Beruflich Dokumente
Kultur Dokumente
393257-T
Prepared by :
Planning and Design Division
GENERAL
B.
EXCAVATION
C.
D.
E.
F.
G.
H.
I.
VALVES
J.
K.
L.
CONCRETE WORK
M.
FORMWORK
N.
STEEL REINFORCEMENT
O.
PILING WORK
P.
BRICKWORK
Q.
PAINTING WORK
MISCELLANEOUS
SECTION A: GENERAL
1.0
SCOPE OF WORKS
A.1
2.0
A.1
3.0
CONSTRUCTION SITE
A.1
4.0
A.2
4.1
A.2
4.2
Isolating of Valve
A.2
4.3
A.3
4.4
Dewatering of Trench
A.3
5.0
REINSTATEMENT WORK
A.4
5.1
A.4
5.2
A.4
5.3
A.5
6.0
A.6
7.0
A.6
8.0
ORDERING MATERIALS
A.7
9.0
A.7
10.0
A.8
11.0
A.8
12.0
A.9
13.0
A.10
14.0
A.11
15.0
CONTRACTORS FACILITIES
A.11
16.0
A.11
17.0
A.12
18.0
PROTECTION OF WORKS
A.12
19.0
SITE DRAINAGE
A.12
20.0
PIPE DUMPS
A.13
21.0
A.13
22.0
CONTRACTORS PLANTS
A.13
23.0
A.14
24.0
S.O.S APPROVAL
A.14
25.0
DAYWORK
A.14
26.0
COVERING UP OF WORK
A.15
27.0
SIGNBOARDS
A.15
28.0
A.16
29.0
A.16
30.0
A.16
31.0
WARRANTY
A.16
32.0
STATUTORY HOLIDAYS
A.17
33.0
CONTRACT DOCUMENTS
A.17
34.0
A.18
35.0
CONTRACTOR'S AGENT
A.18
36.0
PROJECT DIARY
A.19
37.0
A.19
38.0
TRANSPORT
A.20
39.0
A.20
40.0
A.21
41.0
A.21
42.0
A.21
43.0
A.21
44.0
A.22
45.0
OBVIOUS WORK
A.22
46.0
A.23
47.0
NOISE
A.23
48.0
A.24
49.0
FIRE
A.24
50.0
SUPERVISION
A.24
51.0
A.24
52.0
A.25
53.0
A.25
54.0
TRAINING OF OPERATORS
A.25
55.0
LABELS
A.25
56.0
A.26
57.0
A.27
58.0
ENVIRONMENTAL POLICY
A.27
58.1
General Policy
A.27
58.2
A.27
58.3
Environmental Co-ordination
A.28
58.4
Environmental Audit
A.28
58.5
Environmental Training
A.28
58.6
Close-Out
A.29
59.0
SURVEY WORK
A.29
59.1
Scope of Services
A.30
59.2
Accuracy of Survey
A.31
59.3
A.32
60.0
AS-BUILT DRAWINGS
A.32
61.0
A.33
SECTION B: EXCAVATION
1.0
GENERAL
B.1
2.0
SITE CLEARING
B.1
3.0
EXCAVATION GENERALLY
B.1
4.0
B.2
5.0
ROCK EXCAVATION
B.3
6.0
USE OF EXPLOSIVES
B.4
7.0
B.4
8.0
B.4
9.0
B.5
10.0
B.5
11.0
EXCAVATION IN ROADS
B.5
12.0
B.6
13.0
INSPECTION
B.6
14.0
B.6
15.0
B.6
16.0
B.7
17.0
ROAD REINSTATEMENT
B.7
18.0
REMOVAL OF SURPLUS
B.8
19.0
EMBANKMENTS
B.8
20.0
B.9
21.0
LEVELS TO BE RECORDED
B.9
22.0
B.9
23.0
B.10
24.0
MACKINTOSH PROBES
B.11
25.0
B.11
26.0
B.11
27.0
B.12
28.0
MEASUREMENT OF FILLING
B.14
29.0
B.14
30.0
B.15
31.0
B.15
32.0
B.15
GENERAL
C.1
2.0
C.1
3.0
C.1
4.0
RECORDS
C.2
5.0
C.2
5.1
C.2
Prospecting
6.0
C.3
7.0
C.3
8.0
DANGERS OF FLOTATION
C.3
9.0
C.4
10.0
C.4
11.0
C.4
12.0
C.5
13.0
SPECIALS
C.6
14.0
PIPE CUTTING
C.6
15.0
WELDING OF JOINTS
C.6
15.1
C.6
Welding Procedure
16.0
WELDING PERSONNEL
C.6
17.0
C.7
18.0
C.7
19.0
C.7
20.0
C.8
21.0
PAYMENT FOR MAKING INTERNALLY AND EXTERNALLY WELDED SLIP AND COLLAR JOINTS
C.8
22.0
C.8
22.1
C.8
23.0
C.9
24.0
PIPELINE INSPECTION
C.9
25.0
TESTING OF PIPELINES
C.9
25.1
Testing Pipelines
C.9
25.2
C.12
25.3
C.12
26.0
C.13
27.0
COMMISIONING OF PIPELINE
C.13
28.0
MISCELLANEOUS
C.13
28.1
C.13
28.2
C.14
28.3
C.14
28.4
Valve Chambers
C.14
28.5
C.15
29.0
30.0
28.6
Swabbing of Pipelines
C.15
28.7
Sterilization of Pipelines
C.15
28.8
Flushing of Pipelines
C.16
28.9
C.16
28.10
Clearing Up
C.16
28.11
C.16
28.12
C.17
28.13
C.17
28.14
C.17
PIPE JACKING
C.17
29.1
General
C.17
29.2
Performance Requirements
C.18
29.3
Approval of Owner
C.19
29.4
Jacking Operation
C.19
29.5
Safety
C.20
29.6
C.21
29.7
C.21
29.8
C.22
29.9
C.23
27.10
C.23
C.23
2.0
3.0
4.0
GENERAL REQUIREMENTS
D.1
1.1
Scope
D.1
1.2
Definition
D.1
1.3
D.1
1.4
Submissions
D.2
D.3
2.1
D.3
2.2
Steel Pipes
D.3
2.3
D.5
2.4
Jointing of Pipes
D.5
2.4.1
D.5
Pipe Ends
2.5
Flanged Joints
D.6
2.6
D.7
2.7
D.8
2.8
Collars
D.8
D.8
3.1
D.8
D.9
4.1
D.9
4.2
End Protection
D.9
4.3
Handling
D.9
4.4
Protection in Transit
D.10
4.5
Inspection
D.10
4.6
D.10
4.7
Measurement
D.11
4.8
Miscellaneous
D.11
4.9
Physical Testing
D.11
4.10
External Coating
D.11
4.11
Wrapping
D.11
4.12
D.12
4.13
D.12
5.0
D.12
6.0
D.14
GENERAL
E.1
2.0
PIPES
E.1
3.0
MANUFACTURING PROCESS
E.1
4.0
E.2
5.0
E.2
6.0
E.3
7.0
E.4
8.0
E.4
9.0
PACKING
E.4
10.0
E.4
11.0
E.5
12.0
CERTIFICATION
E.5
13.0
E.5
13.1
Jointing Instruction
E.5
13.2
Method of Assembly
E.7
14.0
CUTTING
E.7
15.0
OVALITY CORRECTION
E.11
16.0
E.11
17.0
E.13
GENERAL
F.1
2.0
MATERIAL
F.2
3.0
COLOUR
F.3
4.0
F.3
5.0
TOLERANCE
F.4
6.0
LENGTH
F.4
7.0
APPEARANCE
F.4
8.0
ROUTINE TESTS
F.5
9.0
PIPE MARKINGS
F.5
10.0
PIPE FITTINGS
F.5
10.1
F.5
10.2
Spigot Fittings
F.5
10.3
Electrofusion Fittings
F.6
10.4
F.6
10.5
F.8
10.6
Storage
F.9
F.9
F.10
11.0
F.10
12.0
F.10
12.1
General
F.10
12.2
F.11
12.3
Off Loading
F.11
F.11
F.11
12.3.3 Fittings
F.12
13.0
CERTIFICATION
F.12
14.0
F.12
15.0
F.12
15.1
General
F.12
15.2
F.18
F.20
F.24
15.3.1 General
F.24
15.3.2 Equipment
F.24
F.25
15.3
15.4
15.5
16.0
17.0
18.0
19.0
20.0
F.26
15.4.1 General
F.26
15.4.2 Equipment
F.27
F.27
Mechanical Joints
F.29
F.30
16.1
Preparation Of Pipes
F.30
16.2
Laying Of Pipes
F.30
F.31
17.1
General
F.31
17.2
F.31
F.32
18.1
F.32
18.2
F.32
F.32
19.1
F.32
19.2
F.32
19.3
F.33
REPAIR METHODS
F.33
20.1
F.33
20.1.1 General
F.33
F.33
F.34
F.34
F.34
F.34
GENERAL
G.1
2.0
COLOUR
G.3
3.0
SCOPE OF SUPPLY
G.3
4.0
SOLVENT CEMENT
G.5
5.0
JOINTING
G.5
6.0
SUPPORT
G.6
7.0
SAFETY PRECAUTION
G.7
8.0
JOINTING PROCEDURE
G.8
9.0
NOTES ON JOINTING
G.9
10.0
G.10
11.0
G.10
12.0
SOCKETS
G.11
13.0
PIPE MARKINGS
G.11
14.0
INSTALLATION OF SADDLES
G.11
15.0
G.12
16.0
FLANGED JOINTS
G.12
17.0
THREADED CONNECTIONS
G.13
18.0
INSTRUMENTATION CONNECTIONS
G.14
19.0
BURIED PIPES
G.15
20.0
G.16
GENERAL
H.1
1.1
Scope
H.1
1.2
Referenced Documents
H.1
1.3
Definitions
H.3
1.3.1
Ferrous Saddle
H.3
1.3.2
Polyamide Adaptor
H.3
1.4
2.0
H.3
1.4.1
Saddle Type A
H.3
1.4.2
Saddle Type B
H.3
1.5
Illustration
H.4
1.6
Materials.
H.4
1.6.1
Body
H.5
1.6.2
H.5
1.6.3
Sealing Gasket
H.5
1.6.4
Polyamide Adaptor
H.5
1.7
H.5
1.8
Workmanship
H.5
1.8.1
Casting
H.5
1.9
Nominal Sizes
H.6
1.10
H.6
H.6
H.6
H.6
H.6
H.7
2.1
Surface Preparation
H.7
2.2
Degreasing
H.7
2.3
Abrasive Cleaning
H.7
2.4
Pre-Treatment
H.7
2.5.
Coating
H.8
2.5.1
General
H.8
2.5.2
Body
H.8
2.5.3
Fasteners
H.8
2.6
Coating Application
H.9
2.7.
H.9
3.0
Holiday Test
H.9
2.7.2
Cure Test
H.9
2.8
Repair
H.9
2.9
Sampling
H.9
2.10
H.10
TESTING
H.10
3.1
H.10
3.2.
4.0
2.7.1
Testing
3.1.1
Test Requirement
H.10
3.1.2
Strength Testing
H.10
3.1.3
Functional Testing
H.10
3.1.4
Corrosion Testing
H.11
3.1.5
H.11
3.1.6
H.11
3.1.7
Adhesion Test
H.11
3.1.8
H.12
3.1.9
Visual Inspection
H.12
H.12
Production Testing
H.12
MARKING
H.12
4.1
H.12
Marking
SECTION I: VALVE
1.0
2.0
3.0
GENERAL
I.1
1.1
I.1
1.2
Drawings
I.1
1.3
I.2
1.4
Quality Assurance
I.3
1.5
Notice of Deliveries
I.4
1.6
Marking
I.4
1.7
Inspection
I.4
1.8
I.5
1.9
Site Conditions
I.5
1.10
Valve Agent
I.5
I.6
2.1
I.6
2.2
Materials
I.7
2.3
I.7
2.4
Test Certificates
I.8
2.5
I.8
2.6
Testing Facilities
I.9
2.7
I.9
2.8
Rejected Material
I.9
REQUIREMENT
I.10
3.1
General Requirement
I.10
3.2
I.13
GENERAL
J.1
2.0
J.1
3.0
MATERIALS
J.1
4.0
DIMENSIONS
J.2
5.0
COATING
J.4
6.0
TESTING
J.5
7.0
MARKING
J.5
8.0
ACCESSORIES
J.5
9.0
FLANGE JOINTS
J.6
10.0
J.6
11.0
CERTIFICATION
J.6
12.0
PACKAGING
J.7
APPENDIX 1
J.8
APPENDIX 1A
J.9
APPENDIX 2
J.10
APPENDIX 2A
J.11
APPENDIX 3
J.12
APPENDIX 4
J.13
APPENDIX 5
J.14
J.18
APPENDIX 6
J.22
APPENDIX 7
J.25
GENERAL
K.1
2.0
MATERIAL
K.2
2.1
K.2
2.2
K.3
2.3
Concreting
K.5
3.0
K.5
4.0
K.5
5.0
K.5
CONCRETE
L.1
1.1
Scope
L.1
1.2
L.1
1.3
Test Certificates
L.1
1.4
Aggregate Samples
L.2
1.5
Records of Concreting
L.2
1.6
Concrete Mixes
L.2
1.7
L.2
1.8
Cement
L.3
1.9
Storage of Cement
L.3
1.10
Aggregates
L.4
1.11
Storage of Aggregates
L.4
1.12
Water
L.5
1.13
Admixtures
L.5
1.14
Test Equipment
L.6
1.15
Grades of Concrete
L.6
1.16
L.7
1.17
L.7
1.18
Workability
L.7
1.19
L.8
1.20
Trial Mixes
L.8
1.21
Material Batching
L.9
1.22
Mixing Concrete
L.11
1.23
Ready-Mixed Concrete
L.11
1.24
L.11
1.25
L.11
1.26
Transporting Concrete
L.12
1.27
Placing Concrete
L.12
1.28
L.12
1.29
Compaction
L.13
1.30
L.13
1.31
Curing of Concrete
L.13
1.32
Construction Joints
L.14
1.33
L.14
1.34
Unformed Surfaces
L.15
1.35
L.16
1.36
L.16
1.37
L.17
1.38
Prestressed Concrete
L.18
1.39
No-Fines Concrete
L.18
1.40
L.19
1.41
L.19
1.42
L.20
1.43
L.20
1.44
Non-Compliance
L.20
1.45
L.21
1.46
Inspection Procedures
L.21
1.47
L.22
1.48
L.24
1.49
L.24
1.50
L.25
1.51
L.25
1.52
L.26
1.53
L.26
1.54
L.26
1.55
L.27
1.56
L.27
1.57
L.28
1.58
L.29
1.59
Sealing Compounds
L.30
1.60
Joint Fillers
L.30
1.61
Waterstops
L.31
1.62
Movement Joints
L.31
1.63
Structural Tests
L.32
SECTION M: FORMWORK
1.0
GENERAL
M.1
1.1
Scope
M.1
1.2
Submissions
M.1
1.3
Materials
M.1
1.4
M.1
1.5
M.2
1.6
Erection of Formwork
M.2
1.7
Removal of Formwork
M.3
1.8
Building in Plant
M.4
1.9
Dry-Pack Mortar
M.4
1.10
M.5
1.11
Movement Joints
M.6
1.12
M.7
1.13
M.8
1.14
Measurement of Formwork
M.8
2.0
3.0
4.0
1.1
General
N.1
1.2
N.1
1.3
Handling of Piles
N.1
1.4
N.1
1.5
N.1
1.6
Extension of Piles
N.2
1.7
Piling Programme
N.2
1.8
Records
N.2
1.9
N.3
1.10
Safety Precaution
N.3
1.11
Definition
N.3
N.4
2.1
General
N.4
2.2
Reinforcement
N.4
2.3
Pile Shoes
N.4
2.4
N.5
2.5
N.5
2.6
N.5
2.7
Length of piles
N.6
2.8.
N.6
2.9
N.7
2.10
N.8
N.8
3.1
N.8
3.2
Straightness of Piles
N.8
3.3
Strengthening of Piles
N.8
3.4.
Marking of Piles
N,9
3.5
N.9
3.6
N.9
3.7
Lengthening of Piles
N.9
3.8
N.9
N.9
4.1
Species of Timber
N.9
4.2
Definitions
N.10
4.3
Quality
N.10
4.4
Sizes
N.03
4.5
Workmanship
N.10
4.6
Preservative Treatment
N.10
4.7
N.10
5.0
4.8
Marking
N.10
4.9
Warranty
N.11
4.10
N.11
4.11
Pile Head
N.11
4.12
N.11
4.13
Lengthening of Piles
N.12
4.14
N.12
4.15
N.12
PILE TESTING
N.12
5.1
General
N.12
5.1.1
N.12
5.1.2
Safety Precautions
N.12
5.2
Definitions
N.12
N.12
5.2.2
Anchor Pile
N.13
5.2.3
Test Pile
N.13
5.2.4
Reaction System
N.13
5.2.5
Kentledge
N.13
5.2.6
N.13
5.2.7
N.13
5.3
Supervision
N.13
5.4
Reaction System
N,13
5.4.1
General
N.13
5.4.2
Kentledge
N.13
5.4.3
N.14
5.5
Testing Equipment
N.14
5.6
N.15
5.6.1
General
N.15
5.6.2
Driving Records
N.15
5.6.3
Cut-off Level
N.15
5.6.4
N.15
5.6.5
Notice of Test
N.16
5.7
Settlement Measurement
N.16
5.8
Test Procedure
N.16
5.8.1
General
N.16
5.8.2
N.16
5.8.3
N.17
5.9
Presentation of Results
N.17
5.10
5.9.1
Submission of Results
N.17
5.9.2
N.17
N.18
O.18
5.12
N.18
5.11.2 Kentledge
N.18
N.19
N.19
5.12.1 General
N.19
N.19
N.19
N.19
N.19
GENERAL
O.1
1.1
Scope
O.1
1.2
Submission
O.1
1.3
Steel Reinforcement
O.1
1.4
O.1
1.5
Accessories
O.2
1.6
Detailing
O.2
1.7
O.2
1.8
O.2
1.9
O.2
1.10
Fixing of Reinforcement
O.3
1.11
O.3
1.12
O.4
SECTION P: BRICKWORK
1.0
GENERAL
P.1
2.0
MORTAR
P.1
2.1
General
P.1
2.2
Cement
P.1
2.3
Admixtures
P.1
2.4
Sand
P.2
2.5
Water
P.2
3.0
BRICKS
P.2
4.0
BRICKWALLING
P.2
5.0
BOND
P.3
General
Q.1
2.0
Q.2
3.0
Q.2
4.0
Q.3
SECTION R: MISCELLANEOUS
1.0
R.1
2.0
R.2
3.0
Pre-cast Chambers
R.3
4.0
Washout
R.3
5.0
Indicator Post
R.3
A- GENERAL
1.0
SCOPE OF WORKS
The Works covered in this Contract comprise the provision by the Contractor at his
own risk and cost which comprise all materials, scaffoldings, tools, plants, labour,
transports, water, power, profit and attendance, overhead and everything else
necessary for the construction and completion of the Works to the entire approval of
the Superintending Officer hereinafter referred to as the S.O.
