready to accept future signals of up to 25% or a minimum of one module, for each RTU.

3.1.229 A.


RTU Software

The RTU shall be capable of processing locally input equipment information before transmitting it to the master station to reduce transmission overheads. Total internal scan time interval for all inputs and outputs in an RTU shall not exceed 10 ms. The RTU shall operate on a report by exception basis. The report shall be triggered by change of state of digital values, analogues reaching threshold values or varying by specified amounts. The RTU shall also report when polled and when the memory buffer is full. The RTU’s shall have sophisticated in built control facilities to permit control loop configuration using simple building blocks. These blocks shall sequence control, three-term control and other control routine components as required by the specification. The RTU shall be capable of routine signal processing including integration, summation, subtraction and totalisation of one or more inputs. The RTU shall be capable of executing sequential control logic. Programming of sequential control shall be by means of high-level function blocks as defined in BSEN 61131-3. The programming language used shall be in ladder diagram format and/or FBD as appropriate to the engineers responsible for the operation and maintenance. The RTU’s shall have standalone capability, able to continue monitoring equipment and executing control loops if the communication link to the master station fails. In the event of such a failure the RTU shall log all alarms and required analogues until all the total memory is filled. When the communication link is restored the RTU will automatically upload the logged data to the data archiving system. The RTU’s shall have a watchdog function and full self-diagnostics capable of detecting and reporting faults to the master station and displayed locally. The RTU shall be fully factory programmed, tested and tagged. It shall be possible to modify the programs remotely by downloading from the engineer’s terminal with and without shutting down the RTU. The RTU programming languages shall be strictly compliant with BSEN 61131-3.

Data Recordin g and Stor age

3.1.230 A.

Analogu e vari ables

Sufficient capacity shall be provided to store in a fully tagged form the instantaneous, maximum, minimum and averaged value of each analogue, as well as pulse inputs at each RTU's. The period between samples shall be configurable, the default being 15 minutes for which storage shall be available for a minimum of 7 days. When the analogue storage is 80% full, the RTU shall contact the corresponding control centre to transfer the stored data.

3.1.231

Events

A. The memory capacity shall be sufficient to store, all events (including alarms). The memory shall be sized to allow a minimum of 20 events per input and output from each RTU with a minimum of 1000 events, per 24 hours. 7 days of storage shall be available at each RTU. When the event storage is 80% full, the RTU shall contact the corresponding control centre to transfer the stored data.

3.1.232 A.

Profiles

It shall be possible to store daily analogue profiles for alarm purposes for 25% (with a minimum of two) of the analogue inputs at the RTU.


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Section 015000

3.1.233


Tables

A. RTU’s shall be capable of receiving and storing for operational control, through user sequence programs, tabular data such as look-up tables for pumping regimes. It shall be possible to download the tables from the corresponding control centre.

3.1.234

Data and Event Taggin g

A. Data and events for local storage and subsequent transmission from the RTU shall be tagged with the time and date at the RTU.

3.1.235

Alarm Taggin g

A. Each alarm shall be tagged in its originating RTU with a source identifier and the time and date of occurrence. Likewise, the time and data of the alarm returning to normal shall also be recorded in the RTU for use in the corresponding control centre.

3.1.236

Alarms and Events

The SCADA system shall be able to detect/generate the following types of alarms at the RTU’s: Status alarms Each change to status or derived status shall generate an event, which can be reported as an alarm. It shall be possible to assign a separate time delay to each status point for which an event has to persist before being reported as an alarm. This delay shall be configurable from 0 to 900s. Analogue Valu e Alar ms Each analogue shall have a minimum of four thresholds or limits. If an analogue or derived value transgresses any one of these limits, an event shall be generated which shall be able to be reported as an alarm. Each threshold transgress shall be a separate alarm e.g. high high, high, low, low low. It shall be possible to assign a separate dead band to each analogue point, which shall apply to all four associated thresholds. Profile Alarms Profile alarms shall be provided to test analogue values against diurnal profiles, i.e. a series of thresholds variable with time. The facility shall test analogue values (e.g. a level) against a profile of thresholds and shall report alarms when the value transgresses the threshold after a value and time dead band period. Rate of change alarms A. a. b. c. d.

The facility to generate alarms on exceeding a pre-set rate of change value shall also be included. It shall be possible to define an alarm on any of the following: Rate of rise. Rate of fall. No change, i.e. an instrument has failed and is not responding to process conditions. Rate of change alarms shall also be definable for pulse count values.

Alarm Suppression A.

B.

A privileged user shall be able to suppress “nuisance” or spurious alarms for a single point and the complete RTU. The SCADA system shall have facilities within the RTU to prevent the occurrence and subsequent reporting. RTU’s shall record failed attempts at communications with a corresponding control centre. This data shall be part of the RTU data polled by the corresponding control centre and used to report and record communications failures to the system manager.

Mains Failure In the event of a mains failure and after expiry of the battery back up, the RTU operating software shall provide an orderly shutdown of the RTU. Upon restoration of the supply, the RTU shall restart in an orderly, and operationally safe manner without intervention, the RTU shall also send an appropriate message to the corresponding control centre. Contract 106, Volume II

Page 555 of 589

Section 015000

3.1.237


Typical Contro l Systems

Instrument t Thermal motor monitoring e w / Moisture detection y r d , s p m u p e l b i s r e m b u S l s a p g m u u f i r p t n e C

Mechanical monitoring

Function Motor protection

seal Pump / motor protection

Bearing temperature monitoring Thermal overload relay

Motor overload protection

Level / Float switch

Dry run protection

Level / Float Switch Bearing temperature monitoring Oil pressure Oil temperature r l e Winding heater v a i c r Thermal motor monitoring i r d

Dry run protection

t c e l E

Thermal overload relay

m Fuse / MCCB / MCB l i p t a u n Under voltage relay c q e i r t Over voltage relay c E e l E Phase failure relay

m l e o t r s t y n S o g C n i p m u P l e s l s e o r V t n o C , k n a T

Hydrostatic level meter Level switch Pressure sensor with transmitter Flow meter with transmitter Conductivity meter Level meter Pressure sensor pH – meter Conductivity meter Dissolved oxygen sensor Residual chlorine sensor

3.1.238

Pump / motor protection Bearing protection Motor protection against water Motor protection Motor overload protection Overload protection Equipment protection Pump operation, Dry run protection, Flooding protection, Stand-by pump operation As back-up for Hydro static

Monitoring

Volume control, Pump control, Process control Pressure control, Volume control Process control

Alarms

Only one type of alarm system shall be used in the stations. It shall be operated from 24 Volt D.C. The alarm panel shall be fully equipped with all relays, alarm lights, reset facilities, push buttons etc. and an annunciator with timer and audible alarm connected to the PLC / RTU . Resetting a push button shall interrupt the alarm. The timer shall have an adjustable range of 0 to 20 minutes plus continuous alarm override switch to enable automatic cancelling the audible alarm after a predetermined interval. The alarm system shall be provided with disconnect switches to prevent activation of the system whilst a unit is being serviced.

3.1.239

Infr a – Red Thermography

The MCC after installation at site shall be subjected to temperature rise test in accordance with IEC 60439-1 :1999 Sub Clause 8.2.1 and temperature rise values recorded at different points of MCC shall not exceed the limit set for temperature rise in table 2 of IEC 60439-1. the temperature shall be recorded at horizontal , vertical busbars, connection points between vertical as well as horizontal busbars and connection points for MCCB and cables. The temperature Contract 106, Volume II

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Section 015000


recording shall be done with thermal imaging camera, thermocouple and monitoring reporter soft ware.

3.1.240 A.

B.

C.

D.

E. F.

G.

The batteries and chargers shall be used as back-up power source for uninterruptible and bump less operation of controls, instrumentation, alarm and monitoring equipment, but not for switchgear tripping/closing or other special function batteries. Where alternate a.c. supplies are available, provide for taking the supply to the battery charger from either source (e.g. from either side of the bus-section switch) with facilities for automatic changeover from one source to the other in the event of failure of the supply system. The battery & charger unit shall be housed in the common control section of the MCC. Charger shall be housed in control section and battery in ventilated compartment below common control compartment, alternatively batteries can be installed in stand alone cubical IP class for battery compartment in MCC or housed in stand alone cubicle shall be 41. A separate sheet steel floor standing cubicle having adequate ventilation and separate compartments for the batteries (lower compartment) and chargers (upper compartment) with associated control and protection devices and accessories may be used as stand-alone for large capacities where it is difficult to accommodate within a dedicated section of the Motor Control Centre and in case of all other applications wherever specified. When used as stand-alone, the access to the batteries shall be via lockable, hinged doors, and to the chargers via removable covers. Batteries and charger units shall be suitable for the intended service under the prevailing climate and environments conditions and Tropical use as specified in Section “General Electrical Requirements”. Stand alone battery bank shall be IP 54 for charger compartment and IP 41 for battery compartment with ventilation.

3.1.241 A. B.

C.

C. a. b. c. d. e. f. D. a. b. c. d. E. F. a. b.

Batteries

Nickel Cadmium sealed batteries shall be used confirming to BS EN 60623. The batteries shall be maintenance free long life Nickel Cadmium sealed type with a nominal output of 24 volts, and shall be of adequate capacity to maintain full operation of the relevant load equipment’s’ plus an additional 20 per cent, for a period of 4 hours during mains failure, assuming a normal charge condition at the start of the mains failure. All batteries shall be supplied in banks sized for easy handling, and all interconnections shall be included. Batteries shall not be housed above charger units or any other equipment and shall be so ventilated that gases do not permeate into adjacent equipment.

3.1.242 A. B.

Battery and Battery Charger

Batt ery Chargers

Battery Chargers shall confirm to BS EN 60146-1. Battery chargers complete with associated controls shall be provided and mounted on its own chassis and housed in one of the section of the MCC, stand-alone panel or in a separate enclosure as applicable. The front panel for each charger unit shall include :1 No. “ON/OFF” Mains switch 1 No. Lamp to indicate “A.C. Supply On” (white) 1 No. Charger Ammeter 1 No. Lamp to indicate charger healthy 1 No. Lamp to indicate “Charger Failed” (Amber) 1 No. Lamp test push button Charger unit shall also be provided with:1 No. Set of a.c. supply fuses 1 No. volt-free contact for charger failed alarm 1 No. volt-free contact for low d.c. output voltage alarm 1 No. volt free contact for loss of d.c. output voltage alarm Volt free contacts shall OPERATE in fail-safe mode and be wired to terminal block. The Charger unit shall also be equipped with the followings:1 No. DC output voltmeter, scaled to indicate regions of “Low”, “Normal” and “High” output voltages, by the use of different coloured sectors. 1 No. D.C. output switch


Page 557 of 589

Section 015000

c. G. H.

I. J. K. L. M. N.

1 No. D.C. output Ammeter The charger unit shall also be provided with one set of full capacity rated output d.c. terminals and fuses. In the event of failure of the charger, the batteries shall ensure operation of controls, instrumentation, alarm and monitoring equipment for at least 4 hours. A separate relay contact shall be provided to indicate “Critical Alarm Condition – Charger Fail” The chargers shall be of the constant potential type, and shall be designed to regulate the charger output voltage to within +/- 1 percent. The suitable means shall be provided to the approval of engineer to protect the batteries from deep discharge. The D.C. terminal voltage shall be regulated such that under charge condition the DC voltage does not rise to more than 10 percent above the nominal. The charger unit shall also be provided with both short circuit and reverse polarity functions. Batteries shall be protected from deep discharge and over charging.. Fix inside the cubicle a wiring diagram indicating and identifying all outgoing terminals, components and fuses, and also a warning label in Arabic and English giving maintenance and safety instructions.

3.1.243 A. B.

C.

B.

C.

a. b. c. D. E.

F.

G.

H.

I. J. K.

Source Tests

Type test certificate shall be provided for the charger. The integrated functional test shall be conducted at manufacturer’s works to ensure satisfactorily functioning of the equipment’s. The tests shall be witnessed by the Employer prior to the acceptance. The Assembly shall not leave the manufacturer’s works until the same have been duly approved and stamped by the Engineer and written permission is obtained for their dispatch to site

3.1.244 A.


General Equi pment

This section covers all instruments/analysers necessary for the automatic / manual control and safety process operation of the entire plant. The control and instrumentation systems shall include all the instruments, automatic controls, manual controls, protective systems, trip systems and alarm systems to enable the plant to meet the control, supervisory and operational requirements as specified. The Contractor shall provide & install all instruments, controls, part of instruments and controls, accessories not specially mentioned but essential for the proper functioning of the Plant, all as specified and as required by the Engineer and shall allow in his rates for the costs of such provisions. Instruments shall be procured from one manufacturer. Basic units shall be interchangeable. The manufacturer for the instrumentation and accessories must comply with ISO 9001/2 Instruments shall be of industrial design for heavy duty application, suitable for the ambient conditions prevailing at the place of installation. Instruments or parts of the instruments, having a short lifetime, shall be provided sufficient in number to provide replacements required for a period of 1 year operation calculated from the date of Final Acceptance. Instruments shall be arranged in such a way that the exchange of parts or of a complete instrument is possible without dismantling other parts of the Plant, and without draining the part of the Plant the instrument is connected to. Instruments shall be linked with a flexible connection to vibrating / oscillating equipment in order to avoid malfunction and damages. Flexible connections shall be provided as required, subject to the approval of the Engineer. Unless otherwise specified or approved, all parameters, e.g. pressure, flow, level, temperature, etc. for indication on points remote from the point of measurement shall utilise transmitters which shall convert the measured parameter into a standard DC signal. More than one signal type that is either analogue, binary or digital shall not be permitted in the same cable. Transmitters shall be of the 2 wire type isolated from earth and shall have an output signal range of 4 - 20 mA DC, and shall be equipped with test connections. Equipment shall not generate any type of interference (e.g. electrical, electro-magnetic, audible, vibration, etc.) at a level which could be detrimental to the performance of other equipment or which could cause annoyance or discomfort to personnel.


Page 558 of 589

Section 015000

L. M. N. O.


The presence of radio frequency radiation such as from portable VHF or UHF transducers shall not be detrimental to the performance of the control and instrumentation equipment. Sensor points for pressure, temperature shall have a valved test connection for hand-held control/calibration instruments. Zener barrier shall be provided for analogue signals wired to terminals for field mounted instruments located in hazardous areas Signal isolators shall be provided wherever an analogue signal is to be used for process / monitoring at more than one location

3.1.245

Accuracy

A.

Unless otherwise specified, the instruments used shall comply with the accuracy listed below: Parameter Max. Error *) Temperature +/- 0.15 % of full scale Pressure +/- 0.50 % of full scale Flow +/- 0.25 % of full scale Level +/- 0.50 % of full scale Analytical see specification *) full scale is the actual factory or field calibrated working range of the instrument. B.

C.

Instruments / analysers shall be arranged and installed at points of the systems only where interference factors of the media to be measured are zero or at the level tolerated by the instrument / analyser for accurate measuring and reading without any fluctuation and / or malfunction, e.g. the velocity / flow profile must be fully developed, etc. The hysteresis factor shall be as small as possible and shall be stable for a long period, the repetition factor shall be <+/- 0.10 % of the value measured.

3.1.246

Level Contro l & Measurements LT

Level Instrument (Hydrostatic) A.

Measurement and control of a liquid fluid level shall be affected by means of one static pressure sensor at each wet well and storage tank (piezo resistive type or membrane capacitor type). Sensors with housing shall be fully submersible, explosion proof and shall be provided with adjustable stainless steel supported cables and shall be installed in UPVC pipe. B. The supply shall include indicators all cables, accessories and fixing, amplifier, transducer / transmitter, power supply unit installed in the MCC panel. Protection class (sensor) shall be IP 68, explosion proof the accuracy =/- 0.25 % of the calibrated span and the output signal 4 to 20 mA. The sensor shall be of hest alloy (C) steel material. The unit shall be suitable for 24 Volt DCsupply. the indicator shall have 4 Nos. minimum programmable relay contacts with barograph and digital displays Functions per level instrument shall be: a. Start & Stop of pumps b. Dry-run protection for pumps c. Low - Low level alarm d. High-High level alarms e. Level indication f. Analogue signal transfer to indicator / PLC / RTU-telemetry/ SCADA Level Instrument (Float Switch)

A.

a. b. c. d. e. B.

Micro-switch operated float type switch combination, protection class IP 68, explosion proof with adjustable stainless steel supporting cable, including transducers, transmitters, and power supply installed in suitable enclosures and accessories necessary for a fully functional instrument as well as all necessary fixing materials. Functions shall be Start and stop of pumps Dry run protection for pumps Low-Low level alarm High-High level alarm Digital signal transfer to PLC / RTU-telemetry/ SCADA Mercury type switches are not acceptable.


Page 559 of 589

Section 015000

C.


The float switches shall be suitable for 24 volts – DC.

Pressure Transmitt er PT 1 A.

B.

Measurement and control of water pressure shall be effected by means of one pressure sensor per pump (piezo resistive type or membrane capacitor type). Sensor with housing shall be fully submersible. The pressure instrument shall provide pressure alarms, pressure indication, analog signal transfer to indicator / PLC / RTU-telemetry/ SCADA. The supply shall include pipe connection, indicators and all cables, accessories and fixing, amplifier, transducer / transmitter, power supply unit installed in the MCC panel. Protection class (sensor) shall be IP 68, explosion proof ,the accuracy =/-0,25 % of calibrated span and the output signal 4 to 20 mA. And suitable for 24 volts D.C, the indicator shall have 4 Nos. minimum programmable relay contacts with barograph and digital displays

3.1.247

Temperature Measurements & Contro l

Temperature Transmi tter TT1 A.

TT1 shall be a compact sized temperature transducer with vapour pressure sensor and diaphragm piston system, including switch unit shall be provided for over-temperature protection of lubrication systems. The bulb material shall be stainless steel 316L. Functions to be performed are temperature alarm, over temperature shutdown, analog signal to RTU/telemetry system. Protection shall conform to class IP 67 and the accuracy shall be 0.5 to 2.0 x C

Temperature Transmit ter TT 2 A.

This transmitter shall be the resistant type temperature transmitter Pt 100, protection class IP 65, three wire system, output 4-20 mA, temperature proportional, for wet installation and come complete with measuring tube, flange and housing. Material shall be stainless steel 316L for parts exposed to water and cast aluminium or cast iron for the transmitter housing. Functions to be performed are temperature control, high/low alarm and high/low shut down. The accuracy shall be +/- 0.1 % of the calibrated range including hysterese and the linearity +/- 0.1 % of the calibrated range.

3.1.248 Analyt ical Instr uments (Conducti vit y, PH, Turbid ity , D.O) Conductivity Measuring & Control Instrument, AN 1 A.

B. a. b. c. d. e. f. g.

Measurement of the water conductivity shall be effected by means of conductivity sensor (magnetic inductive type) including temperature compensation, fixed with flange complete with isolating and drain valves to the force main pipe line, including adjustable stainless steel grade 316 supported cable for free hanging installation. The supply shall include indicator and all cables, accessories and fixing accessories, amplifier, transducer / transmitter, power supply unit installed in MCC panel. Sensor shall be Protection class ( sensor) : IP 68, Explosion Proof Accuracy : =/- 0.5 % of calibrated span Output signal : 4 to 20 mA Measuring range : 500-20000 μS/cm Conductivity level programmable digital display indicator with minimum 4 programmable relay contacts Signal to PLC / RTU – telemetry/ SDADA system High conductivity alarm

pH Value Measuri ng & Cont rol Inst rument, AN 2 A.

B. a. b. c.

Measurement of the pH-value shall be effected by means of one pH-sensor per wet well including temperature and pressure compensation, fully submersible, including adjustable stainless steel supported cable for free hanging installation. The instrumentation shall be suitable for measuring pH values ranging between 2 and 13. The supply shall include all cables, accessories and fixing, amplifier, transducer / transmitter, power supply unit installed in MCC panel, including one spare measuring cell each. Protection class (sensor): IP 68 Accuracy: 0.1 % of full scale Output signal: 4 to 20 mA


Page 560 of 589

Section 015000

C. a. b.

c. d.


Function per sensor: Control of chemical dosing Signal to RTU / telemetry system/SCADA system pH-value indication (digital) High / low pH value alarm

Turbidity Measuring & Control Instrument, AN 3 A.

B. C. a. b. c.

The solid contents in water shall be measured by a turbidity meter. The method of measurement shall be the optical light scattering (nephelometric) single channel system for measuring of solids after a filtration and shall be the multi channel system for liquids with a high content of solids, like raw water, sludge, etc. before any filtration and shall be provided as indicated on drawings and BOQ. The measuring cell shall be fully submersible, IP 68, with wiper function for self cleaning, including adjustable stainless steel grade 316 supported cable for free hanging installation or including adapter for pipe installation. The supply and installation shall be complete including all cables, power supply unit, transmitter unit, calibration vessel for periodically calibration and shall be installed inside the MCC panel. Material for Measuring cell shall be Stainless Steel, 1.4571 Measuring Range 0-1000 ppm (0-4000NTU, nephelometric turbidity units) Output signal 4-20 mA Function: Turbidity level indication Signal to RTU / telemetry/SCADA system High turbidity alarm

Dissolved Oxygen Measuring & Control, AN 4 A.

b. c. d. e. f.

The dissolved oxygen level in water shall be measured for process control at aeration systems and odour control system for sewage pumping and treatment plants, and shall be provided and installed as indicated on drawings. The supply and installation shall be complete including cables, power supply unit and accessories, whereby the sensor shall be submersed free hanging installed with stainless steel, grade 316L support chain and brackets. The measuring and control system shall mainly consist of: Oxygen sensor based on the potentio-statically operating 3-electrode system, membrane covered including automatic air pressure & temperature compensation, IP 68, full submersible Transmitter unit including weather protection enclosure, IP 64 Controller unit, installed inside the MCC panel Measuring range 0.035 to 9.00 mgO 2/l at +20°C Re-calibration cycles not less than 3 months Output Signal 4 – 20 mA

B. a. b. c.

Function: Dissolved oxygen level indication Signal to RTU / telemetry / SCADA system Low dissolved oxygen level alarm

a.

3.1.249 A.

B. a. b. c. d.

Flood Sensor

Flood. / leakage sensor system shall consist of two integrated, electrode plates (one control electrode, one mass electrode), amplifier, waterproof epoxy resin enclosure, wall mounted bracket, cabling, separate electrode relay with cable break control resistor, LED controls, flashlight & horn alarm signal for outdoor installation, power supply unit, back-up battery for min. five hours operation, fixing material and accessories for sensing water at floor level in case of water leakages in the dry well pump room area. Electrode relay, power supply unit and back-up battery shall be installed in the main MCC panel. Material shall be for Electrodes Stainless Steel 1.4.571 (316Ti) Enclosure Epoxy Resin Fixing material Stainless Steel 1.4571 Power supply shall be 240V/50Hz A.C. and control voltage 24V DC

3.1.250

Flow Meter

A. Electromagnetic flow meters shall be installed at each common discharge pipe. The measuring range shall be between 25 % and 125 % of the combined pump capacity and the accuracy shall Contract 106, Volume II

Page 561 of 589

Section 015000

a. b. c. d. e. B.

a. b. c. d. e. f. g. h. i. j.

be 0.5%. Flow meters shall be supplied and installed complete with amplifiers, cables, transducers/transmitters, indicators, flow recorders for installation in the motor control centre. Magnetic Flow Meters shall be used for: Common flow per lifting / pumping station with local and removed continuous flow rate reading, accumulating of total flow, low/high flow alarm. Dosing flow: For each. flow meter one identical spare pipe shall be provided for replacement of the flow meter in case of repair. The analog signal shall be transferred to Display / RTU / Telemetry / SCADA system The flow sensor and transmitter shall be IP 68, explosion proof The sensor material shall be hastelloy (C ) material. Ultra sonic type flow meter system, designed for open channel continuous flow measurement, suitable for installation in explosion hazardous areas, to be mounted above special designed flumes. The system shall mainly consist of: Ultra sonic sensor (sender / receiver) IP 68, explosion proof Transmitter for panel mounted installation Power supply unit (to be installed inside the MCC) Illuminated Display, key bad programmable and flow counter unit (to be installed inside the MCC) Cabling / wiring Supports / brackets made from stainless steel grade 316L Fixing material, made from stainless steel, grade 316L Lifting chain for maintenance and repair including self locking bracket Indicator (panel mounted) with 4 nos. programmable relay contacts Output 4 – 20 mA

3.1.251 A. a. b. c. d. e. f. g.

C. D. E. F.

G. H. I. J. K. L.

Display/Contro l Units

Display / control units, installed at the MCC panel shall also include display for Levels (Analog or digital) Flow velocity / flow volume (digital) Pressure (digital) pH value (digital) not used Conductivity (digital) Dissolved oxygen (digital) not used Turbidity (digital) not used

3.1.252 A. B.


Indust rial Plugs and Sockets

Plug and Sockets shall be of Industrial type confirming to BSEN 60309-2. Sockets shall be mounted on the panels/enclosures/junction boxes as applicable and shall be supplied with associated plugs. The maximum rating of the plugs and sockets used shall be 125 A. Plug pins and socket contacts shall be self cleaning and calibrated type manufactured from solid brass. External screws and springs shall be made of non-corrodible material. Plugs, connectors and sockets bodies shall be manufactured from high impact, self extinguishing, durable and stable engineering plastics resistant to chemical reaction including hydro-chemicals, acids, dangerous gases, salines etc. Moulding material wherever used in the plugs and sockets shall be free from PVC, Cadmium and Halogen. Plugs and sockets shall be colour coded so that the voltage that at which they are operating can easily identified. The design of plugs and sockets shall ensure that only the correct plug can be inserted in each socket. Plugs and sockets used for Generator connections shall be of appliances INLET type. Plug and sockets shall be designed to provide IP67 rating. The plug and sockets shall be designed for ergonomics use.