The Conditions of Contract for the Works, which is embodied in the Form of
Contract, shall be read in conjunction with this Specification. If the Tenderer
considers that any of the clauses in the Conditions of Contract involves additional
expenses not covered elsewhere, the Tenderer shall allow for monetary value for
such clauses in his Tender, otherwise, it will be deemed to have been included.
2.0
3.0
CONSTRUCTION SITE
The location of the Site is shown on the Drawings. The Contractor shall be deemed
to have inspected the Site before tendering and to take into account all the
conditions there, such as means of access, facilities for transport, storage and
movement of plants and materials, and any other contingencies liable to affect his
tender price, as no claim for extra payment in this connection will be entertained.
The Contractor shall be liable for and shall indemnify SYABAS against any damage,
expense, liability, loss, claim or proceedings whatsoever whether arising at common
law or by statute in respect of personnel injury to or death of any person
whomsoever or to any property arising out of or in the course of or by reason of the
visit to the Site.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.1
4.0
4.1
4.2
i.
Detailed utility detection using radio and or ultrasonic machine. The drawings
must be submitted to the S.O in 2 set in A1 size, coloured to differentiate the
type of services. The type of utility, size and depth shall be clearly indicated.
ii.
Where necessary, trial pits and exploration trenches to ascertain the exact
portions of these services shall be excavated, well ahead of pipe repair /
maintenance excavation, in places where they are known or thought to be and
elsewhere and these shall be backfilled with approved materials.
iii.
All damages to the existing services shall be made good to the satisfaction of
SYABAS and the relevant authorities. SYABAS shall be identified against any
action taken against the Contractor/developer due to their negligence.
Isolation of Valves
Before any excavation, SYABAS representative and the Contractor shall jointly locate
all value pipelines in the area. (This is based on their working knowledge of the water
distribution system or based on maps / water reticulation plan of the area and / or from
their past experience).
1. Ascertain the type, size and estimated length of pipe that may be affected due to
the excavation and repair works. The information will enable the maintenance
team to mobilize the appropriate tools, spare parts, etc. The information will be
important in estimating the volume of water loss due to pipe bursts or pipe leaks .
2. Sketch the location plan and the distribution network layout in a Record Form for
updating and record purposes.
3. SYABAS representative shall identify all isolating and scour valves affected by the
pipe to be repaired as well as valves located in the vicinity. It is important to
ensure that water scouring will not result in flooding of the area, in particular the
area for excavation.
Prior to excavation, shut the isolating valves as identified. As a direct effect, the
pipeline pressure will drop and hence, water will stop. When this has been
confirmed, the scour valves may be opened to discharge the remaining water
from the main prior to excavation work.
4. However, if water pressure neither drops nor leakage subsides after closing of
the identified valve, then SYABAS representative and his team may need to
locate any possible unknown inter-connections.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.2
5. When the inter-connections have been identified, the isolating valve shall be
shut to facilitate repair work. Update the sketch of the pipe layout in the attached
Record Form. The sketch shall then be submitted to SYABAS representative upon
completion.
4.3
D + 450 mm
D + 600 mm
D + 900 mm
D + 1050 mm
D + 1200 mm
D + 1500 mm
Dewatering of Trench
The Contractor shall note that certain parts of the pipeline may be laid in ground with
high water table, especially in areas adjacent to the streams, river crossings and ponds.
1. The Contractor shall allow cost for dewatering and keeping all the excavations and
trenches dry for the pipeline repair work to be carried in a safe manner during the
execution of the work.
2. Dewatering shall be carried out using dewatering pump with long hose. The
dewatering pump shall have the capacity to drain a trench ( 1m x 1m x 1.5m )
within 5 minutes ( 70 igpm ).
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.3
5.0
REINSTATEMENT WORK.
Reinstatement work for the following types of road shoulder are described
accordingly.
1. Normal earth shoulder.
2. Shoulder with hardstanding / tiles.
3. Metalled premix road.
5.1
5.2
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.4
5.3
6.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.5
The levels and dimensions, which have been agreed by the S.O, shall form the basis
of measurement for the appropriate Works.
7.0
8.0
ORDERING MATERIALS
The Contractor shall be responsible for placing his orders for all materials and
articles required to be supplied by him at the earliest possible date for the
completion of this Contract.
Before placing any order for materials or articles to be incorporated in the Works,
the Contractor shall submit to the S.O. for his approval, a complete description of
such items and the names of the suppliers from whom he propose to obtain them.
Where so directed, the Contractor shall submit samples and test certificates for
approval. The Contractor shall not place any order without the approval of the S.O.
which may be withheld until samples have been submitted and satisfactorily tested.
The source of supply shall be approved by the S.O.
Additional testing of materials and complete pipes, fittings and specials may be
carried out at any time by the S.O. Any of the materials, pipes, fittings and special
not complying with this Specification shall be rejected by the S.O.
Unless specifically provided for in the Specification or the Bill of Quantities, the cost
of any testing including the supply of materials, pipes and fittings carried out on
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.6
samples submitted by the Contactor shall be borne by SYABAS. If, the tests show
that the materials, pipes and fittings to be not in accordance with the requirements
of this Specification, the said batch of material will be rejected. The contractor shall
remove all the rejected materials out of the site immediately. For further quality
control, the S.O may require testing of other materials, whether installed or not. The
cost of testing shall be boned by the contractor. If results show similar trend, then
the material must not be further used. The contractor must demonstrate how
rectification measure can be implemented on all installed items.
9.0
10.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.7
11.0
12.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.8
13.0
14.0
15.0
CONTRACTORS FACILITIES
The Contractor shall, at his own expense, provide and maintain in good condition
throughout the Contract Period such temporary buildings, tanks, stores, temporary
sanitary conveniences, access roads and other facilities as may be necessary for the
execution, completion and maintenance of the Works. The location of all such
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.9
facilities shall be subjected to the approval of the S.O. All such facilities shall
comply with the requirements of the Local Authorities.
16.0
17.0
18.0
PROTECTION OF WORKS
From the commencement of the Works until the date stated in the Certificate of
Practical Completion for the whole of the Works, the Contractor shall take full
responsibility for the care thereof. In case of damage, loss or injury to the Works, or
any part thereof, from any cause whatsoever, the Contractor shall, inform the S.O in
writing. He shall make proposals, submit method statement for the S.Os approval.
After the S.O. has consented to the work, the contractor shall at his own cost, repair
and make good the same so that at completion the permanent works shall be in
good order and condition in every respect as per requirements of the Contract. The
contractor is not allowed to undertake any repair work until he has received specific
instruction from the S.O. The S.O. shall also not delay his approval unless he has
specific reasons or comments on the proposed rectification measures.
19.0
SITE DRAINAGE
The Contractor shall make proper provision for the drainage of water from the Site of
the works including rainfall run-off from surrounding areas, which drain onto the
Site.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.10
The Contractor shall at no extra cost to SYABAS provide, form, fix, maintain and
work as and where directed by the S.O. such pumps, chutes, walls, drains, bunds
silt traps and other temporary works necessary for the proper drainage of the Site so
that no flooding, silting or other damages or disturbances is caused in the areas
surrounding the Works or to the Works for the duration of the Contract.
20.0
PIPE DUMPS
The Contractor shall be solely responsible to find a suitable pipe dumps and stores
to store the pipes, valves and fittings supplied by or to the Contractor.
The Contractor shall allow in his Contract Rates for expenses incurred in locating,
hiring, preparation and reinstatement to original condition of pipe dumps and stores.
The Contractor shall be responsible for obtaining the consent of the owner, tenants
or occupier of lands to the use of such land for storing of the pipes, valves and
specials. The Contractor shall pay all cost, expenses, rental, compensation or other
disbursement, which may be incurred by him in negotiations with the owner, tenant
or occupier and during the subsequent use by him of such land for these purposes.
No reimbursement will be made to the Contractor in this respect. The full cost
thereof shall be deemed to be included in the Contract Rates.
21.0
22.0
CONTRACTORS PLANTS
All mechanical plants used by the Contractor in the execution of the Works shall be
of such type, size and method of the working as the S.O. shall approve.
The S.O. shall not unreasonably withhold approval for the use of any plant but if, in
the S.Os opinion, circumstances arises which made it desirable that the use of any
plant should be suspended either temporarily or permanently, the Contractor shall
change the method of performing the work affected at the Contractors own cost and
the Contractor shall have no cause for claim if any order issued by the S.O. result in
any plant having to stand idle for a period of any duration whatsoever or having to
be removed from the Site.
23.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.11
and remove all temporary roads if directed, clean out all gutters, clear away all
rubbish, and leave the whole of the Site of the Works in a clear and tidy condition
acceptable to the S.O.
The Contractor shall clean and wash all windows, paintwork, walls and floors, and
shall leave permanent buildings, tanks and other structures in a clean and tidy
condition ready for use by SYABAS.
24.0
S.O.S APPROVAL
Any S.Os approval given to any portion or stage of the Works shall not absolve the
Contractor from his liability to make good any defects which may be discovered or
occur subsequently during the Defects Liability Period of the Contract.
25.0
DAYWORK
The S.O. may order in writing that any additional or substituted work be executed
on a day-work basis. The Contractor shall then be paid for such work under the
conditions set out in the Day-work Schedule included in this Contract and at the
rates and prices agreed to by both parties.
The Contractor shall furnish to the S.O. such receipts or other vouchers as may be
necessary to prove the amounts paid and before ordering materials shall submit to
the S.O. quotations for the same for the S.O.s approval.
In respect of all work executed on a day-work basis, the Contractor shall during the
continuance of such work deliver each day to the S.O. an exact list in duplicate of
the names, occupation and time of all workmen employed on such work and a
statement also in duplicate showing the description and quantity of all materials and
plants used thereon or therefore. Upon agreement by the S.O., one copy of each list
and statement shall be signed by the S.O. and returned to the Contractor. At the end
of each week the Contractor shall deliver to the S.O. a priced statement of the
labour, materials and plant used. All price statements, which have been agreed to
between the Contractor and the S.O. shall be incorporated in the subsequent
certificate or payment.
The rates shown shall include all allowances for administration and profit, all
traveling and accommodation expense, statutory overheads such as EPF
Contributions, SOCSO, holiday pay, annual and sick leave as appropriate where
these apply. Rates shown for Plant shall be the complete compensation required by
the Contractor for the operation of this Plant, including the cost of the operator, fuel
and transportation and maintenance.
In the case of materials used in labour work, the Contractor shall be paid the
complete on site cost of any materials used, plus a maximum allowance of fifteen
percent to cover purchase of material and organization by the Contractor etc
including profits.
Payments for day labour work will only be certified for the actual hours worked. No
payment will be made for standby time caused by inclement weather.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.12
26.0
COVERING UP OF WORK
Before any part of the Works be permanently covered up, the Contractor shall give
due notice to the S.O. of his intention. The S.O. shall, without unreasonable delay,
examine and measure if necessary, the said part of the Works unless the S.O.
considers it unnecessary and advises the Contractor accordingly.
27.0
SIGNBOARDS
Where specified in the Bill of Quantities, the Contractor shall provide, erect, paint
and maintain signboards as shown on the relevant drawing or as directed by the
S.O. The signboard shall be erected at a prominent position at the site as approved
by the S.O. and the Contractor shall pay all charges in connection with this,
including obtaining permission, licences and fees etc.
On completion of the project, the Contractor shall dismantle and clear away the
signboard as directed by the S.O.
28.0
29.0
30.0
31.0
WARRANTY
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.13
The accepted tender under this Contract shall deemed to warrant that,
notwithstanding that any part of the equipment supplied has been satisfactorily
factory tested and/or inspected on site before installation, if any equipment or part
thereof shall fail to perform its specified function under test or during the Contract
Defects Liability Period, and it is determined that such failures are the responsibility
of the Contractor, then all costs of replacing all faulty equipment or parts thereof
shall be borne by the Contractor.
For equipment supplied but not manufactured by the Contractor, a guarantee shall
be provided by the Contractor that he shall arrange any necessary repair or
replacement of defective equipment that fails within the warranty period of the
installation, free of charge.
The operation staff, using the knowledge gained during the Contractors training
scheme and using the documentation supplied, will endeavour to identify any faulty
equipment or sub-assemblies held as a spare part and will return these, at the
Contractors cost using his nominated freight carrier, for repair by the Contractor.
If the operating staff is unable to determine the cause of any system problems with
telephone assistance from the Contractor, the Contractor shall dispatch at his cost
within 3 days, if the system is totally inoperative, or within 10 days for a fault
affecting only redundant equipment, specialist engineering staff to remedy the
problem.
The Contractor is required to provide, within the Warranty period, a maximum 3
day turnaround (excluding weekends) on all repairs and/or equipment replacement.
The operating staff will not undertake any repairs unless authorised by the
Contractor.
32.0
STATUTORY HOLIDAYS
Extension of time will not be allowed for statutory holidays.
33.0
CONTRACT DOCUMENTS
The Contractor shall be deemed to have fully examined the Contract Documents,
have read each and every Clause and all details therein and have had full
opportunity to consider the same and make necessary investigations in relation
thereto. He shall not make any claims or any other occasion because of
misunderstanding of the Contract Document or because of lack of information.
If the Contractor considers that any of the conditions and/or instruction in the
Contract Document involves additional cost, he shall allow for the same in the
Tendered Price as no claim extra in this connection will be entertained.
All parts and sections of the Specification shall be read in conjunction with one
another and unless particularly specified otherwise, the provisions and requirements
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.14
of any Clauses under any one section apply to the Works under the Contract where
Work is of as similar nature.
Drawings are included in the Contract Document. Further drawings may be issued
to the Contractor as work progresses.
34.0
35.0
CONTRACTOR'S AGENT
A competent, duly authorised, and responsible site agent or representative of the
Contractor shall be appointed. The agent's name, qualification and experience shall
be submitted to and approved, in writing, by the S.O. prior to appointment and who
shall have full authority to act for and bind the Contractor. The agent shall reside on
the Site and shall have an office thereon. This agent shall attend at the S.O.s office
at all reasonable times when required to do so. He shall be fluent in Bahasa
Malaysia or English and all correspondence will be conducted in either of these
languages.
The agent shall be stationed on the site for the duration of the contract. If Contractor
desires to replace his agent, the name of the proposed new agent shall be submitted
to the S.O. for approval prior to replacement.
In the event of the agent being absent from the works for any period exceeding 3
consecutive days, he shall notify the S.O. in writing of the name of his responsible
and fully authorized deputy. In any case, the agent shall always inform the S.O. in
advance, should he intend to be absent from the Works.
36.0
PROJECT DIARY
The Contractor shall keep a daily project diary, which shall record the major events
of each day. The format shall be approved by the S.O.s Representative and as a
minimum, it shall include:Weather record for the day
Number of operatives present on site; categorised by trade or skill
Number of items of major plant; giving make, model and physical location on
site
The locations and description of major activities on site
At the end of each week the Contractor shall give a copy of that weeks diary to the
S.O. duly signed and dated.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.15
37.0
38.0
TRANSPORT
The Contractor shall provide and keep available at all times during the period of
construction and such times during the period of maintenance as shall be required
by the S.O.'s Representative, in the performance of his duties in this Contract the
following means of transport:i)
ii)
New 4-door four wheel drive manually geared petrol vehicles of not less than
1300cc capacity complete with air-conditioner and other necessary
accessories.
New motorcycles of not less than 100 cc. Each motorcycle shall be equipped
with two crash helmets.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.16
39.0
40.0
41.0
42.0
43.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.17
approval of the S.O. as soon as practicable after the receipt of the S.O.'s Order to
commence the works. Each statement shall be fully detailed and six (6) copies shall
be submitted to the S.O. through his Representative.
44.0
45.0
OBVIOUS WORK
The intent of this Contract includes the survey, preparation of detailed drawings or
shop drawings, manufacture, test, supply, erection and commissioning of all pipes
and fittings for the proper completion and operation of the Works. Notwithstanding
that these documents have been drawn up with all possible care, if any details of the
Works have not been included within this Specification or detailed on the Drawings
but the necessity of which might reasonably be implied from the above stated intent,
and, such details are usual or essential to the completion of the Works, the same
details shall be deemed to be included within this Contract whether so particularly
itemised or specified or detailed or not, at NO additional cost to the Contract.
The word `approved' or `to be approved' used in conjunction with equipment or
material, the make of which is not defined, shall mean that the S.O., shall select or
reject a type from samples or drawings, which the Contractor shall provide and that
the S.O. decision shall be final.
46.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.18
The Contractor shall be responsible for obtaining the necessary approvals from the
relevant Departments and Authorities for all items of Works under this Contract. It
shall also be deemed that the Contract Price includes the attendance to local
authorities, Chief Electrical Inspector, Fire Officer, the Machinery Inspector, etc. and
all costs to ensure conformity with current regulations of the above-named
Departments. The approval of Equipment and materials by the relevant authority
shall not prejudice the right of the S.O. to reject such Equipment or materials which
may not comply with the Specification.
The supply of all danger notices, warning notices, etc. to the requirements of the
Chief Electrical Inspector and other relevant Departments or Authorities shall be
included in the Contract.
The Contractor shall allow for and obtain all necessary permits and licenses, etc.
required from the relevant authorities in connection with the carrying out of the
works and pay all deposits, fees, royalties in connection therewith. The Contractor
shall also allow for the costs of arranging for inspection by officials of Local
authorities from time to time during the Contract period and defect liability period.
47.0
NOISE
The S.O. operates and enforces a policy of noise reduction. The Contractor is
required to adopt this policy. Prior to the use of any plant or the commencement of
any noisy work on the site, the Contractor is required to submit a noise assessment
report. These are to be agreed with the S.O. and relevant authorities.
The Contractor shall comply with the NR Ratings stipulated by the Department of
Environment (Kementerian Sumber Asli dan Alam Sekitar).
48.0
49.0
FIRE
All rubbish, packing, discarded or surplus materials shall be removed from the site
periodically and shall not be burned on site.
50.0
SUPERVISION
The Contractor or his authorised representative shall be fully responsible to ensure
all the works included in the Contract are faithfully executed and commissioned in
accordance with the provisions of the Contract Documents.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.19
The Clerk of Works, Inspector or Resident Engineer (R.E) appointed for the purpose
of supervising work under this Contract will be responsible for:-
51.0
(i)
(ii)
Inspecting the works in progress from time to time to ensure accord with the
design intent.
iii)
Verifying and recording the quantity of any works carried out by day labour
under a variation order or for the purpose of monthly payment.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.20
52.0
53.0
54.0
TRAINING OF OPERATORS
Following the complete acceptance testing of all the Equipment installed under the
Contract, and satisfactory commissioning of the Plant, the Contractor shall give full
training to the plant operators in the proper procedures for operation and
maintenance of all items of Equipment provided under the Contract. The Contractor
shall allow in his Tender Price for such training to be carried out.