Page 562 of 589

Section 015000

3.1.253 A.


Cables and Wires

All cables shall be of a suitable voltage grade and shall be selected for the climatic conditions specified and shall be derated by factors approved by the Water and Electricity Authority. Before ordering any cable the Contractor shall prepare and submit for the Engineer's approval a detailed cable schedule showing all data and information of power - and control cables / wires required for the Works. All cables necessary for the complete operational installation shall be included.

3.1.254

Design Requir ements

Cable Code HP

Power Cable, (>1kV), Stranded Copper Conductors, Wire armoured (rated for carry the through fault current with earthing resistance short circuit), Over sheath of medium density polyethylene as per ADWEA specification LP Low Voltage Cable, PVC insulated, (<1kV), Stranded Copper Conductors LPA Low Voltage Cable, PVC insulated, Armoured, Stranded Copper Conductors LPX Low Voltage Cable, XLPE insulated, Stranded Copper Conductors LPXA Low Voltage Cable, XLPE insulated, Armoured, Stranded Copper Conductors C Control Cable, PVC insulated, Stranded Copper Conductors CA Control cable, PVC insulated Armoured, stranded Copper conductors CAS Control cable, PVC insulated Armoured, shielded stranded Copper conductors CS Control Cable, PVC insulated, Shielded Stranded Copper Conductors FM Fire Resistant Cable, Mineral insulated, Copper Sheathed Solid Conductors FG Fire Resistant Cable, EPR insulated, Mica Glass protected Stranded Conductors SM Submersible cable, with additional in resin embedded conductor, material suitable for aggressive liquid media.

3.1.255

Core Colo ur Code

2 core cable Black / Red 3 core cable Red / Yellow / Blue 4 core cable Black / Red / Yellow / Blue Multi core cable core identification by black numbers continuously printed on a white background Single phase load (240 volts) shall be connected with cable having one of core as Black Colour as neutral conductor.

3.1.256 A.       

Rating

To assess the rating and cross-section required for each cable, the following factors must be considered as a minimum: The normal full-load current of the equipment circuit or the anticipated maximum full load current of distributor. Fault level. Conditions of ambient temperature relevant to method of laying. Voltage drop Voltage drop in motor circuits due to the starting method. Over current settings circuit breakers. Location of cabling, whether in air, ducts or soil.

3.1.257 Insulatio n, Conduct ors, Arm ouri ng for Power Cable A.

All LV - power cable shall be of the thermoplastic insulated type of polyvinyl chloride (PVC) or equal and shall consist of multi core stranded copper conductors, XLPE insulation, bedding, steel wired armour and PVC sheathed and shall be of 600/1000 V grade confirming to BS 5467. Each cable shall be supplied in lengths suitable for a continuous run, as no "through joints" will be permitted in any cable run without the prior consent and written permission from the Engineer. All the power cables, except provided with the submersible pumps / munchers by the manufacturer as built in for connections up to nearest junction box, XLPE insulated, armoured PVC 600/1000 volts. Small wiring cable for use on lighting and small power shall be single core PVC insulated conform to BS 6004 and BS 6346, 600 / 1000 Volts, having a minimum


Page 563 of 589

Section 015000

B.

conductor size of 2.5 mm² for lighting circuits and 4.0 mm² for power circuits. The neutral conductor's cross-sectional area shall not be less than that of the phase conductors. Each circuit laid in conduit shall be provided with an individual earth continuity conductor, having sufficient cross-sectional area as per standards adopted by ADWEA. Silicon rubber insulated flexible cable rated at 105 C shall be used between cut out in pole and light fixture on the top of the pole.

3.1.258 A.

      

B.

B.

B.

B. C. D. E.

F.

Control and Instru mentation Cables

Control and instrumentation cables shall be the PVC insulated, armoured copper conductor multi-core type 600/1000 V confirming to BS 5308 part 2 or equivalent, shielded as per instrument’s manufacturer requirements. Each multi-core cable shall at installation have not less than 25 % spare cores. All cores shall be clearly identified and terminated. Use of Multi core cable to BS 6346 or equivalent shall be permitted for cables transmitting digital signals only, in a low noise area where the use of screened cable is not warranted

3.1.261 A.

Cable Ends

Cable entrances shall be designed to enable easy sealing with compound. Clamps and supports for cables shall be provided and shall be arranged to allow the earthing for the cable armours. All terminals, racks and blocks shall be mounted in positions easily accessible for inspection and maintenance. Terminal sealing shall be by heat shrink kits. The terminals shall be insulated and shrouded to allow replacing of the cable without shutting down any other circuit. Wiring for control panels shall be strictly done in accordance with the control and interlock diagrams as provided by the manufacturer and shall be completed in the manufacturer's work shop.

3.1.260 A.

Cable Schedules

The Contractor shall prepare complete Cable Schedules showing all principal power and control cables/wires to be supplied under the Contract. All such cables and wires shall be numbered in the Schedule, using the same reference numbers as in the Working Drawings. The Schedule shall contain the following data: Cable identification No. Route From/To Type of cable with reference to cable code Derating factor used Cross sectional area (mm²) Length (meters) The circuit load current The circuit load (kW) Protective device Volt-drop for the load Number of spare cores Number of cores (excluding earth conductor) The format and the details to be included in the Record Schedules shall be agreed with the Engineer. All cables necessary for the complete operational installation shall be included.

3.1.259 A.


Installation

As far as practicable cables, serving electrical installations in the pump room, shall be installed inside Class 6 PVC-u conduits. The Contr actor shall, w ithin 60 calendar days after award of contract, provide fully detailed drawings showing diameter, bends and location of such conduits. Suitably dimensioned PVC-u end caps, providing a neat appearance, shall close the ends of conduits. Visible cable runs shall be installed with the utmost accuracy with regard to alignment and neatness of appearance. Cables shall be securely fixed to structures individually or in-groups as required. Where cables are exposed to climate suitable protection against weather and sun radiation shall be provided. Cable crossings into structures shall be installed in ducts or sleeves and shall be sealed with an approved waterproof compound. During installation works the Contractor shall arrange for temporary sealing all conduits, openings, ducts and the like in order to prevent accidental flooding, or animals or dirt entering the structure. Cables shall be securely clipped in straight runs using the correct type and size of saddle fixed at intervals not exceeding 450 mm. Where bends in cables are necessary a radius of 15 x cable diameter minimum shall be maintained. Cable routings shall be executed in such a manner as to provide a neat and workmanlike appearance. Protection against mechanical damage shall be provided where required.


Page 564 of 589

Section 015000

G. H.

I.

J. K. L.

Cables shall be so routed that they will not be subject to heat from adjacent hot piping or vessels. Wherever practicable, a minimum of 300mm spacing shall be maintained. Cables shall be terminated with correct size and type of cable glands. Armoured cables shall be Glanded with brass mechanical glands providing mechanical support to the cable by locking on to the cable armouring, brass earthing tag with earth ring shall be provided with the gland for earthing of armour of the cable. Unarmoured cables shall be provided with brass mechanical glands with special ring / insulated adopter inside gland for support to cable to avoid injury to the outer PVC of the cable. Cable gland for single core cables shall be of non ferrous material. PVC gland shroud shall be provided over the gland to provide effective seal on the cable and cable gland. PVC slip over coloured sleeves, matching with colour of the cores of the cable, shall be provided over the terminals of the equipment. . All cut ends of cables shall be immediately sealed or terminated in their final position. Cables shall always be drawn from the top of their drum. Cable rollers or skid boards shall be used when long cables are being drawn. Sub-main cables shall be routed on cable trays and installed by leaving a spacing between adjacent cables greater than twice the outer diameter of the larger cable. Where cable shall pass below roads or any other structure they shall be installed in suitable ducts or concrete trenches. Where cable passes through floor, fire proof barriers suitable and from civil defence authorities approved fire shops shall be used.

3.1.262 A.

B.

C.

D.


Trench Work

The excavation and backfilling of cable trench work shall be carried out by the Contractor and he shall be responsible for ensuring that all trench work is adequate for his needs. The Contractor shall supply and lay the sand bedding, cables, sand blinding, cable cover tiles and marker tape. When u-PVC conduits used in a duct bank, cable pulling pits shall be foreseen at change of cable direction and at distances of not exceeding 20 m. Cables crossing in paved areas shall be laid in conduits, PVC-u pipes DN >= 150 mm, encased in concrete. with 2 spare conduits are to be foreseen at each crossing. Pulling pits shall be precast concrete with watertight cast iron covers. Markings on covers shall be "ATTENTION ELECTRIC CABLES". Coating of covers shall be as specified for manhole covers. Before laying cable, cable trenches shall be backfilled with a 100 mm thick layer of clean sand and compacted. Cables shall be snaked to avoid tension during backfilling. After cables are laid, checked and tested, the trench shall be backfilled with a 100 mm thick layer of sand, measured from the top of the largest cable and compacted. Cable tiles, manufactured from concrete B25, or from plastic as approved by the Engineer and ADWEA, shall then be placed on top of the sand and the remainder of the trench backfilled as specified under civil works. The warning tape mentioning “600 / 1000 volts electrical cables” shall be placed 30 cm from the final ground level. Backfilling works shall only commence after the Engineer has inspected the cables and has given his written approval for back fill. Where in accordance with the regulations of the Water and Electricity Authority cable-routemarkers are required, the Contractor shall carry out such work. The dimensions, labelling and construction of cable - route -markers shall be as required by the ADWEA.

3.1.263 3.1.264

Field tests D.C High Volt age

D.C High Voltage test shall be carried out, injecting 3.5 KV between phase to phase and 7.0 KV between core and armoured, after isolating the cable, for one minute.

3.1.265

Insu lation Test

Insulation test with 500 Volts insulation tester shall be carried out between cores and cores & the earth, the result shall be as specified by the manufacturer

3.1.266 A.

Cable Trays

The Contractor shall supply and install all cable trays. The drawings to be submitted by the Contractor for the Engineer's approval shall include separate cable tray drawings showing their routing, details and method of installation.


Page 565 of 589

Section 015000

B.

C.

D. E. F.


Trays shall be heavy duty perforated sheet metal type and/or ladder rack type confirming to requirements as specified in BS 7671 , NFPA 70 national electrical Code, or equivalent standard manufactured from heavy duty galvanized mild steel with approved fixings. The design of the tray assemblies shall allow movement under thermal conditions without detrimental affecting the entire installations. Bends, tees and junction fittings shall be of standard design and manufacture having an inside radius of not less than 300 mm. Where large size cables are to be installed this radius shall be sufficient to fully accommodate the minimum cable radius required. Cables shall be saddled or cleated to the cable tray by insulated straps in position as they are installed along the route. Particular care shall be taken on vertically rising tray work, and adequate cable fixings shall be supplied to ensure even security and distribution of load. Cable trays and ladders shall be continuous earthed, flexible earthing strips shall be used at the points where sections of cable tray are joint together

3.1.267

Trunki ng System

Trunking systems shall be obtained from one manufacturer. It shall be complete with purpose made angles, tees, covers, connection sleeves etc. and shall be dimensioned to accommodate the cables foreseen but not less than 50 x 50 mm. The material used shall be hot dipped galvanised profiles. Each length of trunking shall be fitted with a screwed on, easily removable cover. Continuous earthing shall be provided.

3.1.268 3.1.269

Small Power and Lighting Distri buti on Boards

A.

The distribution boards shall be totally enclosed metal clad pattern manufactured in accordance with BS EN 60439 using manufacturer standard type tested assembly facilitating plug in f ixing / removing of MCB, RCCB/MCCB and shall be IP 54 class equipped with: a. MCCB incomer b. 4 pole ELCB 30/100 mA as per ADWEA prevailing requirements c. Pan type busbars assembly d. neutral terminal block e. earth terminal block f. 1 or 3 pole miniature circuit breaker for outgoing circuits B. Single phase consumer unit shall be of IP class 31, equipped with a. Single phase RCCB incomer b. Pan type busbars assembly c. neutral terminal block d. earth terminal block e. Single phase MCB for outgoing circuits and subject to the approval of the Engineer and ADWEA C. D.

E.

All circuits shall be labelled to indicate the area served by each miniature circuit breaker. The ELCB. shall provide accident protection by interrupting dangerous contact voltage that may be present in faulty electrical appliances. It shall also provide a high degree of protection against earth fault and electric shock. It shall be designed to function trouble free under climatic and specific conditions prevailing on site and shall be suitable for the load required. The tripping current shall be 30/100 mA. The MCB shall be type (B) {Type (II)} for lighting circuits and type (C) {type (III)} for the other loads and shall have a braking capacity depending on the source of incoming supply but minimum breaking capacity shall be 10 K.A. The frame size of all the MCB's shall be the same, subject to suitability. The single line drawing of installation shall be got approved from ADWEA before the D.B. is manufactured.

3.1.270 A.

Socket Outl et

Sockets in wet rooms (kitchen etc.) and workshops shall be installed 1.50 m above finished floor level and in dry wells of pumping stations 2.00 m above finished floor level. Sockets in all other rooms shall be installed 60 cm above finished floor level 13 Amps. Sockets shall be the three rectangular pin type confirming to BS 1363 with fully recessed switch dolly. For indoor


Page 566 of 589

Section 015000


installation, such as offices, stores, corridors etc. the socket shall be flush mounting and grid switch pattern with matt finish covered with heat cured lacquer finish. Sockets for outdoor, for installation in wet rooms, pump room, dosing plant and workshops shall be water tight, iron clad galvanized / harden moulded PVC water tight with switch and cover (covering the socket when plug is removed). The cover shall be chained to the casing of the socket, to keep the cover in position when socket is in use. Sockets shall be installed complete with plug. Outdoor sockets at 240 volts shall be 3 round pin and 415 V, 16 Amps, 25 Amps and 45 Amps socket shall be the 4 pin plus centre earth, industrial, fully interlocked, switched type as per r equirements under industrial plugs and sockets and shall be installed complete with an interlocked angled plug. Two sockets protected with 15 Amps MCB fed through 4 sq mm cable shall in one circuit, sockets more than 2 and less than 6 Nos. shall be fed in ring circuit protected by 30 Amps MCB fed through 6 sq mm wire. Socket for emergency light and 415 Volts socket shall be from individual circuit. Light switch, socket, plugs, other accessories etc. for indoor and outdoor installation shall be from one approved manufacturer.

3.1.271 A.

Switches for outdoor installation, for the pump room and dosing plant shall be iron clad galvanised / hardened moulded PVC watertight with rotary switch action, safety factor IP65. Switches shall be suitable for surface or concealed surface installation. The light switches for MCC room, offices, workshops, stores etc. shall be of “multiple phase” type with switches arranged in multi gang boxes wherever applicable and flush mounted, grid pattern with matt chrome finish outer cover with heat cured lacquer finish.

3.1.272 A.

Ligh tin g Switch

Conduits

Concealed cable conduits and fittings shall be PVC-u pipes Class 6 for conduits between 16-50 mm and conduit above 50 mm shall be Class 10. Exposed conduits shall be of galvanized steel. The size of conduits will be determined by the number and size of cables drawn as detailed in IEE regulations. The dimensions of conduits shall be stated in the list of cable requirements to be provided by the Contractor. Flexible conduits shall be the metallic PVC sheathed type. In office rooms, control rooms etc. conduits shall be concealed under plaster or in slabs. Metal conduits shall be continuous earthed. Minimum size of conduit (metallic, uPVC & flexible) shall be 25 mm.

3.1.273

Junc tion Boxes

Junction Box for Conduit Wiring A.

Junction and distribution boxes shall be installed at an equal distance from the ceiling. Junction boxes within hand reach shall be provided with screwed covers. They shall always be mounted vertically above switch boxes. Concealed boxes shall be set flush with the finished surface and shall be provided with the proper extension rings or plastic covers where required. Boxes shall be installed in a very rigid and satisfactory manner. Exposed boxes shall be secured by at least 2 dowels

Junction Boxes for Power & Control Cables f or out door Pumps and Macerator (Not Appli cable) A.

A GRP enclosure of minimum 5.0 mm thickness measuring 1000 mm (Height) x 1000 mm (Width )x 300 mm (Depth) on suitable RCC foundation shall be provided near the wet well to serve as junction box for the power and control cables for pumps / macerator / other equipment for isolation of power and controls. The enclosure shall be manufactured from UV resistant material and shall be IP class 65, the enclosure shall be vertically divided in three portions, upper portion of 200 mm with separate door for installation of emergency switches for pumps and macerator, middle portion of 600 mm for isolation of power and controls, lower portion of 200 mm with front separate opening for accommodations of cables and glands. The enclosure shall be divided horizontally into two portion, one portion for termination of power cables and other for control cables. Suitable sizes of terminals as per load of pumps and other power loads shall be provided and fixed for cables from MCC and from pumps etc. An earth bus bar of suitable cross-section at the bottom of enclosure shall be provided and shall be earthed with two independent PVC insulated earth conductor of 70 sq mm dia connected with the main earth busbar of Motor Control Centre. If the distance between MCC and junction box is more than 50 meters, two independent earth electrodes shall be provided instead of earth continuity conductor of 70 sq mm from MCC.


Page 567 of 589

Section 015000

B. C. D.

E. F. a. b. c. d. e. G.


All the outgoing earth connections to pumps, munchers etc. shall be connected to this earth bus bar. Terminals for all cores of control cables including spare cores shall also be provided and terminated on the terminals. Termination for power and control cables shall be done at the bottom through suitable sizes and type of cable glands. Individual gland plates of suitable size as per gland size shall be provided at the bottom of enclosure. Connection to the terminals shall be through cable lugs. The enclosure shall have three doors one for each portion with suitable locking arrangement, In the middle a handle with cylindrical lock open able with Master Key shall be provided. The below mentioned sockets with plug as specified under industrial plug and sockets, and emergency push button as specified under push buttons shall be installed: 1 No. - 13 Amps, 240 volts (industrial type flat pins, IP 67 ) 1 No. - 16 Amps, 240 volts (industrial type round pins, IP 67) 1 No. - 16 Amps, 415 volts (industrial type, IP 67 ) 1 No. - 5 Amps, 24 volt D.C with D.C supply unit (industrial type IP 67) 3 Nos. – Emergency push buttons, IP 67 red colour mushroom type, twist release All the wiring terminals shall be shrouded and protected against accidents by removable transparent plastic plates.

Junction Box f or Mobile Generator A.

B.

C.

A GRP junction box of minimum thickness of 5 mm of IP 65 measuring 1000 height x 600 widthx250 depth on suitable RCC foundation shall be provided near the MCC room for hooking up of the mobile generator. The junction box shall be divided in two portions, lower portion of 200 mm with separate door, for accommodation of cable from MCC, cable and plug from mobile generator and earthing conductor from earth pit for earthing of neutral of the generator. The upper portion shall be equipped with 125 Amps industrial type socket, and plug of IP 67 class as specified under industrial plug and sockets and having single door with 3 point locking arrangement, a handle with cylindrical lock open able with master key shall be provided

3.1.274

Indoor and Outdoo r Ligh tin g

A.

Lighting fixtures, fittings and workmanship shall be of first class quality and in accordance with the regulations of the ADWEA. In order to have easy access to replacements or spares, the fixtures and fittings etc. shall be obtained from a well reputed manufacturer represented in the U.A.E. All lighting fixtures shall be complete with all internal wiring, lamp holders, starters, supports etc. Where light fixtures can not be fastened to ceilings they shall either be suspended or fastened to the wall as directed by the Engineer. Fluorescent lights shall be of standard manufacture, the instant start type and its tubes shall be "Day Light" colour model. The control gear shall be suitable for 240 volts, 50 Hz and for climatic conditions prevailing on Site. They shall be power factor corrected for 0.93 or better. Fixtures with audible hums are not accepted. The internal wiring shall be the silicon rubber insulated copper conductor and shall be clipped neatly in position. High frequency electronic starters shall be used in locations where stroboscopic effect needs to be minimised. The resistance of lighting system, when tested with all the fitting and fixture installed and switches in ON position, should be more than 1 mega ohms between phase to earth and neutral to earth with neutral disconnected from main supply during testing. B. The contractor shall submit schematic layout drawing for lighting illumination indicating intensity of illumination, supported with illumination level calculation at different locations / areas for approval. The design shall be in accordance with DIN 503, maintaining level of illumination as indicated below. The quantity of lighting fixture mentioned in B.O.Q are only tentative, exact no. of fitting shall be as per approved layout drawings based on illumination level calculations. C. The light intensity shall be measured at 80 cm from ground level and the results submitted to the Engineer for approval and acceptance: a. MCC room, pump room 400 lux b. Roads 20 lux c. Footpath & paved areas 15 lux d. Outdoor equipment operation areas 300 lux *) e. Outdoor tanks/ storage areas 100 lux f. Other rooms 300 lux *) to be achieved with spotlights or directed floodlight. Contract 106, Volume II

Page 568 of 589

Section 015000

D. E. F.


F. Lighting facilities shall be provided to all paved areas and to the access road of the pumping station site. G. Lamps shall be installed at locations approved by the Engineer and shall be of the type indicated on drawings. H. Outdoor lighting system shall be fed MCC and shall be controlled through photo electric sensor backed up by timer.

3.1.275

Luminaires

Type A

2 x 58 W, damp and wet resistant fluorescent fittings, body manufactured from fiberglass reinforced flame retarding polyester and equipped with a non-discoloring acrylic diffuser. Safety code IP 65.

Type B:

Totally enclosed ceiling mounted corrosion resistant fixture, IP 65 suitable for 100 W G.L.S. lamp or with suitable wattage compact fluorescent lamp and opal polycarbonate diffuser.

Type (D):

Flood light with 150 W high pressure sodium lamp, wall mounted, die cast aluminum body with cooling fins, IP65, salt spray resistance polyester powder coating, anode oxidized aluminum reflector, thermal chock resistant tempered glass diffuser, adjustable lamp position.

Type E1:

2 x 24 W self-contained portable emergency light fixture, IP 54, with carrying handle, providing illumination continuously for 3 hours, complete with 2 adjustable flood lights mounted on top of the unit, 12V sealed Nickel cadmium long life type battery, fully automatic charger supplying a constant voltage, fuse protection, switches, status indicator, wall mounted brackets. The units shall be connected to a circuit separated from the other lighting or small power supply.

Type (E2):

Surface mounted self-contained, non-maintained emergency light, IP 54 with 2 x 8 W fluorescent tube, polycarbonate diffuser, battery and charger.

Type (E3):

Emergency light as type (E2) but maintained and with "exit" sign.

Type H:

Flood light with 250 W metal halide lamp, IP 65, GRP body and hinged front frame, anodized aluminum reflector, heat resistant clear glass, front cover, integral control gear including P.F correction capacitor, and fixing accessories for single / multiple adjustable mounting on poles.

Type H1:

Flood light with 70 W metal halide lamp, IP 65, Die cast Aluminum body and hinged front frame, anodized aluminum reflector, heat resistant clear glass, front cover, integral control gear including P.F correction capacitor, and fixing accessories.

Type S:

High bay 250 W metal halide lamp, IP65, Die cast Aluminum body, high purity Aluminum reflector, heat resistant clear glass cover and stainless steel suspension brackets.

3.1.276 A.

Lig ht Poles

The light pole shall be hot dipped galvanized steel. The cut-out shall be of sheet steel, rust proofed, suitably dimensioned to allow mounting in the lower compartment of the pole. The cutout shall be suitable for termination of the two cables up to 16 sq mm / 4 c XLPE with suitable terminals for loop in and loop out of cable. Each lighting fixtures on the pole shall be individually protected with MCB of 10 Amps with 10 kA fault level The control gear components shall be mounted in the upper compartments of the pole on aluminium base plates. Heat resistant,


Page 569 of 589

Section 015000

B.

rubber insulated, 600 V, flexible rated at 105 ºC cable shall be installed between the bulb and the control gear components. Foundations shall be pre-cast waterproof concrete B 35, size 50 cm x 50 cm x 100 cm deep (or as shown on drawings) complete with anchor bolts and cable ducts for entry and exit. Surfaces of concrete shall be fair faced and coated with 300 micron epoxy. The pole foundation and anchor bolts shall be covered by hot dip galvanized steel sheet canopy after pole installation.