55.0
LABELS
When instructed by the S.O., mechanical equipment items shall have an
identification plate securely fixed to the body. The identification plates and labels
shall be of approved non-corrodible metal and the data shall be engraved or
stamped. Neither glue fastening nor painted nor printed on data shall be acceptable.
Data required for mechanical equipment shall include the manufacturer, the date of
manufacture, the country of manufacture, the operating conditions and supply
conditions that might be applicable.
The direction of opening of valves shall be permanently indicated by arrows on
handwheels or operating levers. All valves shall be clearly labelled with the
appropriate function and identification.
56.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.21
(a)
Every item for which payment (in whole or in part) is being claimed up to the
date of the application, listed in the manner and in the order of the Bill of
Quantities.
(b)
(c)
Details of Variation Orders, if any, approved by the S.O., with the amounts to
be added or deducted in respect of each,
(d)
(e)
(f)
(g)
(h)
(i)
(j)
A fixed date for measurements shall be agreed upon with the S.O. on a monthly
basis for which measurements for Works completed are conducted. This fixed date
shall not vary from month to month without the prior and written consent of the
S.O.
The application for payment shall be duly certified by the S.O.'s Representative and
the Contractor's Site Agent.
57.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.22
58.0
ENVIRONMENTAL POLICY
58.1
General Policy
The Contractor shall comply with all applicable laws, regulation, guidelines and
terms and condition of approvals issued by the Deputy of Environment. The EQM
shall cover both the construction stage and operation stage, addressing, among other
things, to submit report and the application of the Occupational Safety and Health
ACT 1994, Occupational Safety and Health (Use and standards of exposure of
Chemical Hazardous to Health/Regulation 2000-JKKP Dept), Environmental Quality
Act and Regulation, Occupational Safety and Health (Control of Industrial Major
Accident Hazards) Regulations 1996 (or CIMAH Regulations), the Emergency
Response Programme (ERP) and Erosion and Sediment Control Plan (ESCP). The
Contractor shall take into account the condition of approval of the scheme issued by
Jabatan Alam Sekitar when preparing the EQM.
58.3
A.23
58.5
Environmental Training
The Contractor shall provide on site construction inspection and audit training for
Engineers or Supervisors designated by S.Os Representative. The purpose of the
training is to provide S.Os Representative personnel with a complete understanding
of environmental inspection and co-ordination of all phases of construction
reclamation and maintenance activities. The Contractors environmental specialist
will co-ordinate the training activities and report to the S.Os Representative on the
status and progress of training.
58.6
Close-Out
Upon completion of work, the Contractor shall hand over all minutes of meetings,
correspondence, reports and other records pertaining to discussion meetings, site
visits and compliance audits by the Department of Environment (DOE).
On an on-going basis, the Contractor shall keep the S.Os Representative informed
of all communications and correspondence with the Department of Environment
(DOE). Upon completion of the activities, the Contractor shall hand over to S.Os
Representative, copies of all minutes of meetings, correspondence, reports and
records pertaining to dealing with such parties.
59.0
SURVEY WORK
The Contractor shall engage a licensed surveyor registered with the Institution of
Surveyors to carry out ground survey of the work.
Complete topographical survey of the site shall be completed within 30 days after
the acceptance of the tender. This information shall be forwarded to S.O. for design
updating.
Survey works shall include:
Planimetric control
Height control
Monumenting
Longitudinal profiling
Presentation of survey data shall be according to standard pipeline survey format
(plan and longitudinal section) including overall plan approved by the S.O. Three (3)
sets of the drawings shall be issued in hard copy format (A1 size), three (3) sets of
the drawings in A3 size and soft copy format (ACAD drawings in drawing format).
All hardcopy drawing shall be signed and stamped by a registered surveyor.
The Contractors surveyor shall update the survey data during the construction for
preparation of as-built drawings, which shall include
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
Cost for this survey works shall include provision of drawings and CDs.
59.1
Scope of Services
(b)
(c)
(d)
Set out a control traverse connecting the above to the nearest State Grid net
and provide height control from existing bench marks (BM)
(e)
Set out a control traverse for the proposal pipeline route carry out a strip
survey at 1m contours and setting out of routes
(f)
(g)
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
i.
ii.
Location and extent of all existing grave sites, burial plots and holy
ground, if these are evident on the ground
iii.
Location and extent of all existing and proposed structures which will
influence the design of the scheme to the extent that such information is
available, at the time of survey, from the Local Offices of the Authorities
concerned.
iv.
Location and depth, within the specified survey of all existing service
conduits both overhead and exposed such as water mains, Tenaga
National Berhad (TNB) cables, drainage pipes or channels (indicating
discharge direction), Telecom cables; including location of all associated
chambers, valves, valve boxes, pits, inspection chambers and other
similar appurtenances.
v.
vi.
A.25
The following information and details are required only where relevant to design of
pipelines.
i.
ii.
iii.
iv.
v.
(h)
59.2
All work shall conform to the standard of accuracy given below and any work found
not conforming to any of the following requirements shall be rejected and resurveyed without any additional cost.
The maximum allowable error for all measured distance shall not exceed 1 in 4,000.
The maximum allowable error in all levels shall not exceed 0.02 K m where K is
the distance in kilometer. Daily work shall be tied back to the starting point of the
day.
59.3
The Surveyor shall prepare the following survey plans based on the data and
information of the field surveys:-
60.0
(a)
Computer drawn plans, in State Grid Net where possible to a scale of 1: 1000
or other suitable scale to fit A1 size for the incorporating all features detected.
(b)
AS-BUILT DRAWINGS
As built drawings shall be produced by the Contractor on a continuous basis and as
soon as possible after the construction of the various system, or within one month
after completion of the work. For this purpose, an item has been allowed in the Bill
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.26
of Quantities. The standard and details to which such as-built plans shall be drawn
up as directed by the S.O.
The Contract Price shall be deemed to include the cost of preparation, supply and
delivery of all original drawings and information duly certified by the Contractor and
his surveyor as follows: a)
5 full sets of drawings in paper (A1 size)
b)
5 full sets of drawings in paper (A3 size)
c)
1 full set of drawing in digitised format (Auto-cad in the released to be
approved by the S.O)
All such printed drawings shall be well bounded with thick covers.
All drawings submitted to the S.O. shall be in accordance with the following
guidelines:(a)
Each Drawing shall have a Title Block indicating the Title of the Job, Title of
the Drawing, Scale, Date, Contractor's Name and Address, Revision Index and
Drawing No.
(b)
On each Drawing, details such as pipe invert level, size, valves, bends, etc
shall be indicated as clearly as possible to include all the works to be carried
out on site. Such details shall be provide presented in both plan and
longitudinal section.
(c)
Plan and longitudinal section of pipe profile drawings showing invert level of
pipe, alignment of pipe, details of pipe particulars.
(d)
Details drawing showing air valves, washout, valves chamber, crossing pipe
bedding method, jointing etc.
(e)
(f)
*Standard symbols and legends for SYABAS requirement as per Standard Drawing.
61.0
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.27
unless otherwise specified to ensure that the equipment and materials being
supplied meets the requirements of the Specification.
The fulfilment of the declared guarantees shall be verified at the Manufacturers
work tests.
All costs inclusive of S.O.s travelling, accommodation and other related expenses to
be incurred by the manufacturer in carrying out witness testing of the equipment
and/or materials shall be included in the contract sum.
The Contractor shall give sufficient notice to the S.O. before the intended date of
inspection and testing at the Manufacturers Works as per Specification. Details of
testing, measurements and recording instruments including calibration certificates
shall be submitted to the S.O. for approval. All instruments shall be calibrated and
certified by an approved independent testing authority not earlier than one (1)
month before the tests.
The S.O. and S.O.s representative will each nominate an authorised representative
to inspect and examine the equipment and material and witness tests at the
Contractors premises or at Manufacturers Works. The S.O.s representative will
endorse all copies of Manufacturers Certificates of successful tests witnesses by him.
When the S.O. or S.O.s representative witnesses a test, they shall be given a copy
of the test certificate immediately. When tests have been conducted in the absence
of the such representative, this fact should be noted by the Contractor on the test
certificate.
Upon the satisfactory completion of all tests required by the Specification for an item
of equipment and materials, the Contractor shall send to the S.O., four (4) copies of
particulars of the tests carried out, readings obtained, performance calculations and
details of calibration certificates referred to in the previous paragraphs. Test
certificate shall be submitted in booklet forms and securely bound.
No material or item of equipment and materials shall be delivered to Site until its
certificate has been approved in writing by the S.O. The approved by the S.O. of
the results of any inspection or test shall not prejudice the rights of the S.O. to reject
the equipment and materials, if it fails to comply with the Specification when
erected or to give complete satisfaction in service.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.28
B EXCAVATION
1.0
GENERAL
Excavation work shall include site clearing, the removal, hauling, proper utilization
or disposal of all excavated materials and the construction, shaping and finishing of
all excavations and embankments over the entire extent of the Works in conformity
with the Drawings and this Specification.
2.0
SITE CLEARING
The Contractor shall remove and dispose off trees and bushes within the site of the
Works as and wherever directed by the S.O. However, all trees and bushes within 2
metres of either side of all pipelines to be laid under the Contract shall be removed
and disposed off. Site clearing shall include clearing, grubbing, demolishing,
breaking up and removing all trees, shrubs, vegetation, stumps, structures such as
walls, fences and other obstruction within the Site except those which have been
designated to be retained. Materials suitable for disposal by burning shall be burnt at
locations and on periods as approved by the S.O.
3.0
EXCAVATION GENERALLY
The Contractor shall carry out all excavations in such manner and order as approved
by the S.O and in whatever material as may be found. All excavated materials shall
be deposited so that it will cause as little damage and inconvenience as possible.
All excavations shall be carried out to the required lengths, breadths, depths,
inclinations or curvatures as may be necessary for the proper construction of the
Works or as shown on the Drawings. All excavations shall be sufficient to provide
for the necessary working space, shuttering and any other temporary structures
required during construction. Where so directed by the S.O. the turf and top sub-soil
shall be reserved and stacked separately until required for re-use in reinstatement.
Top soil shall mean the top layer of soil which can support vegetation.
Unless otherwise stated, the excavation, whether in open cut or in trench, shall be
proceed in such portions at a time as the S.O. may approved and shall not in the first
instance be carried down to a depth nearer than 150mm above formation level. The
last 150mm of depth to formation level shall be carried out by manual labour
immediately in advance of placing concrete screed, concrete or pipe laying.
The bottom of all excavations shall be carefully trimmed and leveled, well rammed
and consolidated to ensure good solid foundations.
The contractor shall be responsible for keeping dry all excavations, whether in open
cut or in trench, so as not to interfere with the work in progress. He shall without
extra cost to SYABAS provide, form, fix, maintain and work as and where directed
by the S.O. such pumps, wells, drains, bunds, and other thing necessary to
effectively deal with all water which may collect or find its way into the excavations
from any cause whatsoever. Nevertheless, all methods employed for dealing with
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.1
the water shall be to the approval of the S.O. Such approval shall not relieve the
Contractor from his liability for any damages to the Works or adjoining land and
property or water courses due to his operations.
The Contractor shall be responsible for the stability of the excavations at all times.
He shall, without extra cost to SYABAS and to the approval of the S.O., slope the
sides of the excavations and or provide and fix strong and sufficient timbering to
support the sides and or bottom of the excavations to prevent against collapse, and
shall maintain the same until, in the opinion of the S.O., the construction work is
sufficiently advanced to permit the timbering to be withdrawn. Timbering shall be
removed only under the personal supervision of the competent foreman.
The Contractor shall be responsible for any injury to the Works or consequential
damages caused by or arising out of the removal of timbering and any advice,
permission or approval given by the S.O. relating to the removal of the timbering
shall not relieve the Contractor from his responsibility under the Contract.
The Contractor shall carry out any diversion and subsequent restoration of such
existing river, water-courses, land springs, ditches etc. wherever encountered during
the execution of the Works, whether shown on the Drawings or not.
4.0
300 metres if the pipe-laying operations are in the side-tables of a trunk road,
or
The S.O. may, at his absolute discretion, vary the distances stated above if he
considers that traffic, road or weather conditions or road side-table limitations
warrant the variation.
Unless the S.O. permits otherwise, the trenches shall be excavated to the widths
given in Table B1 below.
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.2
Width of Trench
(mm)
D + 450
D + 600* or 900*
Where pipes are to be laid on a concrete bed, the width of the excavation at the
bottom of the trench shall be the width of the underside of the concrete bed. At all
joints the trench shall be so excavated as to give a working space of not less than
300mm all round the joint. Where bends are made by deflecting pipes at joints the
trench shall be widen to permit this operation. The sides of the trench shall be cut
vertical, and where necessary, shall be protected against caving in by timbering to
the approval of the S.O.
The trench shall be excavated to the depths intended or shown in the Drawings and
shall be finished and trimmed accurately to level and grade.
Where no invert levels are shown or indicated the bottom of the trench shall be
graded so that the pipe invert slopes evenly between the adjacent invert levels.
Should the ground be so wet or soft that, in the opinion of the S.O. it does not from
a firm base for the pipe, or should rock be encountered at the bottom of the trench,
the trench shall be excavated 250mm below the level intended or shown in the
Drawings and then brought back to the correct level with good selected earth or
sand well rammed into place. Such deepening of pipe trench and filling back shall
be treated as a variation under the terms of the Contract. Should the bottom of the
trench be inadvertently excavated below the specified level, it shall be bought back,
at the Contractors expense, to the correct level with good selected earth or sand
carefully rammed into place.
5.0
ROCK EXCAVATION
Rock shall mean those geological strata of hard material which necessitate the use of
blasting or approved pneumatic tools for their removal. Solid boulders found in
trench excavation and foundation pits shall be considered as rock if such boulder is
of size each exceeding 0.08 cubic metre or each exceeding 0.17 cubic metre if
occurring in general excavations.
Shale and clay boulders shall not be classified as rock. The S.O.s decision as to
whether or not the material of the excavation is to be classified as rock shall be final.
Notwithstanding the above, rock shall not include materials which in the judgment
of the S.O. can be loosened with a tractor mounted and drawn ripper of the
following description:
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.3
The Contractor shall be entitled to extra payment for rock excavation only if
reasonable notice is given to the S.O. to examine and measure such material prior to
breaking up. The volume of rock excavated shall be taken as its volume in-situ
before it is broken up.
6.0
USE OF EXPLOSIVES
The Contractor shall not use any explosives without the written approval of the S.O.
In the event where the approval for the use of explosives cannot be given or where
an existing approval is withdrawn by the S.O. due to whatever reason the Contractor
shall carry out the Works using other means approved by the S.O.
Where written approval is given by the S.O. for the use of explosives, the Contractor
shall comply strictly with all rules and regulations laid out by the relevant authorities
pertaining to the use of these explosives and shall be solely responsible for
procuring any permit required from the relevant authorities for the use of explosives.
The greatest care shall be taken by the Contractor during all blasting operations is to
ensure that no injury be done to persons or damage to property or finished work. All
blasting shall be performed at the entire risk and responsibility of the Contractor.
7.0
8.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.4
supported in accordance with the Drawings, the Contractor shall at his own expense
be required to fill the excess excavation with Grade 20 mix concrete or other
suitable materials acceptable to the S.O.
9.0
10.0
11.0
EXCAVATION IN ROADS
No trench is to be excavated in the carriageway unless specific approval has been
given by JKR Road Section or the local authority. The whole operation of excavation
and reinstatement of the trench shall be completed as quickly as possible. The
Contractor shall ensure that minimum interference to traffic flow is maintained at all
times.
A joint site inspection shall be arranged by the Contractor before commencement of
work if so requested by JKR Road Section or the local authority. After pegging out,
the Contractor shall inform the local JKR office or the local authority and the police
of the actual date of commencement at least one week in advance of and on the day
of commencement.
If specific approval has been given to lay services across the road by open
excavation, the required width specified by JKR or local authorities and to ensure
that the top edges of the excavation are neat and straight.
All materials from the excavation, if accepted for backfilling shall be neatly stacked
outside the carriageway. Where there is no place to stack the excavated materials
outside the carriageway, all excavated materials shall be removed from the work site
immediately after excavation.
Where specific approval has been given by JKR for half width construction, the
traffic lines may be reduced to not less than 4.0 metres wide and where necessary,
the shoulder should be strengthened by the Contractor to accommodate traffic load
to the satisfaction of the S.O. and at the Contractors cost.
Trenches shall be provided with adequate shuttering, walling and struts to prevent
the adjoining road pavement from cracking and subsiding.
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.5
13.0
INSPECTION
Until the S.O. has inspected and approved the excavation, no concrete shall be
placed and no pipes shall be laid upon the surface prepared by excavation. Any
work built on foundations which have not been approved by the S.O., shall on the
order of the S.O., be uncovered or removed by the Contractor and the foundations
reinstated all at the Contractors own expense.
14.0
15.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.6
In backfilling pipe trenches, only approved materials free from stones or rocks or
other hard materials shall be carefully spread along the trench bottom between the
pipes and the trench walls to a depth of about 150 mm and shall be hand rammed.
Further layers each of about 150 mm thick of the same materials shall then be
spread and rammed in the same manner up to the top of the pipes. The reminder of
the backfilling may consist of coarse materials free from boulders and large earth
clods. It shall be placed in layers each of 150mm thickness and hand or
mechanically rammed until the backfill is 300mm above the top of the pipes. The
rest of the trench backfill shall be in layers each of 300mm thickness and compacted
by a mechanical vibrating tamper to finish off slightly proud of the surrounding
ground. The degree of compaction of each layer shall not be less than 95 percent of
the dry density obtainable using the BS Standard Compaction Test. The Contractor
shall have to make good any settlement to avoid formation of drains at gulleys
within the refilled trenches.
16.0
17.0
ROAD REINSTATEMENT
Road reinstatement works shall be carried out by the Contractor to a standard
equivalent or superior to the road condition existing prior to excavation and to the
approval of the S.O.
All backfilling shall be done by the Contractor with approved sand. No organic soil,
broken pre-mix or stones are to be used. The sand shall be compacted 150mm
layers. The degree of compaction of each layer below the pavement course shall not
be less than 95 percent of the dry density obtainable using the BS Heavy
Compaction Test. The Contractor shall bear the cost of such tests and shall make
good any works which are found to be unsatisfactory.
Sand material shall be deposited in layers on both sides of the pipe simultaneously
and thoroughly compacted and around the pipe working alternately on either side of
the pipe until the trench have been filled up to 150m above the top of the pipe
except for pipes laid in roads where the sand backfill shall be brought up to the base
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.7
course formation level. The sand vibrator and/or by an approved system of water
jet. The topping of the refilling for trench excavation as described above the backfill
with excavated material.
Where necessary the Contractor shall adjust the moisture content of the refill
material either by drying out or by adding water to assist the compaction of the
material.
The Contractor shall reinstate the road pavement by replacing, in the proper
sequence, any block or metalling removed, provided the block or metalling is in
good condition and to the approval of the S.O. The road surface shall be reinstated
with new materials of the type existing on site. Edges of the reinstated road
pavement shall be straight and neatly finished to match the existing road to the
satisfaction of the S.O.