3.1.277 3.1.278 A. a. b. B.

B. C.

D.

Earthing & Lightn ing Protecti on Earthing

The earthing shall comply with the regulations of the Water and Electricity Authority and with VDE - Regulation 0100 & 0190, as approved by the Engineer. The MCC panel shall be earthed by two individual earthing systems. For Diesel generators an additional earthing system shall be provided at the MCC Earth electrodes shall comprise a number of rods with a cross-section of 20 mm diameter, minimum total 3 m long vertically driven into the ground at intervals not less than 6 m. Earth rods shall be made from solid copper and shall be provided with special hardened tips and caps to protect the rod from damage when driven into the ground. To enable testing, electrodes shall be installed in prefabricated concrete chambers with removable covers. The earth electrodes shall be of PVC sheathed copper conductors of not less than 70 mm² cross section buried to a depth of 0.60 m.or laid inside PVC duct The transfer resistance of individual earthing systems, when measured during the dry period, shall not exceed 2 Ohm and transfer resistance of main earthing system shall not be more than 1 Ohms when all the individual earthing pits are connected to earthing system. This limit shall be demonstrated by the Contractor to the satisfaction of the Engineer. If the value cannot be achieved, additional earth rods shall be driven into the ground or additional electrodes shall be provided and connected to the individual earthing system to reduce earth resistance. Test equipment shall be provided by the Contractor. The metallic parts of all electrical equipment supplied and installed shall be securely bonded to earth. Metal frame structures or other metallic equipment shall be earthed to the earth network, cables, trays, conduits, armouring shall be earthed at the supply end. The electrical motors shall have earthing through one of the core of feeding cable of the motor and an additional earthing in case of dry installed pump through separately laid earthing conductors of half the size of the phase conductor but minimum size 6 sq mm. Lighting fixtures and pushbutton stations shall be earthed with an additional earthing conductor. Earthing connection shall be made by brazing or welding by Cad weld methods. For outdoor lighting poles, a separate PVC insulated earth conductor of minimum size 6 sq mm shall be laid with the cable for earthing of poles.

3.1.279 A.


Ligh tnin g Protecti on

All buildings and other structure shall be provided with a lightning protection in accordance with the BS EN 62305. The major components shall be air termination networks, down conductors, earth termination networks, bonding to prevent side flashing. Zones of protection shall be carefully selected. A soil resistivity survey shall be conducted by the Contractor in order to determine the necessary size of earthing rod and depth the rod shall be driven down. Where structures vary in height and have more than one roof termination network, the lower roof network should not only be joined to its own down conductors, but also joined to the down conductors of the taller portion of the structure in order to avoid side flashing. Special precaution measures shall be provided for the electronic equipment (computer, instruments, etc.) regarding lightning protection. The earth rod shall be solid copper of 20 sq mm, earth conductor laid on roof and earthing conductor from earth pit should be 25 x 3 mm copper tape Lightning terminal, of one meter minimum height, of copper with no of fins shall be provided. A test clamp at a distance 1.8 meter from ground shall be provided and copper tape up to test clamp shall be enclosed in PVC covered tape The maximum earth resistance for individual pit for lightning protection shall not exceed 10 Ohms.


Page 570 of 589

Section 015000

E.

The lightning system design shall be approved by the local civil defence authorities prior to the submission to the Engineer / Employer. It is the Contractor's responsibility to obtain this approval.

3.1.280 A.

B.

B.

C. D. E. F.

Fire Exting uish ers

Subject to the approval of the UAE Civil Defence Department the following types shall be supplied and installed: Type Media Capacity Location Quantity Class Offices 1 each Corridors 1 / 10m FE – 01 Water 10 l Lobby 2 each A Canteen 2 each Stores 2 each FE – 02 CO2 5 kg E- rooms 1 each E – rooms 1 each Kitchen 1 each Generator set 1 each Work shop 3 each FE – 03 5 kg B,C Dry powder Guard rooms 2 each Pump room 4 each Laboratory 1 each P - transformer 3 each FE - 04 30 kg Generator set 1 each

3.1.283 A.

Fire Fighti ng System

The fire fighting system shall consist of sufficient quantities and types of portable fire extinguishers with extinguishing agents suitable for that specific area to be protected. The fire extinguishers shall be wall mounted on original brackets. For highly hazardous areas wheel mounted fire extinguishers with a minimum extinguishing agent capacity of 30 kg, shall be provided. All fire extinguishers shall be of the same brand, the manufacturer must have an service agent located in Abu Dhabi.

3.1.282 A.

Fire Fighti ng and Alarm Systems

The Contractor shall design, provide install, test and commission a complete fire fighting and alarm system in accordance with the local and international civil defence rules and regulations, subject to the approval of the Civil Defence Department and to the satisfaction of the Department and the Engineer. Before start of works the Contractor shall furnish and submit detailed technical descriptions, material specifications and layout drawings for the entire systems. This documentation shall be accompanied by the written approval of the Civil Defence Department.

3.1.281 A.


Fire Alarm Syst em

The fire alarm system covers various automatically controlled fire detection and alarm zones and includes manually controlled fire alarm points given locally audible and visible alarms The ventilation- and AC/ systems shall be linked to the fire alarm system and shall be automatically switched off in case of fire alarm. A Fireman’s override panel shall be provided close to the fire alarm panel for individual operation of the exhaust fans only for smoke separation and exhausting. Fire alarm occurring in the generator-set room shall switch off the generator set and shall prevent automatic operation of the set. Fire alarm occurring in the cabling area or in the electrical rooms shall de-energize the total electrical system including the generator set Each zone shall be self-controlled by line-end resistors. The fire alarm system shall comprise:


Page 571 of 589

Section 015000

G.


A local fire alarm control panel with programmable processor, event memory, field power supply and battery back-up power supply including all alarm and control devices as required by the Civil Defence Department. A mimic diagram showing the fire alarm zones with indicators for each zone (green = no alarm / red blinking = alarm) shall be on the panel’s front side.

3.1.284

Fire Alarm Detectors

Type 1 Heat detector to be VDS approved and comply with the requirements of EN 54: Part 5. it shall provide fixed temperature heat plus rate of rise sensing the detector shall have 360 degree viewing LED fire detector.

Type 2 Optical Smoke detector to be VDS approved and comply with the requirements of EN 54: Part 7. the optical element shall detect visible smoke from slow smoldering fires the detector shall have 360 degree viewing LED fire detector.

Type 3 Gas sensor/detector spot type with catalytic elements that accelerate the oxidation of combustible gases resulting in rise of temperature and actuation Location: Dry/Wet well areas

3.1.285

Manual Call Points

Manual call points shall be protected with an easily breakable glass cover and shall be designed for a single line. Each zone shall be equipped with at least one push button unit, always located at the emergency exit area.

3.1.286 A.

B.

Alarm Flush Ligh t and Alarm Horn

Alarm horns shall be provided in machinery rooms, public areas, guard room, electrical rooms, corridors, master office, and work shops and outdoor at each building within view of the guard room. At areas, where high noise deter hearing the alarm horn, flash lights shall be installed at the alarm horn in addition.

3.1.287

Cabling / Wiri ng

MICC cabling or FP200 wiring system shall be used for the entire fire alarm system.

3.1.288

Fire Alarm Zoning

Individual fire alarm zones shall be: Smoke: under floor cable area, switchgear & control rooms, administrative areas, machine rooms Heat: cooking areas, chlorination station, work shops, emergency power station

3.1.289

Fire Blankets

Fire blankets shall be provided and deposited at the following locations: a. Cooking area: min 2 No. b. Fuel areas: min 3 No. c. Work shop: min 2 No.

3.1.290

Fire Alarm System at Pumping Stations

The fire alarm and fire protection system in structures for the MCC of individual lifting and pumping stations shall be as per the approval of Civil Defence Authorities but the minimum requirements are: a. 4 No. Smoke detectors ( 2 MCC room and 2 Cable room ) b. 2 No. Push button (manual call point) c. 1 No. Fire alarm panel d. 1 No. Fire alarm horn e. 1 No. Fire alarm bell f. 1 No. Flushing alarm light mounted on top of building g. 2 No. Dry powder fire extinguisher 5 kg h. 1 No. CO2 fire extinguisher 5 kg Contract 106, Volume II

Page 572 of 589

Section 015000

i.

cabling and wiring as required

3.1.291 A.

B. C. D. E.

4


Telephon e Syst em

The Contractor shall supply and install all ducts, conduits, trunking, wiring, boxes, and accessories including pulling wires for telephone and intercom system along with telephone and intercom outlets. The main cable entry ducts for telephone shall be independent, separate and have a minimum 2 Nos. size of DN 150 with manhole of minimum size of 600 x 600 x 700 mm , conduits shall not be less than DN 25 and each conduit shall not serve more than 3 telephone outlets. Telephone outlets including plates and intercom outlets shall be procured from the same manufacturer as for those of the electrical works and to the approval of the Engineer. A wooden cabinet with terminal block of suitable size as per requirements of ETISALAT shall be provided for termination of ETISALAT incoming cable Telephone cabinet shall be provided for the telephone and intercom facilities inside dry well. Earthing for telephone systems shall be separate and isolated from all other earthing systems of buildings. The earth lead from the main distribution panel shall not be less than 16 mm². All telephone installations and all works shall be in accordance with ETISALAT regulation. The Contractor shall allow in his rates for coordinating with ETISALAT for approvals and installation including the service charges for providing of telephone connection.

Part 4 Inspect ion 4.1.1 Tests , Inspecti ons and Commis sioning

A.

B. C. D. E.

F.

G.

H.

The Contractor shall furnish and shall allow in his rates for the costs of all supervision, material, plant, apparatus, labour, etc. required for carrying out the tests, for re-testing and commissioning the plant as specified. In the event that site tests indicate a deviation from the factory tests of any part of the plant supplied, the Contractor shall take all necessary steps to rectify the short-comings. All equipment / instrumentation shall be tested and commissioned by the manufacturer representative. All services / maintenance through the guarantee period shall be done by the manufacturer representative. All instruments and apparatus used for testing shall be calibrated and calibration test certificates, not older than one month, for such instruments shall be made available. Calibration shall only be carried out by a recognized testing laboratory The Contractor shall arrange with Abu Dhabi Water & Electricity Authority (ADWEA) for the inspection, testing and reading of electric / water meters prior to completion of the works in order to obtain clearance for the connecting of power and water to the plant. Fire alarm, fire fighting and lightning protection systems shall be tested in the presence of and in accordance with the regulations of the Civil Defence Department. It shall be the Contractor's responsibility to co-ordinate with the Civil Defence Department in this respect. The Contractor shall allow in his rates for the supply of all labour, material, plant, calibrated instruments etc. required for the proper execution of tests, retesting and recording.

4.1.2 Third Part Inspecti on A.

The contractor shall allow in his rates all costs for third party inspection from a reputed and approved international companies for the following equipment: pumps, macerator, valves, generator, and electrical control panel.

4.1.3 Factory Tests A.

B.

a.

All plants shall be tested as required by the relevant standards approved by the Engineer. The Contractor shall submit to the Engineer, for the Engineer's approval, all required test procedures within one month after obtaining the approval for the Plant. Test certificates and related documents, as performance curves etc., obtained from tests at the manufacturer's premises and approved by the Engineer shall be submitted in triplicate after testing. Pumps shall be tested with their individual drive to determine head, capacity, efficiency, balance and vibration.


Page 573 of 589

Section 015000

b.

c. d.

e.


Valves shall be tested and certified as being leak-proof against a differential pressure equal to the design pressure. Leakage allowance rate shall be in accordance with relevant standards approved by the Engineer. Cables shall be type tested and shall subject of factory tests prior to delivery according to VDE 0250, VDE 0271, and VDE 027. Panels shall be tested in accordance with VDE 0660 for insulation resistance, general mechanical and operational reliability, simulated operational sequence, primary or secondary injection tests, over-potential (flash tests). Loading test certificates for all lifting gears and crane beams, girders, hoists, etc. shall be provided.

4.1.4 Field Tests A.

B.

C.

D.

E. F.

The plant installed shall be operated by the Contractor in presence of the manufacturers' authorised technical representative and under the supervision of the Engineer through the entire range and sequence of operation in order to demonstrate its compliance with the requirements specified and/or implied in the Contract. Any short-comings, defects and or malfunctions of the plant or any part of thereof, that may become apparent during such tests, shall immediately be made good by the Contractor to the satisfaction of the Engineer. Three months before the expected date of PAC the Contractor shall submit to the Engineer, for the Engineer's approval, a detailed programme and organisation chart for said operation and maintenance, manpower schedule and curriculum vitae of the key personal. Latest two months before start of field tests the Contractor shall submit for the Engineer's approval all required test procedures including a complete set of inspection, testing & commissioning record form sheets for each type and kind of inspection and test to be conducted in the field. These form sheets shall show in detail the proposed inspection and test procedure, their execution and recording. Besides visual inspection the following components and systems are subject of field inspection and testing:

Centrifugal pumps: Minimum / maximum flow reading versus head/Power consumption reading at duty, run-out, closed valve conditions/ Vibration readings at duty and closed valve conditions at pump and motor / Bearing temperature reading. Test shall be run continuously for 48 hours for each pump unless otherwise directed by the Engineer Tanks, pressurised: Leakage test at design pressure with water or gas Valves: Function test/Leakage test (Pipe- work) /Limit switch set-point Indicator Instruments: Function test/Calibration Bench tests Signal Transmitters: Function test / Calibration signal value / Isolation test Electrical Motors: Winding resistance / Megger reading / Heater function / Rotation / Vibration / Bearing temperature Power Transformers: Megger reading / Oil sample test Switchgears: Megger reading / Function tests / Earthing tests / Set points / Injection tests Cabling / Wiring: Megger reading Earthing / Lightning: Resistance tests/Continuity tests Illumination: Illumination tests at night / Function test of emergency lights Flow meters: Calibration test A/C, Ventilation Systems: Air volumes / Noise / Temperature / Humidity / Vibration Emergency Generator: Field test as per manufacturer's instructions / Switch-over test / Load Test Plant Manual Operation: Manual Start-up / Operation and shut down Plant Automatic Operation: Automatic start-up / Automatic operation and shut down Alarms, Automatic Cut-Outs Testing that every designed and installed alarm and safety function operates properly / Testing to demonstrate that every automatic cut out operates at the designed level. Muncher: Blockage cut-out test/Currency reading during normal operation & at blocked situation/Safety test Gearboxes: Oil reservoir breather / Rotation / Vibration / Oil leakage test Odour Control: Activated carbon/Function test/ H2S soluble and gas concentration / inlets & outlets / Smell tests Contract 106, Volume II

Page 574 of 589

Section 015000


Surge Protection: Test run with fresh water under start & stop conditions with empty and filled pressure line, readings at the vent valves / pressure vessel / test run under normal operation conditions

4.1.5 Irrigatio n System Testi ng A. B. C. D.

Immediately prior to hydrostatic testing, all irrigation lines shall be thoroughly purged of all entrapped air. Mainline piping system may be tested in sections. Lateral Systems shall be tested valve by valve. Water shall be discharged from a single outlet by manipulation of isolation control valves and installation of temporary caps. Water shall be introduced into lines to be tested at full operating head and the water flow at end discharge point, and observed until all air and residual debris has been expelled from the line.

4.1.6 Initial System Test A. B. C. D. E.

F. G. H.

I. J.

K.

Individual parts of the main network between isolation valve points having a length not greater than 500 meters shall be tested together with dead legs before backfilling operation. Test shall be made only after completion of the above operations and not until at least seven days after the last concrete thrust anchor block has been cast. Contractor shall supply all testing material and equipment, including all caps, valves, pumps, tanks and gauges as required. Pressure gauges shall be dual reading in bar and psi units. Calibration shall be such that accurate determination of potential pressure loss can be ascertained. The section of the main pipeline to be tested shall be filled with potable water and all air expelled. After the main pipeline has been completely filled, the pressure shall be steadily and gradually increased until the specified test pressure has been reached. Simultaneous pressure and leakage tests and separate pressure test shall be made at 150 % of working pressure at the point of test, but not less than 125% of normal working pressure at highest elevation. Separate elevation test shall be made at 150 % of normal working pressure of the segment tested. Duration of simultaneous pressure and leakage tests shall be 2 hours and duration of separate pressure tests shall be 1 hour. All testing shall comply with AWWA M23-80, Polyvinyl Chloride Pipe Design and Installation. A graph shall be produced showing water input against time and the test shall run until the graph curve flattens out. Testing shall comply with AWWA specifications and requirements. Separate tests shall be applied to the lateral distribution pipe work and the irrigation pipe work from the remote control valves outwards. Test pressures for these shall be as described above. When testing the irrigation lines from the valves, discharge devices shall be replaced with temporary plugs or caps. All trenches with pipe installed shall be immediately backfilled with preliminary sand backfill sufficient to prevent arching or slipping under pressure. All joints, fittings and connections are to remain exposed until successful completion of hydrostatic testing. Other than for preliminary sand backfill over pipes, no work shall be covered before it has been inspected, tested and approved by the Engineer. During the tests, all exposed couplings, fittings and valves shall be carefully examined for defects and leakage. Leaking pipes, couplings, joints, fittings and equipment shall be repaired or replaced and the section retested as previously specified. Upon receipt of approval of the Engineer to proceed, the remaining backfill shall be placed and compacted to ninety percent (90%) of maximum dry density. For further details for backfilling, refer to respective Section of t he Specifications.

4.1.7 Final System Test A.

The tests as specified above shall be repeated for the entire network after pipelines have been backfilled, cleaned and inspected. Each test shall be restricted to pipes of one class and particular care shall be taken to isolate air valves, etc. and not to apply higher pressures than specified at any point on the pipeline and to ensure that the pipelines are adequately anchored before any test is carried out.


Page 575 of 589

Section 015000


4.1.8 Test Result s A.

Written records of every test clearly identifying the tested section of the pipe together with time of test and name of testing engineer in tabulated format shall be submitted for review and approval by the Engineer upon completion of the tests.

4.1.9 Flushing A.

General: On completion of the system t est, the system is to be thoroughly flushed, the velocity of water being at least 1 m/s. Should the main water supply be unavailable or inadequate for this purpose at the time of flushing, then a swab of adequate size shall be used to remove all foreign matter from the pipeline. This process shall continue until the pipeline is completely clean. Each control valve shall be opened separately and the terminal systems also thoroughly flushed. After completion of flushing, the emitters and other discharge devices shall be fitted.

4.1.10Operatio n Test A.

B.

After the hydrostatic test, emitters or bubblers shall be installed and the system completed and tested to demonstrate functional efficiency. This shall be prior to covering the laterals with mulch. The lines shall be operated for a period of 24 hours, not necessarily in one continuous period, and all emitters checked for satisfactory operation. Any faulty/blocked emitters shall be replaced.

4.1.11System Testing A.

B.

C. D.

E.

The following tests shall be carried out prior to the issuance of the PAC and before irrigation water is discharged to the system. The Contractor shall allow in his Contract Price for all labour, plant, material, instruments, etc. required for carrying out the tests. Water used for testing may be effluent water or potable water. It shall be the Contractor's sole responsibility to arrange for the timely supply of electricity and water required for testing. Costs for the supply of water and electricity are to be included in the rates. Temporary power supply (Generator) should be made available during the testing, if the permanent main power supply is not available till that time. Recirculation of water is acceptable. Together with the testing program the Contractor shall submit a detailed description of temporary measures / installations, required for recirculation of water. Costs for such arrangements shall be included in the appropriate rates. The program shall consider that the performance of AC's shall be tested during August.

4.1.12Indivi dual Plant Compon ents 4.1.13 Testin g Step I All plant components shall be tested and commissioned, as far as practicable, under dry-run conditions, strictly in accordance with the manufacturers' instructions.

4.1.14 Testin g Step II After successful completion of Step I the hydraulic performance of each plant component shall be tested, using effluent or potable water.

4.1.15 Hydraulic Performanc e Tests A. B.

C.

After successful completion of individual plant component tests the hydraulic functioning of the plants shall be tested as follows to verify the performance as specified: The wet well of the pumping stations shall be filled with sweet water in such intervals to enable running of the stations for one hour under expected high flow conditions with a minimum of 6 pumping cycles. The water shall be discharged to the pressure pipeline / network connecting the pumping stations with the main pumping station. Each pump shall be individually tested for a period of at least 48 hours continuously.


Page 576 of 589

Section 015000

5


Part 5 Pre-Conditio n Pac 5.1.1 Pre-Condit ions f or the Issue PAC Certificate

The PAC - Certificate will be issued only after the Contractor has complied with all the below listed conditions, in addition to other conditions mentioned elsewhere in the Contract: a. Hydraulic performance tests b. Contractual trial tests c. Snag list of outstanding items to be completed d. O&M manuals & as-built documentation including catalogues etc. e. Workshop laboratory & safety equipment, tools and instruments, f. Spare parts, consumables g. Site cleaning

6

Part 6 Traini ng 6.1.1 Training of Operator s

A.

B.

C.

D. E. F.

G.

H.

7

Not later than three months before start of training the Contractor shall submit to the Engineer a training program indicating the periods of training, the qualifications and number of technicians, operators and labourers required for a proper and efficient operation and maintenance of the Plant. The Contractor shall be responsible for and arrange for the adequate training of personnel, delegated by the Department to the Project, in all aspects of installing equipment, checking installation, testing, operation and maintenance procedures, replacing equipment, documentation related to ordering spares from manufacturers, setting up a parts and equipment reference, stock keeping and stock control, receiving shipments and documentation related thereto. The Contractor shall make trainees fully aware of the contents of all drawings, technical literature, operation and maintenance manuals, faultfinding chart for each item of the Plant before demonstrating any maintenance work. He shall set up, demonstrate and maintain for the duration of the training period all the correct daily, weekly, monthly procedures necessary for the proper operation and maintenance including log books at each station for recording hours, run duty charges, performance of equipment, date and type of inspections, readings of power and chemical consumption, flow rates, etc. The contractor shall provide training for PLC and RTU to the satisfaction of the Engineer, Employers and the representatives of operation and maintenance company. The Contractor shall demonstrate to trainees all routine procedures for the testing, checking and examining of equipment before putting in use. Daily records, in the form proposed and provided by the Contractor and approved by the Engineer, shall be kept by each trainee and the Contractor shall submit such records in weekly intervals to the Department and the Engineer. Should, during the course of training, it become obvious that any one of the delegated trainees is not capable to achieve the expected goal, the Contractor shall immediately inform the Department who in turn will provide replacement. After completion of the training program the Contractor shall submit a detailed evaluation of the personnel trained.

Part 7 App endix 7.1.1 List of Approv ed Manufacturers

A.

The Department maintains a Data Base of materials which have been previously approved for specific applications and used on various contracts. The Data Base is a live document and subject to regular up dates. The Contractor may propose new materials provided they comply with the Contract Specifications in all respects. However the Department shall not be bound to accept any such offer and need not to assign any reason for the non-acceptance..


Page 577 of 589

Section 015000


B.

All materials, equipment and machinery (including electrical motors) shall be manufactured in the original country of manufacturer and similar items of Plant like pumps, motors, etc. shall be obtained from one manufacturer only.

C.

The Contractor shall provide comprehensive information and detailed schedules for each type of material / equipment proposed showing type, manufacturer, country of origin, local agent and all other data and information required for a technical appraisals. The submittals shall be accompanied by detailed technical descriptions, catalogues, lists of references, showing that the material / equipment is suitable for the climatic and environmental conditions prevailing at the Site. When evaluating the offers, emphasis will be paid to durability, ease of operation and maintenance, access to major items of the Plants. Submittals shall, in addition to requirements listed elsewhere, include schematics and flow diagrams showing the built up of the plant.

8

Part 8 Control Philosoph y For Pumping Stations 8.1.1 General

A. B. C.

a. b. c. d. e. D. E. F. G. H.

The Control Philosophy shall be applicable typical for all small and medium irrigation pumping stations and where a defined water (potable / treated) capacity are known. In general the irrigation controller will be responsible for operation of the pumps for a certain time duration depending on the water, which will be consumed by the zone area. Irrigation controller shall have connection and interface with the following instruments as a minimum which are either prohibiting and permitting pump/s operation and it should be either connected directly or through PLC located in the main MCC panel: Level transmitter backed up by a float switches Pressure transmitter DP for filters Pressure transmitter on the main delivery line Flow meters Irrigation controller shall have a site interface either integrated or separate to enable the management of the pumping station centrally. Irrigation controller should be either working automatic / semi automatic or manual operation with the features, which will be explained later in this text. The controller shall be able to share data with the neighbouring controllers back and forth. The contractor shall provide the software to enable long distance controlling. The local RTU, which connected to the SCADA system, will be used for monitoring of the pumping station.