For pipe trenches the Contractor shall be as required by the authorities or as
follows:
If the Contractor fails to carry out the reinstatement to the satisfaction of the S.O. or
any further reinstatement that may be necessary of any trenches across roads and
footpaths, the S.O. or the appropriate authority may proceed with such repairs and
the cost of such reinstatement shall be deducted by the S.O. from any payments due
or to become due to the Contractor.
18.0
REMOVAL OF SURPLUS
The contractor shall dispose off all surplus excavated materials, earth, rubbish and
waste matters to an approved tip to be provided by him unless otherwise directed by
the S.O. If surplus spoil is tipped into or fill materials obtained from private property,
the operations shall be executed with the approval of the owner and occupier of the
same. The Contractor shall have no right of ownership to the surplus materials
excavated.
19.0
EMBANKMENTS
Embankments and filled areas shall be made by depositing approved soil in regular
layers not more than 300 mm in loose thickness. Each layer shall be well compacted
with approved mechanical rammers or rollers before the next layer is placed.
Compaction shall continue until the soil is at a density not less than that of any
adjacent cuttings in the in situ state. All practical steps shall be taken to avoid the
inclusion of excess water in the fill and the finished surface of each layer shall be
sufficiently even to prevent the ponding of rain water in ruts and hollows. The S.O.
may direct the filling to stop in inclement weather. In dry weather effective
consolidation shall be assisted by watering. If the soil of the fill or the previous layer
of compacted soil is too moist for further effective compaction, compaction shall be
deferred until in the opinion of the S.O., it has dried sufficiently. The Contractor
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.8
shall disk harrow the soil to aid the drying if so directed by the S.O. The fill
materials shall be obtained from the surplus excavated materials at the site of the
works or from approved borrow pits.
20.0
21.0
LEVELS TO BE RECORDED
Before the surface of any part of the site is disturbed or the commencement of each
stage of filling the Contractor shall take and record levels of any such part, in the
manner specified or as agreed with the S.O. in his presence and such levels when
agreed with him shall form the basis for measurement.
The Contractor shall obtain the S.O.'s prior approval to the proposed methods of
obtaining and recording this information and shall afford the S.O. all facilities to
attend and check each survey and recording. The Contractor shall give to the S.O.
notice of his intention to carry out such survey work at least 24 hours in advance of
the commencement of the survey. The Contractor shall carry out to the S.O.'s
instructions, all extra surveys required to resolve any doubts which may arise as to
the correctness of any survey or record and the S.O.'s decision shall be final
regarding what shall be recorded as the correct survey.
A similar procedure shall be adopted to record any rock surface limits and levels
before they are blasted or excavated.
Each survey drawing with agreed data shall be referred to as a "Record Survey"
which shall be signed by the Contractor and the S.O. and shall form the basis of
measurement of the appropriate work. The Contractor shall supply four copies of
each Record Survey to the S.O.
22.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.9
or near the site. Where services are shown on the drawings or where there is
evidence of services in the ground, the Contractor shall also determine their exact
positions. In addition the Contractor shall watch for and determine the position of
any services which may not have been marked.
Where Trench Excavation is carried out close to or across the line of sewers, pipes,
cables and other services the Contractor shall provide temporary adequate supports
to secure the services and where such sewer, pipe, cable or other service is
temporarily displaced or disturbed it shall be restored to its original state. If
restoration or any service to its original state cannot be achieved then it shall be
replaced and made good. The cost of excavating around any service which crosses
the trench and of temporally supporting it while pipelaying is undertaken, shall be
deemed to be included in the rates for excavation.
All damage to services shall be made good to the satisfaction of the S.O. and the
authorities concerned. The cost of making good any damage shall be deemed to be
included in the rates for excavation. In the event that any damaged services shall
only be repaired by the authority concerned, all costs whatsoever relating to the
repairing of the damaged service undertaken by the authority shall be at the
Contractors expense. Where damage to a service had already existed prior to
excavation or other work, repair of the damaged service shall be undertaken by the
Contractor, if so ordered by the S.O. and the Contractor shall be paid on Daywork
for repairing such service.
Where in the opinion of the S.O., construction of the pipeline cannot reasonably be
carried out unless the sewer, pipe, cable or other service is permanently severed or
permanently diverted or permanently supported the Contractor shall undertake such
work is so ordered by the S.O. Any such work if carried out shall be to the
satisfaction of the S.O. and of the authority concerned and shall be paid for at
Daywork where necessary and at the appropriate Contract Rates.
Where pipes are laid under culverts they shall, subject to other provisions in the
Contract and to the S.O.s instructions, be given a concrete surround extending for
600mm clear on each side of the culvert, and a concrete half haunch to the culvert
shall be provided over the width of the trench cast directly on top of the concrete
surround. The cost of all work in removing any piles and concrete bend under
culverts and of temporarily supporting the culvert during pipelaying shall be
deemed to be covered by the rates for the items in the Bills of Quantities for pipe
crossing under culverts.
23.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.10
the Defects Liability Period all hedges replanted in the above manner shall be
inspected and any dead plant replaced by the Contrator.
24.0
MACKINTOSH PROBES
The apparatus used shall be the standard JKR probes or the normal Mackintosh
probes.
Probing shall stop when the resistance has reached 400 blows/0.30m penetration or
the depth has reached 15 metres, whichever is reached earlier, unless directed
otherwise by the S.O.s representative.
Mackintosh probes shall be measured by the penetration depth in to the ground.
25.0
26.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.11
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.12
except where expressly provided for otherwise by the inclusion in the Bill of
Quantities of any of the following further items :Incidental Excavation for Structures situated in the pipeline shall be measured only
to the extent that the net excavation required to accommodate the structures falls
outside the nominal dimensions of the Trench Excavation.
Incidental Excavation for removal of unsuitable material shall (unless it is held to
be excess Excavation) be measured as the volume ordered by the S.O. to be
excavated beyond the nominal dimensions of Trench Excavation and shall include
for the disposal of the excavated material off the site and for backfilling the
excavation with approved material emanating from Trench Excavation elsewhere or
for backfilling the excavation with the grades of concrete ordered by the S.O.
Rock, measured E.O. Trench Excavation items, shall be measured as the volume of
Rock within the nominal limits of Trench Excavation in Rock. When measured E.O.
Incidental Excavation items it shall be measured as for those items.
Excess Excavation and the backfilling thereof shall not be measured for payment.
Trench Excavations in roads and in footpaths as specified shall be measured (E.O.
Trench Excavation) as the area calculated by multiplying the length of trench so
excavated by its nominal width. The stripping of the top surface and the surface
reinstatement of Trench Excavation in road verges, fields, etc. shall be included in
Trench Excavation and shall not be separately measured.
Crossing hedges, fences and walls shall include for all temporary measures for
dealing with such barriers as specified and shall be measured as the length of such
barriers so dealt with within the nominal width of Trench Excavation. Any
permanent measures required by the S.O. shall be ordered by him as additional
work.
Crossing rivers culverts and other watercourses shall include for all additional
measures necessary to make the crossings as specified. Only such crossings as may
be itemised in the Bill of Quantities will be measured (E.O. Trench Excavation) for
additional payment. The length of measured for payment for crossing natural
watercourses shall be defined as the width of the waterway along the pipeline at the
time of construction of the crossing (except flash floods and floods).
Overhaul of refill or excavated materials (E.O. Trench Excavation or Excavation in
borrow areas) shall apply in cases where the S.O. orders material to be transported
from locations of excavation which are more than five thousand metres from the
areas to be filled.
28.0
MEASUREMENT OF FILLING
Items in the Bill of Quantities for filling shall include not only work in connection
with working and supplying of fill materials, within or outside the site transporting,
placing, spreading, watering, drying, compacting and grading approved fill materials
but also field tests, supervision, disposing of reject material and condemned material
at spoil tips on or off the site and construction and maintenance of necessary access
roads, bridges and drainages.
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.13
Fill material shall be measured as the volume placed after filling has completed.
Joint measurement of fill levels shall be taken once the required level has reached.
No allowance shall be made in the measurement for filling for settlement during
construction.
The Contractor shall be deemed to have made due allowance for any delays to
filling occasioned by sampling and testing materials from fill and borrow areas as
specified by the installation and testing of measuring instruments for fill.
The earthworks and all work in connection therewith as specified shall be valued by
the measurement of only such items as are set forth in the Bill of Quantities. No
separate measurement for payment shall be made in respect of any part of this work
unless separate items are expressly provided for in the Bill of Quantities.
Excavation of reject material in borrow areas shall be measured as the volume lying
between the surface recorded after stripping topsoil but before excavation of
unsuitable material starts, and the surface recorded before excavation of suitable
material starts.
If the Contractor excavates unsuitable material from the ground surface with the
intention of later using the underlaying material as a borrow area, and then does not
work the area as a borrow area to the extent required by the S.O., then such
excavation of unsuitable materials shall not be measured for payment.
29.0
(b)
The remaining 25% for any length, will be due on completion of restoration of
the final surface, including reinstatement of all surface damage, completion of
chambers, thrust blocks, etc.
Payment for the second stage shall be due only after restoration of any length has
been inspected and approved by the S.O. and by any relevant authority. Payment
for the separate items in roads, footpaths, etc. will be made at the same time as the
second stage payment for excavation.
30.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.14
Topsoil shall be measured as the areas so treated, and except where expressly
indicated otherwise items shall apply to sloping as well as to horizontal surfaces.
Topsoil and turfing of re-filled trenches shall be included in items for Trench
Excavation and shall not be separately measured for payment.
31.0
at fifty percent of the Contract Rate when the turfing has been carried out;
(b)
Where grass fails to establish itself, the Contractor shall turf the relevant area again
at no extra cost to the S.O.
32.0
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.15
GENERAL
The Contractor shall supply all the pipes and specials required unless otherwise specified
and construct and complete the pipeline and all associated works as shown on the
Drawings and included herein under the Contract.
2.0
3.0
C.1
dropped or let fall onto the ground and under no circumstances shall the pipes or pipe
specials be lifted by means of hooks to the ends of pipes and pipe specials.
All the open-ends of pipes and specials shall be kept closed by means of end-caps or
polyethylene sheets approved by the S.O. before delivery to site from the factory.
After delivery to site, these end-caps or polyethylene sheets shall not be removed until
the pipes or specials are ready to be laid in place. All open ends of pipes and specials in
the trenches shall remain covered to prevent the entry of any dirt, mud, stone and
contaminant. The cover shall also be water tight to prevent the entry of dirty water.
The Contractor shall be deemed to have allowed the cost of providing the above
necessary measures in the Contract Rates for supply and laying.
Any damage to or loss of materials shall be made good, or the damaged or lost materials
replaced, by the Contractor at his own expense and if approved by the S.O. damaged
materials shall be returned to the manufacturer for repair as directed by the S.O.
4.0
RECORDS
The Contractor shall keep full and detailed records including item numbers, size of each,
and location of all pipes and specials which are :
delivered to Site
declared to be defective
used in the Works
cut, broken or removed from Site
The Contractor shall keep such records continuously up to date, and shall have them
available for inspection by the S.O. at any reasonable time.
5.0
5.1
Prospecting
The Contractor shall prospect for the position of buried or otherwise hidden obstructions
such as existing services, drains, pipes, cables, culverts, etc. Trial holes and pilot
trenches to ascertain the exact positions of these shall be sunk, well ahead of pipe-laying
and excavation, in places where they are known or thought to be and elsewhere and
these shall be backfilled with approved materials immediately and in any case not
exceeding 24 hours and subsequently reinstated. Approved marker posts shall be
erected to mark the position of all located services, drains, etc, and these shall not be
removed until reinstatements have been completed. The S.O. shall instruct further
prospecting if he is not satisfied with the sufficiency of the Contractors prospecting.
Where necessary the Contractor shall make arrangements prior to trench excavation
proper for the temporary or permanent support or diversion of services, drains, etc, to the
approval of the S.O. and the authority concerned. The full cost of prospecting shall be
deemed to be included in the Contract Rates for excavation unless separate items are
provided in the Bill of Quantities.
C.2
Attention is drawn to Clauses concerning the responsibility of the Contractor for the
security of existing services. The Contractor shall be deemed to have allowed for the
unavoidable delay of the Works due to any obstruction he may encounter with the
existing services and no claim for any extra costs on account of this will be allowed.
6.0
7.0
8.0
DANGERS OF FLOTATION
Although flotation of pipes in completely refilled trenches or of the completed works will
not occur, the Contractors attention is particularly drawn to the danger of flotation of
pipes laid in trenches left unrefilled and allowed to be flooded with water in the partially
completed works.
The Contractor shall, immediately after pipes have been laid, jointed and approved by
the S.O., refill and compact excavated materials to at least two thirds of the length of the
pipe trench leaving only sufficient space un-refilled to allow for the completion of the
external joint. Notwithstanding this, the Contractor shall make all necessary provision to
avoid the flotation of any pipe during the construction stage.
Any damage caused by flotation of pipes, specials or fittings in un-refilled trenches shall
be made good to the satisfaction of the S.O. at no extra cost.
C.3
9.0
The S.O. may order that no further trench excavation shall be opened until the
outstanding work has been carried out to his satisfaction and the Contraction shall have
no ground for a claim on this account.
10.0
11.0
C.4
locally with a blow lamp and smoothing over with a fettling knife. Additional external
jointing material shall be added wherever necessary.
All defects to linings and sheathings shall be made good to the entire satisfaction of the
S.O. Where in his opinion the damage is such that satisfactory repairs on Site will not be
practicable, e.g. when damage or cracking is extensive and/or inaccessible, the pipes or
specials in question shall be either returned to the factory for proper repair or replaced
completely. The Contractor shall be responsible in either case for all costs involved in
this respect and for any delays to construction work thereby caused. The compound
used for repairing sheathings shall be compatible with the sheathing material and shall
be approved by the S.O.
12.0
C.5
13.0
SPECIALS
The approximate positions of all specials are shown on the Drawings. The exact
positions shall be determined on Site by the Contractor to the approval of the S.O.
14.0
PIPE CUTTING
Where it is necessary to cut pipes to provide closing lengths or for laying pipe specials or
in the repair of damaged or chipped pipes, the cutting shall be neatly and accurately
performed so as to leave the end of the pipe truly normal to the axis of the pipe.
15.0
WELDING OF JOINTS
15.1
Welding Procedure
All electric arc welding equipment shall be to the approval of the S.O. The Contractor
shall submit details of the welding procedure, which he proposes to adopt for the S.O.s
approval. Details shall include:
Direction of welding
Current strength
The Contractor shall make test specimens on pipes of the same size and thickness on the
pipelines to be welded. These pipes shall be supplied by the Contractor. The joints shall
be tested in the presence of the S.O. for each procedure proposed in accordance with
the requirements of Clause 7 of BS 4515.
Only procedures approved in writing by the S.O. shall be adopted in the welding of the
pipelines, and change from one procedure to another will not be permitted without
submitting the new procedure for re-testing.
16.0
WELDING PERSONNEL
Only the most highly skilled welders shall be employed on the Works, and every welder
before commencing any joint welding shall prepare specimens for testing in accordance
with Clause 7 of BS 4515 for each welding procedure proposed by the Contractor. Every
welder shall be tested in accordance to Clause 8 of BS 4515. The Contractor shall be
responsible for the preparation, setting up, provision of specimen, all necessary
equipment and materials for the testing of welding personnel.
The S.O. will advise the Contractor in writing which welders pass the performance
qualification test. Only these welders will be allowed to weld the pipe joints and the
S.O. shall be at liberty to withdraw his approval to any welder responsible for making
joints, which fail to meet the required standard.
17.0
C.6
Before placing the pipes together the portion of the sockets and spigots to be welded
shall be cleaned to a bright metallic finish, the spigot end shall then be placed in the
socket and forced inside so that the spherical surfaces are in contact and that the gap
between the pipes at the end of the spigot is nowhere greater than 1.5mm. For
longitudinally welded pipes, the longitudinal welds on adjacent pipes shall be at least 15
out of line. Details of the socket and spigot welded joint are shown on the Drawings
Where pipes are to be jointed by a steel split collar, the pipe ends and the collar shall be
cleaned to a bright metallic finish. The collar shall then be placed on the ends of the
pipes so that the space between the pipe ends shall be about 25mm from the centre line
of the collar. The collar shall be clamped tightly onto the pipes using the lugs and
welded longitudinally. After completion of the internal and external circumferential
welds, the lugs shall be removed and the longitudinal weld completed.
The weld shall be of the convex full fillet type for lap welded joints made manually by
the metal arc process using approved types of electrodes. Each time the arc is started it
shall be manipulated to obtain complete fusion of the weld metal with the pipe and any
previously deposited weld metal. Before welding over any previously deposited weld
metal all slag shall be completely removed and the weld metal and the adjacent pipe
metal shall be cleaned by wire brushing.
All welds shall be subjected to inspection by the S.O. and shall comply with the
requirements of Clauses 9 and 11 of BS 5135 for freedom from undercutting, fusion
penetration and soundness.
18.0
19.0
As soon as the primer has set the sheathing shall be completed by running hot bitumen
into a metal mould placed over the joint and overlapping the sheathing by 75mm on
either side of the joint. The bitumen shall be Type 2 of BS 4147.
C.7
Priming and sheathing material for the purpose shall be provided by the Contractor
including the supply of all the necessary mould boxes and funnels required to form the
protective mould and whiting for use in lining the mould boxes prior to each pour. The
Contractor shall also supply all necessary boilers to heat the bitumen to the application
temperature recommended by the manufacturer.
20.0
21.0
22.0
22.1
C.8
temperature. The Contract Rates for making coupling and adapter joints shall cover all
costs in complying fully with the requirements of this Clause.
Mechanical couplings and flange adapters located in chambers shall be painted with two
coats of bituminous paint.
23.0
24.0
PIPELINE INSPECTION/CLEANING
On completion of the pipeline, the Contractor and S.O shall inspect and cleaning the
pipeline according as follows:
i.
>1100mm
= Physical Cleaning / Inspection Internally
ii.
600mm 1100mm = Air scouring or swabbing or pigging and full bore scouring
also be allowed / CCTV
iii.
>600mm
= Air scouring or swabbing or pigging and full bore scouring
also be allowed / CCTV
All report shall be provided to confirm the pipe is clean, to be signed by the
consultant/contractor and witnessed by SYABAS.
25.0
TESTING OF PIPELINES.
25.1
Testing Pipelines
After a length of the pipeline has been completed it shall be tested as a whole against
stop ends. The stop ends shall be supplied to the S.O.s approval and fixed by the
Contractor and shall be properly strutted to ensure that no movement can take place and
they shall be of sufficient strength to withstand the full test pressure which is to be
applied.
Testing shall be carried out over completed pipeline by each gang as follows:
No
Description of Pipeline
Max length
1.
Trunk main
3km
2.
Reticulation Pipe
2km
C.9
Testing shall be carried out where possible between air valves but not against adjacent
valves. Testing shall not be carried out until the backfilling of the pipe trenches except at
the joints, have been completed. Backfilling at flexible joints shall be left uncompleted
to facilitate inspection joints during testing.
Temporary marker posts shall be installed immediately after testing at all junctions
between tested lengths.
Before any length of pipeline is subjected to test pressure, care shall be taken to ensure
that all weight thrust and anchor blocks intended to prevent vertical and lateral
displacement of pipes or specials have been properly completed. All valves shall be
checked before the test to ensure that they are in working order.
Prior to filling the line with clean water for water testing, the line shall be thoroughly
inspected jointly with the S.O. to ensure that the line is cleaned from stones, dirt, debris,
plastic paper or any other matter that may have entered after laying of pipework.
The water for filling and testing the pipeline shall be obtained from an approved source. .
It shall be free from silt, contamination and pollution. All water sources used for testing
must be clean and free bacteria and preferably source from SYABAS pipeline. SYABAS
must approve first for water source other than from SYABAS pipeline. SYABAS shall
ascertain and verify the water quality of other water source on water quality tests carried
out by developer. The Contractor shall make all arrangements necessary for conveying
the water to the point of filling. The test ends shall be tapped for suitable size test
connection. The Contractor shall supply all necessary apparatus including pipework,
pumps, pressure gauges and automatic pressure recorder and carry out all work
necessary to test the pipeline. Pressure gauges are to have a dial at least 200mm in
diameter, and are to be checked against a guaranteed standard unit before use and at
other times as the S.O. may direct. The pressure recorder or single channel logger shall
have a 24 hour chart to record the pressure drop continuously. The test pressures to be
applied shall be to SYABAS requirements.
The field pressure shall be carried out first. Each section of the ABS., HDPE and Steel
pipeline shall be tested to the respective pressures as shown in Table 1. Ductile iron
pipes shall be tested to the pressures given in Table 2 respectively. When more than one
material of pipe is used on the same pipeline or pipe network, the lowest of the field
pressure test values stipulated shall be used.
After the section of the main has been filled with water for a period of not less than 7
days for lined pipes and 1 day for another unlined pipes, more water shall be pumped
into the section to raise the pressure slowly increments of 1 bar with a pause of one
minute between each increment. Should any appreciable drop in pressure be noted
during any of these pauses the test shall be stopped until the cause of the pressure drop
has been investigated and rectified. An engine driven pump may used until 90% of the
test pressure has been attained, and thereafter only a hand operated pump shall be used.
The pressure test shall be considered to have been passed when the pressure gauge
shows no reduction in pressure during the specified one minute pause and also during
the period of 10 minutes after full test pressure has been attained. If these conditions are
not satisfied a thorough inspection of the section of the main shall be made. All defects
shall be repaired and the test shall be repeated.
P:\zRAZMANN\SPEC\C-Handling of pipes and special1.doc
C.10
The leakage test shall then follow. The pressure shall be reduced to the relevant leakage
test pressure as shown in Table 1 and 2. The pressure shall be maintained as constant as
possible for a period of 24 hours. Make-up water shall be pumped into the section of the
main from time to time to maintain this pressure. The leakage calculated as 0.34 litre per
cm of pipe diameter per km of pipe per 24 hours per 1.0 bar of water pressure. If this
specified rate of leakage is exceeded a thorough inspection of the section of the main
shall be made. All leaks discovered shall be repaired and the section shall be tested
again.
Every section of all pipelines shall be tested as described above in the presence of the
S.O. Testing may be carried out between sluice valves but not against the gates of
valves.
Table 1: Test Pressures for Field Pressure and Leakage Test of ABS, HDPE and Steel Pipe
CLASS /
SERIES OF
PIPE
TYPE OF
PIPE
ABS
MAXIMUM
PERMISSIBLE
WORKING PRESSURE
(BAR)
12
15
12.5
15
15
10****
PN 12
PN15
PN 12.5*
PN15**
HDPE
** *STEEL
*
**
***
****
PRESSURE FOR
PRESSURE TEST
(BAR)
PRESSURE
FOR LEAKAGE
TEST
(BAR)
PRESSURE FOR
LEAKAGE TEST
FOR PIPELINE
WITH FERRULE
CONNECTION
(BAR)
15
15 X 1.5
15
15 X 1.5
15 X 1.5
15
12
12
12
12
12
10
6
6
6
6
6
6
Table 2: Test Pressure for Field Pressure and Leakage Test of Ductile Iron
Nominal
diameter
(mm)
*80 300
*350 - 600
16.0
16.0
16.0
16.0
12.5
12.5
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
12.5
12.5
12.5
12.5
12.5
1.2.5
16.0
16.0
16.0
12.5
12.5
-
CastOn
Pipes
12.5
8.0
5.0
5.0
5.0
-
21.0
21.0
21.0
21.0
15.5
-
C.11
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
17.5
17.5
17.5
17.5
17.5
-
21.0
21.0
21.0
17.5
17.5
-
CastOn
Pipes
18.5
13.0
10.0
10.0
10.0
-
16.0
16.0
16.0
16.0
12.5
12.5
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
12.5
12.5
12.5
12.5
12.5
-
16.0
16.0
16.0
12.5
12.5
-
CastOn
12.5
8.0
5.0
5.0
5.0
-
Pipes of these diameters are capable of withstanding working pressure higher than 16
bar. If these pipes are used to their Maximum Working Pressure, i.e. half the Factory
Hydrostatic Test Pressure given by supplier, all valves used shall then be appropriate
rating. The pressure used during the pressure test shall then be 5 bars higher than the
selected working pressure. Pressure for the leakage test shall be the same as the selected
working pressure.
25.2
25.3
Testing of HDPE Pipelines (Whole system inclusive of fittings, tapping tees and com
pipes).
Testing Procedure
During first stage, a test procedure of 1.2 times the maximum working pressure (For PN
12.5 Working Pressure = 10 bar) shall be applied to the section test. The test section
should then be allowed to stand without make-up pressure with the allowable drop a
maximum 10% of the test pressure. If there is no leak of the test water after at least 1
hour under pressure, then proceed to second stage test.
The pressure is then reduced by rapidly bleeding water form the system to a nominal
pressure (8 bar). The control valve is then closed and the pressure readings are recorded
at intervals of 5 minutes for 2 hours by an automatic pressure recorder/ chart recorder. A
sound pipeline without leaks should exhibit a stable constant pressure over the time of
measurement after the initial rise in pressure (visco-elastic response of PE pipe), but the
final pressure must not be less than 8 bar.
All recording should use electronic lodger/chart recorder and not manual recording.
Graph shall be plotted and certified by all parties immediately during test or after
plotting from computer. A standard leakage test from certified by all parties during test
shall be submitted.
The section is considered to have passed the leakage if the procedure and results from
the graph plotted complied to requirement.
References:
The following reference publications provide pressure testing information:
ASME B31.1. Power Piping, Section 137, Pressure Tests (Ref 6)
PPI TR-31 Underground Installation of Polyolefin Piping, Section 7 System
Testing (Ref 1)
PPI Inspection, Test and Safety Consideration
JKR Tender Specification for Polyethylene (PE) Pipe Systems for Water Supply
MWA Guideline
SAJ PE Pipe Testing Procedure
C.12
26.0
27.0
COMMISSIONING OF PIPELINE
Pipe shall be commission over completed pipeline by each gang as follows:
No
Description of Pipeline
1.
Trunk main
2.
Reticulation Pipe
Max length
5km
3km or Not Exceeding
1500 Properties
28.0
MISCELLANEOUS
28.1
28.2
C.13
28.3
Anchor blocks
Every third pipe
Every second pipe
Every pipe
Details of thrust and anchor blocks are given on the Drawings. The dimensions shown
may, however, be amended by the S.O. after examination of the ground prior to
concreting, having regard to the likely thrust developed under test pressure and the
actual nature of the ground. Additional anchor blocks may also be needed.
For horizontal bends in cross-fall ground, care shall be taken to ensure that additional
cover over the pipes is allowed in order that the same passive resistance may be
developed as would be the case in level ground.
For thrust and anchor blocks to fulfill their purpose they must abut against undisturbed
ground. Where timbering has been used in the excavation it shall be withdrawn as the
concrete is being placed.
28.4
Valve Chambers
The operation of all valves including scour and air valves shall be checked by the
Contractor and any necessary adjustments made to ensure correct operation. Valve
chambers shall be constructed in accordance with the details shown on the Drawings or
as directed by the S.O. The same care shall be taken as for thrust blocks to ensure that
concrete transmitting thrust abuts against undisturbed ground.
The Contractor shall first obtain from the manufacturers the minimum required size of
the chambers. The S.O.s approval shall be sought should there be any variation. The
Contractor shall pay all subsequent costs due to any such variations.
Drainage from valve chambers to suitable outfalls shall be provided as directed by the
S.O.
28.5
C.14
each crossing. The lines, and levels of the pipe-work shall be as shown on the Drawings
or as directed by the S.O.
28.6
Swabbing of Pipelines
When the final connections have been made and the pipelines have been tested to the
satisfaction of the S.O. the pipelines shall be cleaned by using hard grade polyurethane
foam swabs.
The recommended density of the swabs to be used is 30 to 40 kg/m3. The recommended
speed of the swabs is about 0.6m/s.
The swabs shall be at least 50 mm bigger in diameter than the internal diameter of the
pipe for small size pipe (i.e. 100mm, 150mm, and 210mm). For large diameter pipes of
300mm and above, it is advisable to use a size at least 100mm bigger than pipe internal
diameter. The length of the swab shall be 2 times the pipes diameter.
The cylindrical shaped cleaner was propelled by differential hydraulic pressure using a
pumper truck to provide water pressure (generally 15 to 26 bars for 30 to 40 seconds). A
temporary launch point (possibly a wye or tee) shall be used to enter the foam plug into
the flow of water or it may be inserted into the first joint of pipe laid and remain until the
cleaning process is begun.
As the plug moved through the pipelines, it pushed the debris downstream. A small flow
or bypass around the plug assisted in suspending and carrying the debris to the discharge
end of the pipelines.
After the cleaner has been received at the end of the system (usually fitted with
temporary piping to direct flow to ground level), the pipelines were tied into the desired
final connector.
28.7
Sterilization of Pipelines
The section of the main to be sterilized shall be filled with water mixed with a solution
of chloride of lime containing about 40 milligrams per litre of chlorine. The Contractor
shall have to adopt a dosing system to sterilize the line effectively. The system shall be
provided with a set up of temporary equipment, chemical mixing tank mixer, dosing
pump and other necessary accessories for the solution to be injected into the lines when
potable water will be introduced gradually. After the main has been filled with
chlorinated water, it shall be closed and left for at least 24 hours. The main shall be
deemed to have been sterilized if the samples of water taken from various tappings on
the main show a chlorine residual of 0.2 ppm.
After the main has been sterilized to the satisfaction of the S.O. it shall be flushed with
clean water.
Pipeline shall be filled with solution of Calcium hypochlorite 65% to 40 ppm level and
left for 24hours.
The main shall be deemed to have been sterilized if water samples taken from various
locations of the pipeline show a total chlorine level of more than 10ppm after 24hours.
C.15
28.8
Flushing of Pipelines
Flushing shall be carried out after disinfection has been achieved. Water sources that
being used for flushing must be clean and meet treated water quality. Flushing shall
proceed systematically from water supply source to en of pipe system. Procedure to be
used in flushing shall be discussed and agreed to by SYABAS and the Contractor/
Consultant prior to beginning of flushing works.Flushing of pipeline is deemed to be
complete only when the turbidity level of the water is less than 2 NTU and pH level less
than 9.0, residual chlorine is more than 0.2 ppm, E.coli and total coliform are absent.
Report on flushing shall be completed and signed by Contractor / Consultant and
witnessed by SYABAS personnel.
28.9
28.10
Clearing Up
During the progress of pipe-laying work the Contractor shall clear up the Site and
remove from the surface of the ground all temporary buildings, plants, materials, litter,
rubbish and surplus spoil which may have been left on the ground or in and about the
Works or lands temporarily occupied by the Contractor and he shall leave in a clean and
sightly condition all and any lands occupied by him. Clearing up of the Site as herein
specified shall follow closely on the refilling of the trench.
28.11
28.12
C.16
The paint required for these purposes shall be supplied by the Contractor and approved
by the S.O. and SYABAS. The cost of supplying primer and paint and painting pipe-work
and valves shall be included in the rates for laying pipes and the installation of valves.
28.13
28.14
29.0
PIPE JACKING
29.1
General
Pipe jacking shall be the process of installing pipes below a surface obstruction by
driving them successively through the in-situ soil from one pit (the jacking pit) to another
(the receiving pit) such that the finished pipe forms a watertight continuous conduit
between the pits on the desired alignment.
Plans and details of the equipment, materials and the method of construction to perform
and complete the work shall be submitted by the Contractor and must be approved by
the S.O. before commencing these operations. Approval by the S.O. shall not relieve the
Contractor of his sole responsibility for the efficiency, reliability and soundness of the
method employed in completing the work in a satisfactory manner.
The Contractor shall satisfy himself as to the soil conditions along the pipe jacking route
and if he judges it to be necessary, he shall carry out further soil investigations at his own
cost.
It shall be the responsibility of the Contractor to maintain stable soil conditions at the
jacking face to prevent loss of ground above the jacking operation and movement of the
surrounding earth. The methods of maintaining face stability and preventing ground
movement and subsidence shall be by means of compressed air or other plenum
methods where fluid slurry or earth pressure is applied to the tunnel face. Alternatively,
C.17
unstable ground ahead of the jacking face may be stabilized by the injection of suitable
chemicals. Methods which require dewatering of the ground will not be accepted, nor
will methods which may lead to significant ground loss. The Contractors proposal must
be submitted to the S.O. for his approval.
Movement or settlement of structures, utilities and pavement shall be monitored by the
Contractor during the jacking operation and reported to the S.O.. If movement or
settlement occurs which in the opinion of the S.O. may cause damage, the contractor
shall take immediate action to prevent further movement, settlement or damage. He
shall repair at his own cost any damage and restore structures or pavements to the
satisfaction of the S.O..
The Contractor shall be responsible for inspecting the location and familiarizing himself
with the conditions under which the work will be performed and with all necessary
details as to the orderly execution of the work. The omission of any details shall not
relieve the Contractor of full responsibility for the satisfactory installation of the work in
its entirety. No monetary or other claims made by the Contractor on the grounds of want
of knowledge will be entertained.
The Contractor shall survey the location of pipe-jacking prior to any commencement of
work to identify the exact location of an existing box culvert. The exact location of the
pipe jacking shall be confirmed by the S.O.
29.2
Performance Requirements
The centre-line of the fully jacked pipeline shall at all points along its length be within
75mm of the required alignment in the horizontal plane and 25mm in the vertical plane.
No movement, upheaval or settlement of soil, which in the opinion of the S.O. may
cause damage to structures, utilities or pavements shall be permitted.
The fully jacked pipeline shall pass the water-tightness test specified for the pipelines in
trench.
29.3
Approval of Owner
Before commencing preparations for pipe jacking the Contractor shall obtain the written
consent to his proposed procedures to the Owner or Owners of the land, services and
structures below which (or close to which) the jacked pipeline will pass.
29.4
Jacking Operation
The Contractor shall be fully responsible for the materials, equipment and facilities
required in conjunction with jacking the pipes.
Before starting work, the Contractor shall submit to the S.O. for approval, a detailed
schedule of the entire jacking operation. Approval of such schedule shall not relieve the
Contractor of his responsibility to provide a fully satisfactory installation. The Contractor
shall include with his submission evidence that he has successfully completed a jacking
installation using procedures similar to those proposed.
C.18
Where chemical stabilization of soil is used, a chemical grout shall be pressure injected
into the soil over and ahead of the pipe jacking to stabilize the soil. The chemical grout
used shall have a demonstrated history of success for stabilizing soils similar to that
through which the pipe is to be jacked.
Where a mechanical shield is used, the Contractor must provide proof that the particular
model of shield has been used successfully in soils similar to that on the site. The crew
for the operation of the shield must be specialist, with experience in the use of that
particular type of machine.
After the jacking operation has begun, the Contractor shall work continuously and
expeditiously in accordance to programme until the complete length of jacked pipes is
installed. This continuous work where required shall not be constructed as overtime
work.
During jacking and excavation, the Contractor shall constantly ensure that the internal
lining of the jacking pipes is not damaged, and he shall remove the excavated spoil to
the jacking pit by conveyor to minimize traffic on the invert.
The pipes shall be jacked into place true to line and level. The maximum tolerance
allowable in the displacement of the center-line of the jacked pipe from the design
center-line is 75mm in the horizontal plane and 25mm in the vertical plane but there
shall be no back-fall at any point.
The pipes for the jacking operation shall not exceed 3m long. The pipe ends shall be
jointed by thrust sleeves before the pipeline is jacked. Details of how the pipes are to be
lowered into the pit and welded shall be submitted to the S.O. for approval.
The Contractor shall be required to furnish and install and remove to the extent required,
thrust blocks or whatever provisions may be required for backing up the jack employed
in jacking the pipe forward. The jacking pit shall also be equipped with steel rails or
beams embedded in concrete for placement and alignment of each pipe during the
jacking operation.
The Contractor shall be fully responsible for the design and construction of the jacking
and receiving pits, thrusting wall, installation of jacking equipment, sheeting, bracing,
etc., and for the efficient execution of the jacking operation. Full details of the proposals,
including plants, shield machines, equipment, operating procedures, jacking pits and
intermediate jacking stations etc., shall be submitted to the S.O. and shall be fully
satisfactory to him before construction. However, review of the plans shall not relieve
the Contractor from his responsibility to provide a safe and satisfactory jacking pit. On
successful completion of the jacking operation, jointing of the length of jacked pipes,
hydraulic pressure testing of the pipelines and after the connections at the extreme ends
of the jacked pipeline have been made, the Contractor shall remove completely the
jacking pits and receiving pits together with all the temporary works.
The Contractor shall be required to monitor closely the progress of the jacking operation.
Daily site records of thrusting pressures, rates of thrusting, the line and level
measurements of the jacking pipes and any movement or settlement of existing structures
shall be properly maintained and shall be submitted to the S.O.
P:\zRAZMANN\SPEC\C-Handling of pipes and special1.doc
C.19
For the sections of the pipeline crossing under roads, railway or structures along the
pipeline route, the Contractor shall be required to incorporate in his tunneling method
measures to arrest settlement or upheaval of the soil so as to safeguard the integrity of the
structures and other properties. The Contractor shall ensure that the traffic flows along
railway lines and roads are not affected in any way of his work.
29.5
Safety
The minimum of plants shall be used in the pits, and any which produces noxious gases
or is operated by electricity at a greater voltage than 240V shall be permanently outside
the pit at ground level.
A ladder shall be fixed permanently in the receiving pit. Two ladders shall be
permanently fixed on opposite sides of the driving pit, one on each side of the pipe
jacking line. These ladders shall be kept clear of obstructions to allow rapid exit in an
emergency. Excavated materials and plant other than small tools shall not be passed via
the ladder but shall be handled by crane.
Pits shall be securely fenced to prevent unauthorized persons from entering in.
All persons entering the pits shall wear safety helmets constantly, and shall leave the pits
for meal breaks, rests and the like.