8.1.2 Control Description A.

This control philosophy for multi-pump pumping stations, utilizing the installed analogue level detection system mainly hydrostatic level measurement with a float or conductivity probe system as back-up in the event of a failure of the level detection measurement system.

8.1.3 Process Control Interface A. a. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

The PLC shall include (where applicable) but not limited to the following: Digital Inputs 415 V Healthy PLC power failed Pump No. (1) running Pump No. (1) failed Pump No. (1) available Pump No. (2) running Pump No. (2) failed Pump No. (2) available Sump Pump running Sump Pump failed Sump Pump available Sump level High


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Section 015000

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. b. 1. 2. 3. 4. 5. 6. 7. 8. 9. c. 1. 2. 3. 4. 5. 6. B. C. a. b. c. d.


Battery low dc output voltage Battery dc output failed Reservoir High level Reservoir low level Reservoir low level Pump No. (1) suction strainer High DP Pump No. (2) suction strainer High DP Potable water inlet valve open Potable water inlet valve closed Potable water inlet valve available\ Pump room fire alarm MCC room fire alarm Pump room flood alarm RTU failure (from RTU) SCADA pump permissive (from RTU) Digital outputs Pump No. (1) start / stop Pump No. (2) Start / Stop Ventilation Fan (1) start / stop Ventilation Fan (2) start / stop Potable water inlet valve open / close PLC grouped failed Pump No. (1) failed to start Pump No. (2) failed to start Irrigation network failure Analogue Inputs Pump No. 1 current Pump No. 2 current Potable water inlet flow Potable water outlet flow Pump discharge header pressure Salinity The RTU shall be configured with the same field inputs as the PLC or as requested. The RTU shall also receive the following diagnostic inputs from the PLC: Pump 1 failed to start Pump 2 failed to start Grouped PLC fault Irrigation network failure.

8.1.4 Process Control Operation 8.1.5 A.

B.

C. D.

E.

Irrigati on Contro ller

The irrigation system controller shall be of a solid-state microprocessor type, capable of fully automatic, semi-automatic or manual operation. The controller will be housed in a NEMA-4 rated, lockable, plastic cabinet suitable for wall mounting and should be connected to the RTU and has a communication facility through GPRS/ PSTN/ Radio etc to the central irrigation control system. The controller shall operate on 115 VAC ± 10% at 60Hz or 230 VAC ± 10% at 50Hz and be capable of actuating up to 48 stations plus up to three master valves or pump station relays. Each station may operate up to eight 24 VAC solenoid valves. The controller shall operate up to eight stations plus the three master valves simultaneously. Controller output and input shall be protected against severe electrical surge. The controller shall be capable of either grouped station programming or independent station programming. The grouped programming mode shall have seven grouped programs, which may have different start times, watering days and station timing. Each program shall be capable of up to eight start times per day, and be capable of running as irrigation, non-irrigation or drip program types. Irrigation programs may each be run based on time, volume or ET. The controller shall have up to 48 stations, each station shall be capable to open two valves maximum at the same time and should be agreed by the engineer other wise only one valve should be open.


Page 579 of 589

Section 015000

F.

G.

H.

I.

J. K.

L.

M.

N.

O.

P.

Q. R.

Each capable of an operating time of 1 second to 24 hours in second, minute, or hour increments. The controller shall be capable of either automatic sequential stacking or overlapping program. The controller shall provide a separate water budget feature for each of the programs, allowing simultaneous adjustment of all stations on a program from 0% to 999% of set running time. Adjustments shall be in 1% increments. The controller shall have a 365-day calendar with calendar days and day-of-the-week OFF features. Programs will run on an ODD/EVEN day cycle, a 14-day ON/OFF cycle, or in cycles from 1 to 31 days. The controller shall also have a programmable rain shutdown from 1 to 99 days. The controller shall have three master valve/pump start circuits for use with a master valve to pressurize the system when the irrigation cycle starts, or to activate a remote pump start relay to run the pump during the irrigation cycle. The master valve/pump start circuit shall be ON/OFF programmable by station. The controller shall have the ability to run non irritating schedules for site specific accessories such as outdoor lighting or decorative fountains. The controller shall be capable of ET-based programming via the selection of preinstalled ET values for specific climate conditions, user entered values for each month of the year, or direct input from an electronic accessory such as an ET gauge. e controller shall be capable of manual operation at any time. A single station, group of stations, or program can be selected to run for a programmed time or a new time setting without affecting the normal program. The controller shall also provide an additional manual pause-andresume operation feature for maintenance situations. The controller shall be capable of running a variable system test program without affecting the normal program, and the test cycle may be programmed for various run times. The controller shall have Cycle+Soak™/ or similar if approved by the Engnineer. water management software that is capable of operating each station for a maximum cycle time and a minimum soak time to reduce water runoff and puddling. The maximum cycle time shall not be extended by water budgeting. The controller shall have a 365-day calendar with a day-of-the-year OFF. A date set to OFF shall override the normal, repeating day schedule, shall remain off on that date, and shall display to the operator that the current day is a non-watering day. The user shall have the option of having the date remain OFF, or be reset to ON after the date has passed. The controller shall have three sensor inputs as standard, upgradeable to up to 12 sensor inputs. Sensors can be either switched output or pulse output. Sensor inputs shall either cancel or interrupt irrigation by station. The controller shall provide for easy and accurate setup for flow meters and the amperage used by each station for direction of out-of- parameter conditions. The controller shall have a water usage log based on either theoretical or monitored flows. The controller shall be able to limit the total demand on the hydraulic system to a user-entered maximum flow. The controller shall feature event logs and alarm conditions. It shall be capable of automatically actuating a strobe light on the outside of the cabinet or pedestal in case an The controller shall feature three selectable languages for the operator (English, Spanish and French). There shall be a back-lit LCD display for use in low light conditions. Each station and each master valve will be protected by a diagnostic circuit breaker, which will allow that station to be bypassed during a program. The controller will have an internal non-volatile memory that will protect the program from power outages for up to ten years, and for counting down the program-in-progress during a power outage.

8.1.6 A. B. C.


RTU/ PLC

The pumping station and irrigation system shall be monitored out by PLC mounted in the MCC, SCADA communication shall be through an RTU also mounted in MCC. The PLC shall carry out all control associated with the reservoir and it shall control the reservoir inlet valves based on level and the pumps control via irrigation controller. The panel mounted operator interface will be used to locally enter set points into PLC and display process data (flows, pressures, alarms etc.)


Page 580 of 589

Section 015000

8.1.7 A.


Pump dry run protection

Pump dry run protection shall be provided regardless of the mode of operation of the pumps (Hand or Auto). A low level transmitter backed up with float switch in each reservoir shall provide dry run protection and prohibit the pumps from operation.

8.1.8 Pump Contro l 8.1.9 A.

Pump conf igur ation and MCC arrangement

Each reservoir shall be equipped with a number of two of identical main irrigation pumps, (one duty and one stand-by) configuration.

8.1.10 Pump Contr ol Modes A.

Two modes of pump control shall be available, Hand and Auto. These shall be selectable via hand off auto selector switches on the front of each starter compartment

8.1.11 Hand Control A. B.

When (HAND) control is selected starting and stopping of any pump shall be initiated manually by a Start / Stop Pushbuttons. This mode of operation shall override all controls and protection circuits apart from the starter protection devices except the dry run protection and low level (pump stop).

8.1.12 Auto Control A. B.

C.

D.

E. F.

When auto control is selected the pumps shall run under the zone program selected by the irrigation controller. The pumping station will run in either local or remote operation. When selected to run the pumping station in Local Mode, the pumps shall be controlled, through the Programmable Logic Controller with level measurement backed up by float switches. When selected to run the pumping station on Remote Mode, the RTU shall monitor the operation of the pumps based on the irrigation controller program, and the local controls shall become inoperative. The RTU OK/Remote Relay is driven by one of the RTU’s outputs and is used by the RTU to take control of the pumping station. The relay is energized to take control of the station by disconnecting the local pump run controls. This is a failsafe operation and in the event that the RTU fails, the relay de-energizes and local controls resume. The remote/local selector switch at the station is used to select local control, if so required. Pump duty selection and any other local selection systems are used for local control only. Master station pump duty selection is used for RTU control only.

8.1.13 Duty Selection A

B.

C.

The operator can select either individual pump duty selection, or cyclic duty selection. The pump, which is selected as Duty 1, will start at identified time programmed for zone irrigation, the pump selected as stand-by will start at the identified time for zone irrigation. If cyclic duty is selected, then the duty selection will be rotated/altered each time a pump stops. The next pump to start is the next in the duty list; the next pump to stop is the pump that has been running longest. For a 2-pump station, the duty cyclic duty list will be 1-2, then 2-1. If any pump has a fault or is unavailable, it is not included in the duty list. If a pump fails, then the next pump in the list is started immediately, and the faulted pump is taken out of duty. Alarm for the failed pump should be activated

8.1.14 Run Time Maximum operation time for each pump shall be as per site requirements and as approved by the engineer, accordingly RTU/PLC shall be programmed to change the duty pump if it has run the specified time.

8.1.15 Standby Pump Operatio n For all modes of operation, if a duty pump is not available or faulted, then the next pump in the duty list will be activated instead as a standby.


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Section 015000

8.1.16 A. a. b.

c.

d.

C. D.

E. F.

B.

C.

B.

B.

Pressure Monitor ing

The outlet pressure shall be monitored and displayed on the panel-mounted interface; the signal shall be transferred to PLC and SCADA system through RTU. In addition the on falling pressure the PLC shall calculate the rate of change of the pressure signal and generate an alarm if the rate of change exceeds a preset value configured via panel mounted interface. This is an indication of pipe rupture. The PLC should also send a grouped network failure alarm to SCADA via RTU.

8.1.21 A.

Pump Inlet Strainer Monitor ing and Control

The PLC system shall monitor the differential pressure across the pump suction strainers. If one of the DP switches go into an alarm state the PLC shall start the next duty pump and stop the pump associated with the high DP alarm. The DP shall be monitored by PLC and SCADA system through RTU , the DP switch shall be alarmed on the panel mounted operator interface and the pump put into an “Unavailable” state and not started until the alarm has been cleared. The DP alarm shall remain latched until cleared either by operator via panel mounted operator interface or automatically by the PLC if the alarm has remained active for more than 48 hours.

8.1.20 A.

Sump Pump Control s

The irrigation station sump pump shall be controlled based on the level switches in the sump. The PLC shall start the sump on high level and stop it on low level . the sump pump and level switch status will be monitored by the PLC and RTU system and displayed and alarmed on the operator interface.

8.1.19 A.

Ventil ation Fan Contro l

The duty ventilation fan shall run continuously during summer months and during the daytime in the winter. If the ventilation fans are available the PLC shall cycle the duty selection every 6 hours. If the duty fan fails to start the system automatically start the stand-by fan, and If the duty fan is unavailable state (isolated or in fault) the control system shall not attempt to start the fan and shall start automatically the stand-by fan. The summer and winter operating regimes the system shall be configured with a third time based operating regime that shall be agreed with the engineer prior to software configuration. The ventilation fan-operating regime shall be selectable through the panel mounted operator interface.

8.1.18 A.

Reservoi r Inlet Valve Contro l

The irrigation reservoir inlet shall be controlled by: Inlet Float valve with limit switch and shall be indicated on the MCC for Open / Close, signal shall be transferred to PLC and SCADA system through RTU. Inlet butterfly valve with actuator 24 Volt AC/DC shall be provided and shall be controlled by the level transmitter to open and close based on the water level in the irrigation reservoir shall be indicated on the MCC for Open / Close, signal shall be transferred to PLC and SCADA system through RTU. Each reservoir shall have a high level transmitter installed inside and the high level shall be installed above the shutoff level of the float valve, if the high level activated the PLC shall set high high level alarm and shut the inlet valves to the reservoir. The high high level alarm shall remain latched until the level falls below the high level alarm generated from the analogue level instrument or the high high level float as fallen out of alarm state for more than one hour.

8.1.17 B.


Flow Monito ring

The discharge flow shall be monitored on the individual outlet lines feeding the local irrigation networks the flow data shall be displayed on the panel mounted operator interface and transmitted to SCADA via the RTU. Empty pipe detection sensor shall be available.


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Section 015000

8.1.22 A. a. b. c. B.

a. b. c. d. e. f. g. h. i. j. k. l. m. B. a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. C. a. b. c.