At the beginning of each shift and after any break for refreshment or other reason, the
Contractor shall provide and use an approved instrument to check for noxious gases
before anyone re-enters either pit.
All costs associated with the provision of safety equipment and measures shall be
deemed included in the Contract Rates.
29.6
The length of each pipe shall not exceed 4m and the pipe ends shall be suitable for
jointing with internal split collar by fillet welding in the field.
Each length of pipe shall be provided with steel thrust flanges at the pipe ends
designed to take the jacking load applied and transfer the load to the next pipe.
C.20
29.7
The transfer of the jacking load shall be through the external reinforced concrete
cladding by means of a steel thrust collar between the trust flanges of the pipes.
The thrust collar shall be fitted onto the pipes with flexible rubber rings to prevent
ingress of water into the pipe from outside.
C.21
The Contractor shall provide such assistance, labour, materials, electricity supply,
ultrasonic examination equipment and other apparatus as may be necessary to allow a
thorough and extensive independent examination to be carried out.
29.8
29.9
29.10
C.22
The connections at the two ends of the jacked pipeline will be made at the jacking or
receiving pits. The Contractor shall maintain and keep these pits intact and in a safe
condition to facilitate the connections. The Contractor shall remove all other temporary
works and any concrete blocks including cutting and removing part of the walls of the
pits that are in the way of the pipe-work connections.
When the Contractor has completed the connections of the pipelines and has completed
the protection of these connections with sand or concrete surround, he shall then
backfill the pits with well compacted sand. The removal of the temporary bracings and
struttings shall be carried out systematically together with the backfilling of the pits to
prevent collapse of the pit walls. The walls of the pits shall only be removed when the
backfill of the pits are completed.
30.0
Submittals
i.
Contractor shall submit the following shop drawings, product data as well as design
calculations prepared, checked and approved by a Professional Engineer registered
with the Board of Engineering Malaysia :-
ii.
iii.
Detailed construction scheduling plan complying with overall work progress prior to
the pre-construction meeting.
iv.
Prior to construction, submit the type and capacity of the drilling rig to be used on
the project, include manufacturer, pullback and push torque. Contractor to verify
that allowable pipe stresses of the pipe will not be exceeded by the drilling rig.
Submit information on the type of locating and tracking system. In addition, submit
type and capacity of mud mixing system. Include proposed composition of drilling
fluid, viscosity, and density.
v.
C.23
vi.
vii.
viii.
ix.
The Contractor shall maintain a logbook that includes driller notes and records for bores
using steering and tracking system. Data will include pipe number, depth, pitch, steering
commands, and notes. Log must also include rig performance parameters (thrust, pullback,
torque, drilling fluid circulation, drilling fluid composition), ground conditions, obstructions
encountered, time shift started and ended, footage during the shift). Logbook will include
information on drilling fluid (composition, viscosity, density). This logbook must be
available for review throughout the project and must submitted to the Engineer and Owner at
completion of project.
At the completion of the horizontal directional drilling, the pipe log indicating the horizontal
and vertical position at 5 or 10 meter intervals along the pipe to confirm conformance with
the depth and line shown on the Drawings. This submittal shall include the type and
manufacturer of tracking equipment used, date of most recent shop calibration record, and
the method to ensure the data was captured. No payment for any footage of pipe will be
made until its corresponding log is submitted to the S.O and SYABAS.
(b)
Quality Assurance
The horizontal directional drilling shall be performed by the drilling company who is
experienced in the installation of sewer pipelines utilizing the horizontal directional
drilling method.
The Contractor shall submit data on the horizontal directional drilling companys
experience. The drilling company shall have at least three previous successful projects
of 15-inch diameter or larger of High Density Polyethylene (HDPE) pipe utilizing the
horizontal directional drilling method and at least one previous successful on-grade
installation of 18-inch diameter or larger. The drilling company shall provide an
installation list including the following information: City or District, project name and
location, contact person and phone number, contract amount, project environment
(river crossing, urban area), date of installation, pipe diameter, pipe material,
maximum length of each bore, and total length of directional drilling.
C.24
(c)
Pipe
All pipe installed by the horizontal directional boring method shall be PN10 High
Density Polyethylene (HDPE) pipe.
The butt-fusion method for pipe joining shall be carried out in the field by qualified
fusion technicians following the pipe and fitting manufacturers specifications. The
joints shall be smooth, uniform, and de-beaded while supplying the proper melt,
pressure, and alignment. It shall be the sole responsibility of the contractor to provide
an acceptable butt-fusion joint.
All joints shall be made available for inspection by the S.O. before insertion.
(d)
(e)
Protection
The Contractor shall field verify the location and depth of all existing utilities,
including service connections, to be paralleled or crossed prior to the start of
directional drilling operations. The Contractor shall modify alignment, depth or grade
as necessary to avoid utilities and minimize the number of peaks and valleys along the
alignment.
The Contractor shall expose all utilities that they will be crossing with horizontal
directional drilling. All major utilities (high pressure gas, fiber optic, high voltage
electric, major pipe lines, water and sewer lines, etc.) should be exposed every 30
meter at minimum, if parallel within 1.5 meter of excavation area to verify depth and
location of the utility. If the location is not accurate, the utility owner should be
contacted immediately.
(f)
C.25
Provide installation and receiving pits as necessary for complete installation of the
pipe. The excavation of the installation and receiving pits shall be incidental to the
work.
The Contractor shall not start the pullback unless it can be completed without
interruptions. Contractor shall coordinate scheduling with the S.O.
The Contractor shall provide sediment and erosion control measures to prevent drilling
fluid or borehole cuttings from entering the adjacent parcels to the construction limits.
The pilot hole shall establish the horizontal plane of the pipeline. A plot of length
versus elevation versus left/right variance will dictate the actual as-built plan and
profile of the pipeline. Data feedback and electronic guidance systems shall be used
to provide confirmation of position.
Reaming shall consist of using an appropriate tool to open the pilot hole to a slightly
larger diameter than the carrier pipeline. The percentage oversize shall depend on soil
types, soil stability, depth, drilling fluid hydrostatic pressures, etc. Normal oversizing
shall be from 120 to 150 percent of the product pipe diameter. Drilling fluid shall be
forced down the hole to stabilize the hole and to remove soil cuttings. The Contractor
shall carefully monitor the reaming operations to prevent damage to adjacent utilities.
The Contractor shall maintain accurate alignment and grade control and shall
determine the pipe elevation (above mean sea level) at intervals not exceeding 100
meter.
The pipe shall be installed by continuously pulling and/or pushing the pipe into place
through the drilling fluid along the reamed hole pathway from insertion point to exit
point without causing damage to the pipe and pipe joints being inserted. The pullback
speed shall be within the pipe manufacturers recommendations.
Drilling
fluid/lubricants shall be provided as required by the pipe manufacturers
recommendations and specifications to avoid stressing the pipe and joints past the
materials elastic limits. Proper pipe handling, cradling, bending minimization, and
consistent insertion velocity shall be recorded.
Any bits, drills, reamers, or other tools lost or stuck in the hole shall be removed at the
Contractors expense. If tools cannot readily be removed, Contractor may at
Contractors option abandon the hole. The Contractor will seal the borehole and redrill the crossing. No payment shall be made for any lost equipment, material, or
work on abandoned holes.
Drilling fluid to be used to facilitate the installation of the pipe shall be adjusted within
acceptable limits such that ground heaving and subsurface cavity formation through
erosion are prevented.
A variation greater than 18 inches from the horizontal and 0.5 percentage points
from the designated grade may be sufficient reason for the rejection of the pipe, and
the pipe shall be re-bored to proper grade if so directed by the S.O. at no cost to the
Owner.
The alignment shown on the Drawings shall be adhered to unless existing physical
obstructions prevent otherwise. The number of setups and the length of pipe
installation per set up as shown on the Drawings is merely a suggested layout to
achieve the alignment shown on the Drawings. The Contractor shall be ultimately
P:\zRAZMANN\SPEC\C-Handling of pipes and special1.doc
C.26
responsible for determining the number of set ups required to install the pipe to the
alignment shown on the Drawings. The number of setups shall be incidental to the
work.
The Contractor shall supply portable mud tanks or construct temporary mud pits to
contain excess drill fluids during construction. Spent drilling fluids and cuttings shall
be confined to the entrance and exit pits. The Contractor shall take all necessary
precautions to minimize the damage to the adjacent properties. Any drilling fluid that
enters the pipe shall be removed by flushing or other suitable methods. Upon
completion of the bore, contractor will dispose of any drill cuttings and excess drill
fluids in a manner consistent with the local and state regulations. If working in an area
of contaminated soil, the slurry shall be tested for contamination and disposed in
accordance with local and state regulations. The disposal of the drilling fluids and any
necessary flushing of the pipe shall be incidental to the work.
The Contractor shall be responsible for cleanup and restoration, due to hydro-fractures
from excessive pressure in the drilling fluid. Contractor shall prevent drilling fluids
from entering streams or other water bodies and municipal storm or sanitary sewer
lines (unless prior approval is obtained from the S.O). No additional payment shall be
made for cleanup costs required by S.O., or regulatory agencies due to loss of drilling
fluid.
Pits excavated to permit connection of bored pipe shall be backfilled, and disturbed
areas shall be restored to their original state or better. Sections of sidewalks, curbs,
and gutters or other permanent improvements damaged during horizontal directional
drilling operations shall be repaired or replaces at the Contractors expense. The
backfilling of the boring and receiving pits shall be incidental to the work.
C.27
GENERAL REQUIREMENTS
1.1
Scope
This section of the Specifications covers the requirements for the manufacture and
testing of welded steel pipes together with fittings complete with internal and
external protection systems.
1.2
Definition
The following terms shall have the meanings hereby assigned to them except where
the context clearly renders these meanings inapplicable.
Pipes means straight pipes, whether whole or in cut lengths.
Fittings or pipe specials means tees, bends, tapers, collars, flange adapters, blank
flanges, expansion joints, mechanical joints, ring girders and similar accessories.
1.3
5L
Line pipe
API
5LS
API
1104
BS Handbook 21
BS 12
BS 534
BS 903
BS 1154
BS 2494
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.1
1.4
BS 2569
BS 4147
BS 4232
BS 4360/Part 2/2169
BS 4504
BS 5292
BS 5500
AWWA Mll
BSEN 10025:93
BSEN 1092-1:2002
Submissions
The Contractor shall provide drawings, calculations and data in respect of the
following:For pipes and fittings:
-
drawings with descriptions to show the method of forming pipes and fittings in
standard lengths from steel sheets or strip
For joints:
-
drawings for spigot and socket joints showing allowable tolerances and
arrangements to permit air testing of completed joins on Site.
full details of method of lining and curing including details and sieve analysis
of materials to be used and type of cement.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.2
full details of coating process to be used, including details of the bitumen and
the inner and outer wrappings.
2.0
2.1
2.2
Steel Pipes
Steel pipes shall be manufactured, except where stated otherwise hereunder, in
accordance with API Specification 5L or API Specification 5LS. Material for pipes
shall be made from carbon steel plate to Grade 43A of BS 4360 Part 2 1969 or
better with a minimum lower yield stress of 245N/mm2 supplied in plate or strip
form as of appropriate for the method of pipe manufacture. The pipes shall be
formed by the automatic submerged arc process, with either a longitudinal seam or
a spiral seam at the option of the Contractor. With the method of manufacture
decided upon, the relevant standard will then apply i.e. API Specification 5L for
longitudinal seam pipe or API Specification 5LS for spiral seam pipe. The API
standards shall be referred to hereunder as Std 5L/S and shall be deemed to apply to
all pipe sizes, including those whose outside diameter (OD) falls outside the upper
limit covered by the standards.
The Contractor shall provide a ladle analysis of the steel used for the pipes in
accordance with Clause 6.1 of BS 4360 Part 2 1969. Check analysis of the finished
pipe shall be taken in accordance with Clause 6.2 of BS 4360 Part 2 1969 and
Clause 3.4 of Std. 5L/S. In case of dispute, the methods of chemical analysis shall be
in accordance with BS Handbook No.21.
At the discretion of the S.O. test certificates may be required from approved
independent inspection agencies for all materials used in the manufacture of the
pipes and specials and the cost of this shall be deemed to be included in the
Contract Rates.
With every consignment of pipes, valves and fittings delivered under this Contract,
the Contractor shall furnish a certificate worded as follows :This is to certify that the quality of the pipes, valves and fittings delivered in this
consignment is not inferior to the sample for which the Contract was awarded or
to the quality laid down in the Specification whichever is applicable.
The thickness of steel plates shall be in accordance with Table 1 subject to the
rolling margins for plates as shown in Table 4 of BS 4360 Part 2 :1969 unless
otherwise stated in the Bill of Quantities.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.3
The thickness of pipes used for branch pipe-work off the main pipelines or for use in
forming fittings shall be the greatest of the following :
The thickness necessary to provide the same outside diameter to wall thickness
ratio specified for straight pipes;
The minimum thickness shown in Table 6.2 of Std 5L or Table 6.1 of Std 5LS
for pipes of the appropriate diameter (or the nearest equivalent therein);
Standard length straight pipes shall be manufactured with not more than three
circumferential joints and with an effective length as shown in the table below:
Finished Internal Diameter (mm)
450 to 1200
Below 450
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
Finished
internal
Diameter
(mm)
93.7
149.1
204.0
257.8
313.8
361.7
415.5
469.4
522.7
628.0
651.2
701.2
801.2
901.2
1000.0
1100.0
1210.0
1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
1900.0
2000.0
2100.0
2200.0
Minimum
Steel Plate
Thickness
(mm)
4.1
4.1
4.1
4.1
5.8
5.8
5.8
5.8
5.8
6.5
7.4
7.4
7.4
7.4
8.0
9.5
10.0
11.0
11.0
13.0
13.0
13.0
13.0
13.0
14.0
14.5
15.0
Concrete
Lining
Thickness
(mm)
10
10
10
10
10
13
13
13
13
13
13
19
19
19
19
19
25
25
25
25
25
25
25
25
30
30
30
D.4
External
Diameter
(mm)
121.9
177.3
232.2
285.0
245.4
399.3
453.1
507.0
560.3
667.0
692.0
754.0
854.0
954.0
1054.0
1157.0
1270.0
1372.0
1472.0
1576.0
1676.0
1776.0
1876.0
1976.0
2088.0
2189.0
2290.0
Factory
Hydraulic
Test Pressure
(bars)
70
70
70
70
70
63
56
50
45
42
39
39
39
34
30
30
30
29
29
26
26
26
26
26
25
24
23
2.3
2.4
Jointing of Pipes
2.4.1
Pipe Ends
Ends of pipe to be jointed shall generally be as follows :
Spigots and sockets for jointing in trench or above ground for pipes and fittings
with diameter 700mm and above
Plain ends for use with welded collars, mechanical couplings or flange
adaptors for pipes and fittings with diameter 700mm and above
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.5
The spigot and socket joints for the spherical type shall be designed to take angular
deflection of up to 5 degrees from the axial to accommodate changes of pipe
gradient and/or direction at individual joints. For hemispherical type, the angular
deflection shall be up to 2 degrees.
Spigot and socket joints shall be of the spherical or hemispherical sleeve type with a
minimum penetration of the formed ends. The joint design shall provide for the
contact surface of the spigot end and the sleeve end to be formed to the same
spherical radius which shall be more than 50% of the outside diameter of the barrel
of the pipe for the spherical type and shall not be less than 50% of the outside of the
barrel of the pipe for the hemispherical type. The minimum penetration of the
spigot into the socket shall not be less than four times the pipe thickness and this
overlap shall be obtained at the maximum deflection of 2 to 5 degrees. At zero
deflection the minimum overlap shall be the minimum penetration as above
increased by such allowance as is necessary to ensure contact between the spigot
and socket over the specified maximum amount of joint movement. The joint
engagement tolerance in any position shall not exceed an average of 1.60 mm with
maximum isolated gaps of 2.00 mm adjacent to the weld seams.
Pipe ends of the spherical or hemispherical type shall be formed by hydraulic
pressing using a full circle die or expanding former capable of forming ends
consistently to a constant spherical contact surface through the pipe production run.
The internal surface of the socket and the external surface of the spigot shall be
ground smooth along the pipe axis.
The external surface of the plain ended pipes shall be similarly prepared.
All sockets shall have two tapped holes spaced at 90 degrees apart on the
circumference. They shall be of not less than 6mm diameter and shall be provided
with matching plugs to facilitate the air pressure testing of field welds. These tapped
holes shall be located within the end 30mm of the sockets and shall be cleared of
welding runs.
Ends prepared for butt welding shall be subject to manufacturing tolerances in
accordance with Table 6.3 of Std 5L or Table 6.2 of Std 5L/S.
Plain ends for use with mechanical joints or flange adaptor joints shall be truly
circular with a diameter tolerance of + 1mm over a distance of 225 mm from the
pipe ends.
2.5
Flanged Joints
All flanges shall be of steel, welded to the pipe by the electric arc process or other
approved method. They shall conform in all respects with the requirements of BS
4504 or BS 5500 unless otherwise specified. They shall be of the raised face type
and shall be truly faced over their whole width. Bolt holes shall be drilled off centre
lines, truly in line end to end with the longitudinal axis. All flanges shall be rated as
16 bar. All flanges shall be adequate to withstand test pressures for the fittings to
which they are attached.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.6
All materials required for use in the making of flanged joints including nuts, bolts,
washers and joint gaskets shall be supplied by the Contractor. The cost of this shall
be deemed to be included in the Contract Rates. Joint gaskets shall be contained
within the bolt pitch circle and shall be made from 4.5mm thick rubber to BS 1154
Class Y3 reinforced with two layers of fabric in accordance with BS 5292. Each bolt
shall be supplied and installed with a nut and two washers and each bolt shall be of
sufficient length to show two threads past the nut when so installed. All bolts and
nuts shall be stainless steel.
Test certificates for the flange material shall be supplied. The finish on flange joint
surfaces shall be in accordance with Clause 4.4 of BS 4504.
Blank flanges shall be designed and supplied by the Contractor for an end loading
equivalent to the rating pressure of the flange. Lifting eyes or handles and air release
cocks shall be provided where necessary.
Thrust flanges shall be designed to withstand a longitudinal force equal to the
loading applied to a blank flange of equivalent diameter.
2.6
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.7
2.7
2.8
Collars
Collars shall be provided for jointing cut pipes closure pieces or by means of
internal and external fillet welding. Minimum lengths of collars shall be 250mm.
Collars may be provided as single split collars with temporary bolts and lugs.
Collars shall have two tapped and plugged holes of not less than 6mm diameter to
permit air pressure testing of the joints after field welding, one on each side of the
collar clear of the welding runs and approximately 24mm from the edge of the
collar. The collar shall be 1.5mm thicker than the equivalent standard straight pipe
thickness.
Collars shall make close contact around the circumferences of both pipes connected
and the gap between the ends of a split collar after tightening shall not exceed 3mm.
Split collar ends shall be prepared for butt welding in the same manner as plain ends
of pipes prepared for butt welding in accordance with Std 5L/S. The tolerance of the
collars shall be such that nowhere shall the gap between the inside surface of the
collar and the outside surface of the pipe at fillet weld locations exceed the
tolerances permitted for spigot and socket joints.
The overlap on each pipe shall not be less than 75mm. Collar joints shall not be
required to take any deflection.
3.0
3.1
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.8
4.0
4.1
4.2
End Protection
The concrete lining and the external coating of pipes and fittings to be jointed by
welding shall be omitted for a sufficient distance from the ends to prevent damage to
the protection during site welding.
The unlined surfaces shall be protected with a suitably approved ensis oil or similar
material during manufacture so that extensive cleaning of the surface is not required
before and after jointing on site.
4.3
Handling
Coated pipes shall be lifted and moved only by wide non-abrasive slings or by other
means acceptable to the S.O. Wire ropes, chains and hooks shall not be permitted to
come in contact with the coating. No pipe shall be moved by rolling.
Coated pipes shall be stacked in one layer only and in such a manner that the
coating is not damaged. Adequate packing between pipes for this purpose must be
supplied by the Contractor. Coated pipes must be kept clear of the ground and
rested on padded sleepers or supports.
The pipes shall be so handled, stored and transported as to prevent undue distortion
and shall not be moved in any manner involving rotation of the pipes about the
longitudinal pipe axis.
The pipes shall be lifted by means of two reinforced canvas slings at least 300mm
suspended from a lifting beam so that the slings are positioned at a distance of onefifth of the pipe length from each end of the pipe.
The Contractor shall provide suitable timber end struts and sufficient intermediate
struts to strengthen the pipes to the S.O.s approval to prevent distortion during
handling and delivery.
4.4
Protection in Transit
All pipes and fittings shall be protected prior to dispatch from the manufacturers
works. All flanges shall have wooden discs bolted on. All other ends of pipes and
fittings shall be protected against impact damage and entry of foreign matter. The
protection shall take into account the end use intended for the pipes and whether or
not the final protection has been completed.
Pipes and fittings shall be wrapped or cushioned so that no load is taken directly on
the external coating.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.9
4.5
Inspection
All pipes and fittings to be supplied under the Contract shall be inspected by the
S.O. at the Contractors premises or at the places of manufacture if manufactured at
other premises.
The Contractor shall provide such office facilities, assistance, labour, materials,
electricity supply, fuel, stores, apparatus and instruments ultrasonic thickness
indicators and high voltage holiday detectors as may be necessary to allow a
thorough and extensive inspection to be carried out.
The S.O. shall be entitled at all times during manufacture to inspect, examine and
test on the Contractors premises or at the places of manufacture if manufactured at
other premises, the materials and workmanship of the pipes and fittings. Such
inspection, examination or testing including the inspection by the S.O. shall not
relieve the Contractor from any of his obligations under the Contract.
4.6
Truly circular pipes shall be marked with two longitudinal parallel bands throughout
their whole length.
The diameter and its consecutive number of standard length pipes shall be repeated
on the lining just inside on both ends of the pipes.
The item number and diameter of branch in the case of tees and the angle in
degrees in case of bends shall similarly be repeated on the lining.
4.7
Measurement
The quantities set out in the Bill of Quantities are provisional only and they are not
to be taken as the actual, limiting and correct quantities of the pipes and fittings to
be supplied by the Contractor in fulfillment of his obligations under the Contract.
For the purpose of this clause, spigot and socket ended pipes shall be measured and
paid in effective length. The effective length shall mean the net length of the pipe as
laid, i.e. after deduction of the length of overlap at any spigot and socket joint to be
made with the pipe. Plain ended pipes shall be measured and paid by the gross
length and pipe specials shall be measured by numbers. All pipes and specials shall
only be measured for payment after they have been laid and incorporated in the
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.10
works. Any excess pipes and specials supplied to the Site shall not be measured for
payment.
The cost of all works testing and all other requirements of the Specification
including lining, coating, wrapping, etc, involved in the manufacture and delivery of
the steel pipes shall be deemed to be included in the Contract Rates.
4.8
Miscellaneous
All flanged pipe ends, flanged branches and plain ends for use with mechanical
couplings or flange adaptors shall have a 6mm steel retaining ring welded into the
bore of the pipe flush with the end of the pipe after which the ring shall be zinc
chromate coated as specified followed by two coats of bituminous paint. The radial
thickness of the rings shall be similar to the thickness of the concrete lining and shall
not be less than 6mm.
4.9
Physical Testing
Unless otherwise specified physical testing of the pipes shall also be in accordance
with Section 4 Std 5L/S.
4.10
External Coating
The pipe shall be coated with bitumen generally in accordance with Clauses 29 of
BS 534 except that the protection shall have a minimum thickness of 6mm for pipes
over 324mm o.d. The bitumen shall be Type 2 of BS 4147 and there shall be not
less than 2mm of bitumen between the inner and outer wraps, and between the pipe
and the inner wrap.
The coating shall be stopped short as shown on the Drawing for ends of all spigot
and socket pipes, and 250mm from the ends of all plain ended pipes for use with
mechanical couplings or flange adaptors. The edge of the wrapping shall be
chamfered at 25 degrees.
4.11
Wrapping
The wrapping materials shall be spirally wound onto the pipes and fittings
simultaneously with the bitumen coating. Each wrap shall be from 150-225mm
wide and the edges shall overlap by 12-25mm. Care shall be taken to ensure that
the inner wrap does not come into contact with the pipe metal or with the outer
wrap.
The inner wrap shall be a glass fibre resin-bonded tissue reinforced in the
longitudinal direction with parallel glass threads space 10mm apart. The nominal
thickness shall be 0.5mm and the minimum weight shall 0.046kg/m2.
The outer wrap shall be of glass fibre resin-bonded tissue reinforced in the
longitudinal direction with parallel glass threads spaced 10-25mm apart. It shall be
impregnated with a material fully compatible with the bitumen coating to give a
finished thickness of 0.75mm.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.11
Peel-Off Test and Holiday Test in accordance to BS 534 shall be carried out at a
frequency of 1 in every 50 completed wrapping joints.
4.12
4.13
5.0
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.12
All straight pipes shall be concrete lined by the use of a lining machine designed
and built for the purpose of rotating the pipe and centrifugally applying the lining at
sufficient speeds to meet the requirements set out below. The support or holding
device for the pipe shall be such as to avoid damage to the pipe coating during the
spinning operation. If the pipe is rotated by direct contact drive from the machine it
shall be supported over at least 90 degrees of its circumference and driven by nonmetallic surfaced belts of sufficient width to avoid coating damage. The speed of
rotation of the pipe during the lining compaction stage shall be such as to provide a
radial acceleration of at least 250m/s2. The rotational drive shall be capable of close
control and provide smooth acceleration and deceleration when working up to and
down from the compaction spinning stage.
Immediately before lining commences, the pipe bore shall be cleaned of all loose
scale, rust, oil, grease or any other foreign matter likely to contaminate or harm the
concrete. Areas where an approved primer coat has bonded to the pipe such that
wire brushing does not cause areas to flake off will be acceptable as a base for
applying the lining.
The entire quantity of concrete required for the lining shall be continue until the
specified thickness is evenly distributed over the inside of the pipe, all surplus water
has been removed and the greatest possible density of concrete has been obtained.
Tolerance on the thickness of lining shall be as follows :
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.13
Linings applied to pipes shall be cured in such a manner as will enable concrete to
obtain and subsequently retain optimum strength, density and durability.
Linings shall be kept moist by continuous water spraying for a period of at least 3
days. They shall then be protected from sunlight and kept damp by spraying with
water or other means approved by the S.O. for a further period of 7 days. Pipes
shall not be removed from the factory until at least 14 days have elapsed from the
date of lining.
6.0
The edge of the lining shall be angled back at 3mm to the pipe axis in order to
provide a positive key for in-situ joint protection
Plain ends
-
For butt straps or collar joints the lining shall terminate 90mm back from the
pipe end. The edge of the lining shall be angled back at 3mm.
For mechanical coupling and flange adaptor joints, the lining shall be brought
right against the retaining rings.
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.14
GENERAL
This specification is applicable to Ductile Iron Pipes for water supply systems and
shall conform to BS EN 545:2002.
These specifications will provide necessary information on the product dimension
and requirements for the supply of pipes only.
2.0
PIPES
The pipe shall be manufactured with socket and spigot, plain-ends and flanged-ends
of Class 40 or Class K9.
For all specials/fittings, the products shall be of minimum Class K12.
All Ductile Iron Pipes and accessories shall be designed to withstand hydraulic
working pressure of PN 16.
All flanges shall be of ductile iron complying with BS EN 545 : 2002 or equivalent
standards.
3.0
MANUFACTURING PROCESS
Pipes and the accessories of Ductile Iron may subjected to suitable heat treatment in
order to give them the required mechanical characteristics or tensile properties as
shown below:-
CHARACTERISTICS
CENTRIFUGALLY CAST
PIPES
DN 100 to 800
TENSILE STRENGTH
( N/mm )
420 (Min)
ELONGATION
(%)
10 (Min)
HARDNESS
( HB )
230 (Max)
Table 1
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.1
FITTINGS
DN 100 to 800
420 (Min)
5 (Min)
250 (Max)
4.0
5.0
PIPE CLASS
(CLASS 40)
4.8
5.0
5.4
5.8
6.2
7.0
7.8
-
Application of zinc rich paint containing at least 90% of zinc by mass of dry
film; the mean mass of applied paint shall not less than 150g / m.
Bitumen coating shall not be less than 70m. It shall uniformly cover the whole
surface of metallic zinc layer and free from such defects as bare patches or lack of
adhesion. The uniformity of the finishing layer shall be checked by visual
inspection. Unless otherwise specified, the finishing layer of bituminous product
shall be coated externally with either one of the following :
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.2
Loose Polyethylene Sleeving shall be as specified in ISO 8180 : 1985 Ductile Iron
Pipes Polyethylene sleeving and ISO/DIS 8180 Ductile Iron Pipes for site
application.
The sleeving shall be fitted to effect a smooth, closely contoured envelope with
minimum barrels and socket gaps. There shall be sufficient slack in contouring to
allow the sleeving to follow the profile to the spigot socket interface to prevent
damage during backfill.
Adhesives tape shall be used to seal the free edges of sleeving. The function of the
tape is to inhibit ingress, circulation or passage of ground water inside the
encasement adjacent to the pipe.
The seal is recognized as not only being watertight but still effective in severely
limiting ground water flow.
To assist handling during application and installation, the free edge of the fold shall
be circumference taped at one meter intervals along the barrel of the pipe.
Any damage to the sleeving shall be repaired using tape and cut sections of sleeving
before back filling.
6.0
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.3
The required thickness of the cement mortar lining and its tolerance shall be as
stipulated in Table 2.
NOMINAL DIAMETER
(DN)
MAXIMUM CRACK
WIDTH AND RADIAL
DISPLACEMENT
NOMINAL
VALUE
LIMIT
DEVIATION*
40 to 300
- 1.5
0.4
350 to 600
- 2.0
0.5
7.0
8.0
9.0
PACKING
All ductile iron pipes shall be individually packed with proper methods and
protected from damage during transit.
10.0
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.4
11.0
Serial Number
12.0
CERTIFICATION
Manufacturers or Suppliers are required to provide a copy of the certificate and test
reports either from SIRIM, IKRAM or other recognized certification bodies.
Test reports required shall be those tests conducted within a period of a year.
SYABAS reserved the right to refuse offer or reject supply if the relevant documents
are not enclosed.
13.0
13.1
Jointing Instruction
Before assembling the joint, the spigot of the pipe and interior of socket of the
adjacent pipe shall both be thoroughly cleaned.
Insertion of Gasket
The gasket shall be wiped clean and flexed and then placed in the socket with bulb
leading. The groove in the gasket must be located on the retaining bead in the
socket, and the retaining heel of the gasket firmly bedded in its seat so that the heel
of the gasket is not proud of the mouth of the pipe. The Contractor shall ensure the
gasket fits evenly around the whole circumference, removing any bugles that
prevent the proper entry of the spigot end.
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.5
Lubrication
A thin film of lubricant is then applied to the inside surface of the gasket which will
be in contact with the entering spigot. In addition, a thin film of lubricant should be
applied to the outside surface of the spigot end.
Initial Entry of Spigot
The spigot of the pipe jointed must be aligned and entered carefully into the
adjacent socket until it makes contact with the gasket. Final assembly of the joint is
completed from this position.
Completely Assembled Joint
Joint assembly is completed by forcing the spigot end of the entering pipe past the
gasket, which is this compressed, until the first painted strip on the end of the pipe
disappear and the second painted strip is approximately flushed with the socket
face. If joint is difficult to assemble, the spigot should be removed and rotated 90
degree before attempting to assemble a second time. If the joint is still difficult to
assemble, the spigot should be removed and the gasket examined.
Deflection
The joints can be deflected in any directions up to 5 degree for pipes up to 300mm
diameter nominal size, up to 4 degree for 350mm and 400mm size and up to 3
degree for 450mm to 700mm.
All spigot must be chamfered.
When making a joint, pipes should always be in line and if required, deflection
made after jonting.
13.2
Method of Assembly
Assembly of the joint shall simple, and may accordingly be carried out by any of the
following methods:Crowbar Method
Complete entry of the spigot into the socket may be obtained by pushing with a
crowbar or a suitable lever against the face of the socket of the entering pipe.
Fork Tool Method
This method may be used for 100mm and 150mm pipe. The fork is placed over and
behind the socket of the last pipe laid. A wire rope with eye at one end and a hood
at the other is connected to the socket of the pipe to be jointed. The fork is now
pulled in direction of arrow and the spigot enters the socket. Reasonable force shall
only be used.
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.6
14.0
CUTTING
Ductile iron pipes can be cut by a number of methods.
Where flexible joints are to be made, the cut ends must be trimmed with a file or
grinder to remove the burr formed during cutting and a chamfer must be provided.
A Power Driven Abrasive Disc can be used and is suitable for all sizes. There is no
need for adjustment to suit pipe size or to attach machinery to the pipe. The
abrasive discs are fitted to suitable hand held power tools usually driven by
compressed air or small internal combustion engines.
Semi-Rotary Wheel Type Cutters are available, ranging from the standard chain link
cutters to more sophisticated tools employing a rigid hinged frame. This type of
cutter is normally used on smaller diameter pipe.
It is important when ordering abrasive disc cutting equipment to state that it is for
use with ductile iron pipe and to ensure that the disc type, size and the spindle
speed of the equipment are compatible.
Rotary and Orbital Pipe Cutters, using cutting tools of the simple lathe or milling
saw type respectively, are available throughout the diameter range. Whichever type
of cutter is employed the basic machine is attached to the pipe and the cutting tool
is driven around the pipe by means of gears on a chain link track. The orbital type
cutters have the advantage on the larger sizes of ductile iron pipe in that they a
capable of accommodating the avolities which are sometimes present. Some are
also capable of forming the chamfer in the same operation. These types of machine
are usually driven mechanically, e.g. by compressed air motor although for pipes in
the smaller diameter a hand-operated windlass may be employed. In machines
using lathe type cutting tools, the cutter heads must have a 7 front rake.
Reciprocating Power Saws may also be used for cutting ductile iron pipe. These
tools are usually electrically driven and for this reason they are principally used in
depots or workshop where power supply is available.
The pipe DN<300 the external diameter (measured circumferentially) enable
assembly of the joint over a minimum of two thirds of pipe length from the spigot
end when the pipes need to be cut on site. For pipes DN>350 the same applies to
a percentage of the pipes.
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.7
a)
Nominal
size DN
350
400
450
500
600
Measured circumferentially
with standard tape
Maximum
Maximum
mm
mm
379
374.5
430
425.5
481
425.5
533
528.5
636
631.0
A diameter tape is calibrated to enable diameters to be read off directly when the
pipe is measured circumferentially.
After cutting the pipe check the cut end and where is found to be oval, locate
and mark the major axis. Measure the length of the major axis. Only where
this exceed the dimensions specified in the table, will ovality correction be
required prior to jointing.
Note : Cut spigot joint must be chamfered
Maximum major axis of spigot ends
Nominal size
DN
350
400
450
500
600
700
b)
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.8
15.0
OVALITY CORRECTION
Two methods are recommended for ovality correction.
Method A
The use of this method is recommended where it is possible to remove the tackle
after ovality correction and subsequent jointing.
Position the timber strut and jack (approximately 5 tons capacity) inside the spigot
end of 90 degree to the major axis. Rubber pads should be placed in position to
prevent possible damage to the pipe lining. Extend the jack until the major axis has
been reduced to the appropriate limit specified in the table. Complete the jointing
operation with the major axis of the spigot vertical.
Note : In some instances, e.g. jointing into couplings, it may be necessary to use
two jacks in order to obtain a `round profile.
Method B
The use of this method is recommended where it is not possible to remove the
tackle described in Method A. After ovality correction and subsequent jointing,
place the tackle around the spigot end of the pipe at a position approximately
450mm from the pipe end and with major axis of the spigot the re-rounding tackle
and protection system to prevent damage.
Tighten the two nuts evenly until the major axis has been reduced to the appropriate
limits specified. Complete the jointing operation with the major axis of the spigot
vertical. After jointing, remove the tackle.
Note : Where the pipes are to be concreted into a structure they should, if
necessary be re-round before this is done and left until the concrete has set, before
the re-rounding tackle.
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.9
GENERAL
This specification is applicable to High Density Polyethylene (HDPE) Pipe for water
supply systems and shall conform to JKR Standard Specification JKR 202000-0053-99
and MS 1058:2002.
Relevant standards are:BS 4505
Specification for flanges and bolting for pipes, valves & fittings.
Metric series.
BS EN 545
BS 970 Pt. 1
AS 1646
MS 672:99
BS 5292
BS 2789
BS EN 1563
BS EN 10025
BS 3643
BS 4190
BS 6681
BS 6920
AS/NZS 4158
WIS 4-52-03
F.1
2.0
ISO 12162
ISO 12176-1:98
EN 712
EN 713
EN 715
EN 921
ISO 13953:1995
ISO 13954:1997
ISO 13955:1997
ISO 13956:1995
MATERIAL
The High Density Polyethylene (HDPE) Pipe shall be made from base polymer and shall
conform to the requirements as specified in MS 1058 Part 1:2002.
The base polymer shall be a single grade of polyethylene, PE 80 with a derived density
greater than 0.93g/cm tested at 20 C.
No rework material is allowable for the manufacture of the pipes.
No additives that may contribute to toxic hazard, impair the fabrication of properties
and chemical and physical properties in particular to long term mechanical and strength
is allowed.
3.0
COLOUR
F.2
The colour of the pipes shall be black with blue stripes. The material for stripes shall be
of the same type of resin as used in the compound for the pipe.