B. C.

Panel Mounted Operator Interface

The Contractor shall supply, install and commission a panel mounted operator interface to be located on the MCC. The panel mounted operator interface unit shall be used display the status of the irrigation reservoir and its associated pumping station. The information displayed shall include but not limited to the following: Reservoir level Inlet Float valve status Inlet butterfly valve status Strainer DP switch Pump status ( running, available, fault) Pump duty Ventilation fan status Ventilation fan duty Flow switch status Level switch status Discharge flow Discharge pressure SCADA system status The operator interface shall include an alarm package, the data alarmed shall include but not limited to the following: Reservoir flow high Reservoir level high high Reservoir level low Reservoir level low low Strainer DP high PRV activated Sump level high Pumping station flood alarm Fire alarm pump room Fire alarm MCC room 415 V fault PLC power failed Low battery Battery fault RTU failure Common discharge pressure low low The operator interface shall also be used to enter system configuration and control data: This shall include but not limited to the following Pump duty selection PID controller terms Alarm thresholds

8.1.24 A.

Fire Alarm and Fire Protecti on System

The following data shall be monitored for each pumping station: Pump room fire alarm MCC room fire alarm Pump room flood alarm These inputs shall be digital inputs and will be input to both the PLC and the RTU. The alarms shall be displayed on the panel-mounted interface and on the SCADA system.

8.1.23 A.


PLC and Operator Interface Unit Configu ration

The Contractor shall configure both the PLC and the operator interface units to achieve the functionally specified. The irrigation controller shall be interfaced with the PLC to give full function as configured in the irrigation controller. All software (PLC and operator interface) shall be written using a structured format and shall be fully annotated. The software shall be written such that the same core software shall be installed in each location and the software configured for the application specific conditions.


Page 583 of 589

Section 015000

D. E.


The Contractor shall prepare a function design specification (FDS) for approval by the engineer before starting software configuration. The FDS shall be written in accordance with Department standard SCADA / Control System Specifications.

8.1.25 RTU and SCADA Configu rati on A. B.

C.

D.

E. F.

The Contractor shall configure the RTU to have the functionally, the main function of the RTU shall be together plant and PLC data for transfer to the SCADA system. The RTU shall be configured to provide a fail safe RTU healthy output to PLC. This output shall go low if the RTU senses a fault through its internal diagnostics or if there is a failure of SCADA / RTU communications. The SCADA system already exists and the contractor shall be responsible to upgrading the existing SCADA software to include the monitoring and control required for the pumping stations covered by this project. The SCADA and RTU software shall be written using a structured format and shall be fully annotated. The software shall be written such that the same core software shall be installed in each location and the software configured for the application specific conditions. The Contractor shall prepare a function design specification (FDS) for approval by the engineer before starting software configuration. The FDS shall be written in accordance with Department standard SCADA / Control System Specifications.

8.1.26 Symbols & Abbr eviation Symbols and abbreviation, used in this Contract, shall be understood as below: Symbols / Abbreviation Stands for: A Ampere A/C Air Conditioning BS British Standard cm Centimetre cd Candela d Day DFT Dry Film Thickness DIN Deutsches Institut für Normung e.V. Dn Diameter Nominal Eta (Efficiency) η hr Hour ID Inside Diameter ImpG Imperial Gallon K Kelvin kG Kilogram’s kW Kilo Watt l Litre l/hr Litre / Hour I/s Litre / Second mol Mol MW Mega Watt m Meter 2 m Square Meter 3 m Cubic Meter mm Millimetre mA Mille Ampere m Micro Meter (1/1000,000 meter) μ NFPA National Fire Protection Association OD Outside Diameter O/I Output / Input pH Pondus Hydrogenii PLC Programmable Logic Controller PN Pressure Nominal RTU Remote Terminal Unit Contract 106, Volume II

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Section 015000

s USG V W ζ


Second USA Gallon Volt Watt Zeta (friction loss coefficient)

END OF SECTION


Page 585 of 589

Section 015100, Ductile Iron Pipe & Fitti ngs 1

General 1.1.1 Submittals

A. The Contractor shall submit for the Engineer’s approval at least but not limited to the following: a. Detailed product data, manufacturers literature including general assembly. b. Shop Drawings indicating layout, general assembly, components, dimensions, weights, clearances, and methods of assembly. c. Test Reports indicating results of hydrostatic tests performed. d. Manufacturer's Instructions indicating support details, connection requirements e. Operation Data: Include manufacturers instructions, start-up data, trouble-shooting checklists f. Maintenance Data: Include manufacturers literature, cleaning procedures. g. Manufacturer Qualifications: Company specializing in manufacturing the Products specified in this section with minimum three years documented experience h. Handling, storage, installation instructions and recommendations i. Minimum 10 years performance warranty backed by insurance company with paid premium or as instructed by the Engineer.

1.1.2 Delivery , Storage and Handling A. The Contractor shall protect all products from physical damage during delivery, storage and handling. B. The Contractor shall inspect all products for damage. Defective products shall be removed from the Site.

2 Products 2.1.1 General A. All valves and accessories under this contract shall be designed, manufactured and tested in accordance with the appropriate standards and codes subject to the following: a. The Contractor shall prepare and submit for approval a complete valve schedule, showing for each individual valve the identification number, service, type & manufacturer, size, pipe identification number, location, mode of operation (normally closed [NC] or open [NO], drain, etc.). b. Valves shall be designed for a nominal pressure of 10 bar unless otherwise specified. c. Manually operated valves with a size > DN 350 shall be provided with a gearbox for easier operation unless otherwise specified. d. Valves (except pen stock valves), with a size > DN 150 shall be equipped with a drain/vent valve DN 25 at the upstream port unless otherwise specified. e. Valve spindle shall be of the non-rising type unless otherwise specified. f. Open/close direction shall be indicated at the operation wheels. Plastic hand wheels will not be accepted. All manual operated valves shall be fitted with locking facilities. g. On directional valves the flow direction shall be clearly indicated with an arrow at the valve body. h. The material of the complete valves with accessories and corrosion protection shall be as described below for gate valves unless otherwise specified. i. Where valves are exposed to outdoor conditions adequate protection covers against dust, sand, etc. for the rotating parts shall be provided. j. Valves shall be arranged for convenient operation from appropriate level and shall be provided with extension spindles or gearing if necessary. Where extension spindles are fitted, all the thrust when operating the valve shall be taken direct on the valve body. k. Pipes and fittings, shall be installed and positioned to allow ease of operation and maintenance. l. Pipes and fittings shall be flanged to PN 16. m. Joint gaskets shall be full-faced EPDM as per nominal requirement to assure water tightness. n. Valves & appurtenances, mounted in pipe work, shall be supported individually.


Page 586 of 589

Section:

o. p. q. r. s.

Toilet, Bath & Laundry Accessories

Fixing nuts and bolts supplied by the manufacturer shall be stainless steel grade A4 / 316 in accordance with the Specification. Flanged pipe and fittings shall be factory produced and shall not be fabricated on site. Sizes of pipes indicated on the drawings are nominal diameter, unless indicated otherwise. Bolts, studs, nuts and washers shall be made of stainless steel Grade A4 / 316. Supports, foundations and fixings shall be as indicated on the Contract Drawings.

2.1.2 Penstocks A. Penstocks shall be of flush invert, rising / non-rising spindle and mount in to the concrete walls as shown on the drawings and site conditions. Penstocks shall be designed to ensure watertight closure. Ap pl ic ati on

Item

Sewage

Storm Water / Subsoil Water

Sea Water

Flush invert, rising / non-rising spindle type and mount into the concrete walls

Type

Ni-resistant Iron with removable gussetted

Frames

Stainless Steel 316 L

yoke place to allow removal / fitting of door Ni-resistant

Doors & Door guides

Iron

suitably

stiffened

incorporating a nut pocket to accommodate

SS – Duplex Stainless Steel 316 L

DIN 1.4462

the door nut Gunmetal,

Shall

have

good

bearing

characteristics, hard wearing and non-

Seals

EPDM Rubber

corrosive, sealing faces shall be chemically bonded and riveted to the frame

Flush Invert Sealing Strip

EPDM fixed to the bottom of the door

Operating

Rising / Non- Raising, Stainless Steel

Stem

and

Extension spindles

Gr.316L

Rising / Non- Raising, Stainless Steel Gr.316L

Pillars

Ni – Resist Iron / Cast Iron

Tenzaloy (aluminum alloy)

Fixing Bolts

Stainless steel A4 / 316 expandable chemical type Hand wheel installed on pedestal complete with level indicator

Operation

Beveled gear box to be provided for > 350 mm

Hand-wheel

Cast Iron with open / closure direction

Tenzaloy (aluminum alloy) with open / closure direction

embossed

embossed

Stem Nut

Gun Metal

Stem Cover Tube

To be provided if rising

Fasteners

Stainless steel grade A4 / 316

Surface Finish

Smooth without casting defects

Natural Stainless steel finish

Corrosion Protection

See Section 09900

N/A

General

Passivated by glass bead

•

Gasket between penstock and wall shall be EPDM rubber.

•

Maximum allowable leakage shall be according to BS 7775.

•

Leakage tests shall be carried out at factory and at the site

2.1.3 Gate Valves A. Gate valves shall be of the flanged, non rising stem type to DIN 3352, complete with hand wheel, gearbox where necessary for easy operation, bolts, nuts, washer and gaskets. Material shall conform to the following: a. Valve body, bonnet, yoke and stuffing box parts shall be made from GG-25, DIN 1691. Internal surfaces shall be protected by factory applied 2 layers abrasive resistant enamel 200 micron or equal and approved. b. Stem shall be made from stainless steel X 20 Cr 13, DIN 17440, material # 1.4021, or equal and approved. c. Stem nut, stem thrust nut shall be made from GGG-50, DIN 1693, or equal and approved. d. Yoke nut shall be made from GG-25, DIN 1691, or equal and approved. e. Bonnet flange seal shall be made from natural rubber.


Page 587 of 589

Section:

Toilet, Bath & Laundry Accessories

2.1.4 Valves

DN400

A. Wedge shall be made from GGG-50, core fully encapsulated with EPDM rubber, with internal wedge nut made from de-zincification resistant brass, CZ 132 to BS 2874.

2.1.5 Non-Return Valves A. Non-return-valves shall be designed to allow horizontal or vertical installation. They shall be of the quick action, single door type complete with hand lever where required and shall be equipped with tapped bosses fitted with air release cocks, cleaning orifice and drain cock. Material and protective coating shall be as for gate valves. B. The non-return valves shall be the non-slam recoil type check valve with a closing time not exceeding 0.5 sec.

2.1.6 Air Release Valves A. Air release valves shall be the “one floating ball” type. B. The body shall be manufactured from cast iron GG-25. The floating ball, seat rings, nozzles and connecting bolts shall be made of stainless steel grade A4. C. Plastics used for seals, ball guides etc. shall be resistant to the environment generated under the temperatures specified. To prevent sedimentation of solids the bottom part of the valve’s body, connected to the gate valve, shall be funnel shaped. D. Valves shall be designed to prevent clogging of the floating mechanism and to allow the escape, and admission of air respectively to the pipe system. Internal protective coating with tar epoxy shall be foreseen. E. Air release valve shall be combined with gate valves to allow dismantling of air valve whilst the system is in operation.

2.1.7 Dismantl ing Joi nt / Flange Adapters / Coupli ngs A. Installation of dismantling joint / flange adapters / couplings shall be according to the approved drawing. B. Components of joints and their material descriptions shall be as following: Components

Flange(s) Sleeve Follower Anchor bolts, studs, nuts and washers Rubber Seal Ring Protection Coating

Material

Ductile Iron Ductile Iron Ductile Iron Stainless steel grade A4 / 316 EPDM Trapezoidal Wedge type. Minimum shore hardness 70. See Section 09900

Pressure Class

PN16 PN16 PN16 PN16 PN16 N/A

C. Washers used for anchor bolts shall be spring type or utmost care shall be taken into account by providing flexible rubber washer in between (e.g., EPDM) to secure damages of coating while tightening. D. Dismantling Joint / Flange Adapters shall be allowed a movement of at least +/- 25 mm. E. Coating DFT and methyle ethyle ketone checks shall be conducted and recorded.

2.1.8 Wall, Floor, Slab, and Roof Penetrati ons A. Ductile iron wall pipes will have integrally cast puddle flanges as shown on the drawings and will provide a watertight installation.

2.1.9 Particul ar Requir ements A. B. C. D.

Pipes shall be internally lined with cement mortar and externally protected with a zinc rich primer. Pipes shall be coated externally as specified. All ductile iron pipe work and fittings shall be supplied and installed as shown on the Drawings. Drainage pipe work shall be installed at the lowest level on every pumping main section between sluice valves or eccentric plug valves. The drainage pipe work routes and diameters shall be as shown in the contract drawings.


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Technical Specs Construction (Abu Dhabi)

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