4.0
WALL
THICKNESS
(mm)
2.0
2.3
3.0
3.7
4.6
5.8
6.8
8.2
10.0
11.4
12.7
14.6
16.4
18.2
20.5
22.7
25.4
28.6
32.2
36.3
40.9
45.4
50.8
57.2
INTERNAL
DIAMETER
(mm)
18
22.7
29
36.3
45.4
57.2
68.2
81.8
100
113.6
127.3
145.4
163.6
181.8
204.5
227.3
254.6
286.4
322.8
363.7
409.1
454.6
F.3
OUTSIDE
DIAMETER
(mm)
20
25
32
40
50
63
75
90
110
125
140
160
180
200
225
250
280
315
355
400
450
500
5.0
TOLERANCE
The tolerance for wall thickness is determined by the difference between the wall
thickness and the nominal wall thickness as follow:
PN 12.5
NOM. DIAMETER
FOR OTHER PIPES
(mm)
WALL
THICKNESS
(mm)
Min
WALL
THICKNESS
(mm)
Max
WALL
THICKNESS
(mm)
Min
WALL
THICKNESS
(mm)
Max
2.0
2.3
3.0
3.7
4.6
5.8
6.8
8.2
10.0
11.4
12.7
14.6
16.4
18.2
20.5
22.7
25.4
28.6
32.2
36.3
40.9
45.4
50.8
57.2
2.3
2.7
3.4
4.2
5.2
6.5
7.6
9.2
11.1
12.7
14.1
16.2
18.2
20.2
22.7
25.1
28.1
31.6
35.6
40.4
45.1
50.1
56
63.1
2.0
2.3
3.0
3.6
4.5
5.6
8.4
10.1
12.3
14.0
15.7
17.9
20.1
22.4
25.2
27.9
31.3
35.2
39.7
44.7
50.3
55.8
2.3
2.7
3.4
4.1
5.1
6.3
9.4
11.3
13.7
15.7
17.4
19.8
22.3
26.0
27.9
30.8
34.6
38.9
43.8
49.3
55.5
61.5
20
25
32
40
50
63
75
90
110
125
140
160
180
200
225
250
280
315
355
400
450
500
560
630
6.0
PN 16
LENGTH
The required length of HDPE pipes in coil for nominal diameter 63 mm and below will
be100 meter.
The standard length of HDPE pipes for nominal diameter 125 mm and above shall be
9m or 12m.
7.0
APPEARANCE
The internal and external surfaces of pipes must smooth, clean and free from scoring,
cavities and other surface defects which may affect pipe performance.
The ends of pipe shall cut cleanly and square to the axis of the pipe. Appearance shall
be checked at the point of manufacture.
F.4
8.0
ROUTINE TESTS
The pipe suppliers shall, as and when requested by the S.O., furnish results of the
routine tests carried out in accordance with the requirements as stipulated in MS 1058:
Part 1 : 2002.
The minimum Oxidation Induction Time (OIT) for pipes fitting shall be 80 min. The
manufacturer must have their own differential Thermal Analyzer or Differential
Scanning Calorimeter available for SYABAS representatives to carry out the OIT.
9.0
PIPE MARKINGS
All pipes must have the following markings:
10.0
PIPE FITTINGS
10.1
10.2
Spigot fittings
Electro-fusion fittings and
Mechanical fittings and joints
Spigot Fittings
Spigot fittings fall under three classes as shown below.
Class
Description
Moulded
Fabricated
o PE 80 min. (PN 12.5 pressure rating)
The dimensions of spigots up to and including nominal size 63 shall conform to the
requirements of standards.
F.5
10.3
Electro-fusion Fittings
Electro-fusion fittings shall be injection moulded fittings made of PE but incorporating
integral heating element(s) to enable fusion jointing with PE pipes. All PE100 fittings shall be
jointed by couplers only.
10.4
General
Metal and plastic fittings available for use with PE pipe are:
The materials and constituent elements used in making the fitting (including elastomers,
greases and any metal parts) shall be as resistant to the external and internal environments
as the other elements of the piping system and shall have a life expectancy under the
following conditions as least equal to that of the PE pipe conforming to MS 1058 or EN
12201-3 with which they are intended to be used :
a)
During storage;
b)
Under the effect of the fluids being conveyed;
c)
Taking account of the service environment and operating conditions.
The requirements for the level of material performance for non-polyethylene parts shall be
at least as stringent as that of the PE pipe systems.
All mechanical joints and fittings shall be of approved types designed specifically for PE
pipe system. They shall be supplied with all necessary coupling rings, nuts, bolts, washers,
rubber rings/sealing gaskets and restrainers/stiffeners.
All mechanical joints, fittings and systems shall conform to the requirements specified in MS
1058 or BS EN 12201-5 of Table below as applicable.
Characteristics for fitness for purpose of the joint, fitting of system
Test Method
Characteristics
o
Hydrostatic strength at 80
EN 921
Cohesive resistance for
ISO 13954
Electro fusion
ISO 13955
Socket fittings
ISO 13956
For electrofusion saddle fittings
Resistance to tensile force
ISO 13953
Mechanical joints
Leak tightness under internal pressure
EN 715
Leak tightness under internal pressure when
EN 713
Subjected to bending (up to and
including 63mm)
External pressure text
EN 911
Resistance to pull out under constant
EN 712
longitudinal force
F.6
ii)
Plastic Parts
All fittings/components shall conform to the relevant EN standards. Alternative
standards may be utilized in cases where suitable EN standards do not exist provided
a fitness for purpose can be demonstrated.
iii)
Metal Parts
All metal parts shall be made of ductile iron (BS 2789) of Grade 420/12) or carbon
steel (BS EN 10025 Grade S275, S355JR or BS 4360 43A) or stainless steel (BS970
Part1). No gray cast iron shall be used.
All metal components (except parts made of stainless steel BS 970) of the mechanical
joints and fittings shall undergo the necessary surface preparation for polyamide
coating purposes. Bituminous coating is not allowed. Either one of the following
polymeric coating is acceptable:
For coating using cold applied high solid liquid epoxy (solvent or solventless)
which meet the requirement of AWWA C210-84, the coating thickness shall not
be less than 356 m.
Elastomers
The rubber wedge joint rings shall have a hardness range of 66-75 IRHD and shall
meet the requirements as detailed in MS 672-1999 or AS 1646 : 1992
Flange gaskets shall be of flat section minimum 5mm thick (medium grade) (Hardness
60 5 RHD) rubber reinforced with two-ply flexible fabric and complying with BS
5292.
v)
vi)
F.7
10.5
Material
Materials used shall not to be inferior to:-
ii)
a)
Ductile Iron
b)
Carbon Steel
Drilling Detail
Flanges shall be machined and still to BS 4504/BS EN 545 Table 16 and shall be
protected from corrosion as in clause Metal Parts
iii)
Dimension
Dimension of backing Ring made of ductile iron or carbon steel shall be shown below
Dimension of Backing Ring (Slip on Flange ) to suit PE Pipe
Pipe
O.D
Nominal
Bore
Flange
O.D.
D
Flange
I.D.
C
Pitch
Circle
Diameter
K
Diameter
of Bolt
Hole
H
50
63
75
90
40
50
65
80
150
165
185
200
62
78
92
108
110
125
145
160
110
125
160
180
100
100
150
150
220
220
285
285
128
135
178
188
200
225
250
280
200
200
250
250
340
340
405
405
315
355
400
450
300
350
400
450
500
560
630
500
600
600
Bolt
Flange Thickness
T
Carbon
Ductile
Steel
Iron
Size
Nos
18
18
18
18
16
16
16
16
4
4
4
8
16.0
18.0
18.0
20.0
19.0
19.0
19.0
19.0
180
180
240
240
18
18
22
22
16
16
20
20
8
8
8
8
20.0
20.0
22.0
22.0
19.0
19.0
19.0
19.0
235
238
288
294
295
295
355
355
22
22
26
26
20
20
24
24
12
12
12
12
24.0
24.0
26.0
26.0
20.0
20.0
22.0
22.0
460
520
580
640
338
376
430
517
410
470
525
585
26
26
30
30
24
24
27
27
12
16
16
20
28.0
32.0
36.0
40.0
24.5
26.5
28.0
30.0
715
840
840
533
618
645
650
770
770
33
36
36
30
33
33
20
20
20
44.0
52.0
52.0
31.5
36.0
36.0
F.8
iv)
Workmanship
a)
All casting shall be homogenous, smooth and shall be free from flaws, cracks,
blowholes, cuts or other harmful defects. All surfaces in close proximity to the
pipe shall be smooth and free from sharp edges.
b)
All steel flanges cut from plate shall have their surfaces machine finished and
shall be free from surface defects.
10.6
Storage
10.6.1
Storage at Depot
All materials should be carefully inspected at the time of delivery and any defective material
set-aside before accepting the delivery into stores. The defective materials should be return
to the suppliers immediately.
Pipes and fittings should be used in the order of delivery to ensure the correct rotation of
stock.
All pipe stacks should be made on sufficiently firm, flat ground to support the weight of the
pipes and any necessary lifting equipment. Stacking heights should generally be kept to a
minimum and adequate space allocated for lifting machinery to manoeuvre without causing
accidental damage.
For safety and convenience of handling the stacking height of bundles should not be more
than 3m. To prevent possible deformation of the pipes, bundles must be stored timber to
timber.
For similar reasons, pipe coils should be stored flat and the number of coils per stack should
be limited to:
Where individual pipe lengths are stacked in pyramidal fashion, deformation may occur in
the lower layers. Such stacks should therefore be not greater than 1m high.
Electro-fusion and compression fittings should be stored under cover, preferably on racking
and in the manufacturers protective wrapping or cartons which should be kept intact until
the fitting is required for use except spigot fittings.
At all times pipes and fittings should be stored away from exhaust outlets and all other high
temperature sources. Care should also be taken to avoid contact with lubricating or
hydraulic oils, gasoline, solvents and other aggressive chemicals.
All special tool and equipment associated with the jointing of pipes and fittings should be
stored separately and securely until they are required for use.
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- High Density1.doc
F.9
10.6.2
Storage on Site
All pipe store locations should be on suitably firm, level ground, free from damaging
material with adequate access for construction vehicles and/or lifting equipment.
In all storage sites, careful consideration should be given to the following aspects:
Security of all materials and equipment from theft, vandalism, accidental damage or
contamination.
Safety of pedestrians.
When stringing is adopted, pipes should be placed well clear of the excavators and away
from excavated material area. They should be wedged to prevent accidental movement.
Where necessary protective barriers complete with adequate warning signs and lights
should be erected.
11.0
12.0
12.1
General
Polyethylene pipes are characterized by being tough and resilient and are relatively light.
Though it is easy to handle, they are prone to damage by scoring by sharp objects.
Therefore, careful handling is always required and the dragging of straight pipes and coils
should be avoided whenever possible.
The maximum allowance depth of scoring of the external surface of the pipe is 5% of the
wall thickness. Pipes and fittings showing obvious defects, excessive scoring or sharp deep
cut even if less than 5% of the wall thickness should be withdrawn and returned to the
suppliers.
Pipes up to 125mm are usually supplied and delivered loose or strapped into convenient
bundles or banded coils. Fittings are normally supplied in separate bags or cartons/pallets.
F.10
12.2
12.3
Off Loading
12.3.1
Bundled Pipes
When lifting by crane, non-metallic wide band slings or ropes should be used. For pipe
length greater than 6m, load spreading bars of a length at least equivalent to one quarter of
the length of the pipe or bundlepack should be employed.
Chains or end hooks should not be used. Care should be taken to avoid damage to pipes
and pipe ends during lifting.
Some bending should be allowed for in the middle of the lift when loading and unloading
pipes. However to avoid excess bending, lifting points should always be well and evenly
spaced.
Six meters long bundlepacks may be handled by fork lift trucks but the positioning of the
forks shall cause minimum bending of the pipes.
Bundlepacks longer than 6m long should be handled either by side loader with a minimum
of four supporting forks, or by a crane using a spreader beam and suitable slings. Off
loading on site may be made easier by using skid timbers and rope slings.
12.3.2
Coiled Pipes
Coils of pipes can be handled by fork lift truck. Where individual coils are too heavy for
manual lifting, a fork lift truck with suitable protected boom attachments should be used.
They should NOT be rolled off the edge of loading platforms or trailers.
Complete coils are secured by outer and intermediate bands and individual layers are also
independently secures. Plastic tape at least 10mm wide should be used for banding.
F.11
The bands should not be removed until the pipe is required for use. The bands securing the
outer end of the pipe should be removed first and the movement of the free end carefully
controlled. This should be followed by those securing successive layers, and only those
bands necessary to release the length of pipe immediately required should be cut and
removed.
When removed from the coil or drum, the pipe will be oval and curved. Although both
ovality and curvature will reduce with time, special tools are available a facilitate handing
and jointing.
12.3.3
Fittings
Hocks should not be used to lift fittings which are generally supplied with cardboard boxes.
Special care should be taken in the handing of pup fittings to ensure that the weight of the
fittings is not transferred to the fabricated joint.
13.0
CERTIFICATION
Manufacturer or supplier is requirement to provide a copy of the certificate and test
report either from SIRIM, IKRAM or other recognised certification body.
Test reports should be those tests conducted within a year period.
SYABAS reserved the right to refuse offer or reject supply if the necessary documents are
not enclosed.
14.0
15.0
15.1
General
Butt fusion is process of welding HDPE pipes and fittings using an electrically heated
plate. It is suitable for jointing HDPE pipes and fittings of size from 110 : OD and
above. However, only pipes and fittings of the same material type, size and rating shall
be butt welded, e.g. PE 100 pipes should not currently be welded to PE 80 pipes. PN 10
pipe should not be welded to PN 6 pipe or fitting.
The following table shows the recommended conditions.
F.12
Single pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
90
90
90
90
90
21
17.6
13.6
11
9
(mm)
4.3
5.1
6.6
8.2
10
(MPa)
0.150
0.150
0.150
0.150
0.150
(mm)
2
2
2
2
2
(seconds)
105
110
125
140
160
(MPa)
0
0
0
0
0
(seconds)
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
110
110
110
110
110
110
21
17.6
17
13.6
11
9
5.2
6.3
6.5
8.1
10.0
12.2
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
115
125
126
141
160
185
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
15.0
15.0
15.0
15.0
20.0
8
9
9
9
10
10
15
16
16
16
17
17
125
125
125
125
125
125
21
17.6
17
13.6
11
9
6.0
7.1
7.4
9.2
11.4
13.9
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
120
130
145
150
175
199
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
15.0
15.0
15.0
15.0
20.0
8
9
9
9
10
11
16
16
16
16
18
18
21
140
17.6
140
17
140
13.6
140
11
140
9
140
Tolerance
6.7
8.0
8.2
10.3
12.7
15.6
0.150
0.150
0.150
0.150
0.150
0.150
0.02
2
2
2
2
2
2
125
140
145
165
185
215
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
15.0
15.0
15.0
20.0
20.0
20.0
9
9
9
11
10
11
16
16
16
18
17
18
Outside
diameter
SDR
Soak Time
F.13
Cooling
Time in
Clamps
Min
Max
(Minutes)
15.0
15.0
15.0
15.0
20.0
(mm)
8
8
9
9
9
(mm)
15
15
15
16
16
Single pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
160
160
160
160
160
160
21
17.6
17
13.6
11
9
(mm)
7.6
9.1
9.4
11.8
14.8
17.8
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
(mm)
2
2
2
2
2
2
(seconds)
135
150
154
180
205
240
(MPa)
0
0
0
0
0
0
(seconds)
10
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
180
180
180
180
180
180
21
17.6
17
13.6
11
9
8.6
10.2
10.6
13.2
16.4
20.0
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
145
160
165
195
225
260
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
10.0
20.0
20.0
20.0
20.0
35.0
9
10
10
10
11
12
16
17
17
17
18
19
200
200
200
200
200
200
21
17.6
17
13.6
11
9
9.5
11.4
11.8
14.7
18.2
22.2
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
155
175
180
205
240
285
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
20.0
20.0
20.0
20.0
35.0
9
10
10
11
11
12
16
17
17
18
19
19
225
225
225
225
225
225
21
17.6
17
13.6
11
9
10.7
12.8
13.2
16.5
20.5
25
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
170
190
195
225
265
310
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
20.0
20.0
20.0
35.0
35.0
9
10
10
11
12
15
16
17
17
18
19
24
21
250
17.6
250
17
250
13.6
250
11
250
9
250
Tolerance
11.9
14.2
14.7
18.4
22.7
27.8
0.150
0.150
0.150
0.150
0.150
0.150
0.02
2
2
2
2
2
2
180
200
210
245
285
340
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
20.0
20.0
20.0
20.0
35.0
35.0
10
11
11
11
15
16
17
18
18
19
24
25
Outside
diameter
SDR
Soak Time
F.14
Cooling
Time in
Clamps
Min
Max
(Minutes)
15.0
15.0
15.0
20.0
20.0
20.0
(mm)
9
10
10
10
11
11
(mm)
16
17
17
18
18
19
Single pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
315
315
315
315
315
315
21
17.6
17
13.6
11
9
(mm)
15.0
17.9
18.5
23.2
28.6
35.0
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
(mm)
3
3
3
3
3
3
(seconds)
210
240
245
290
345
410
(MPa)
0
0
0
0
0
0
(seconds)
10
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
355
355
355
355
355
355
21
17.6
17
13.6
11
9
16.9
20.2
20.9
26.1
32.3
39.4
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
230
260
270
320
380
455
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
35.0
35.0
35.0
45.0
45.0
14
15
15
16
18
19
23
24
24
25
27
28
400
400
400
400
400
400
21
17.6
17
13.6
11
9
19.0
22.7
23.5
29.4
36.4
44.4
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
250
285
295
355
425
505
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
35.0
35.0
35.0
45.0
55.0
14
15
15
16
18
20
23
24
24
25
27
29
450
450
450
450
450
450
21
17.6
17
13.6
11
9
21.4
25.6
26.5
33.1
40.9
50.0
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
274
316
325
390
470
565
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
35.0
35.0
35.0
45.0
55.0
65.0
15
16
16
18
19
22
24
25
25
27
28
31
21
500
17.6
500
17
500
13.6
500
11
500
9
500
Tolerance
23.8
28.4
29.4
36.8
45.5
55.6
0.150
0.150
0.150
0.150
0.150
0.150
0.02
3
3
3
3
3
3
300
345
355
430
515
620
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
35.0
35.0
35.0
45.0
55.0
65.0
15
17
17
18
20
22
24
26
26
27
29
31
Outside
diameter
SDR
Soak Time
F.15
Cooling
Time in
Clamps
Min
Max
(Minutes)
20.0
20.0
20.0
35.0
35.0
45.0
(mm)
13
14
14
15
17
18
(mm)
22
23
23
24
26
27
Single pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
560
560
560
560
560
21
17.6
17
13.6
11
(mm)
26.7
31.8
32.9
41.2
50.9
(MPa)
0.150
0.150
0.150
0.150
0.150
(mm)
3
3
3
3
3
(seconds)
325
375
390
470
570
(MPa)
0
0
0
0
0
(seconds)
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
630
630
630
630
630
21
17.6
17
13.6
11
30.0
35.8
37.1
46.3
57.3
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
360
415
435
525
630
0
0
0
0
0
15
15
15
15
15
0.150
0.150
0.150
0.150
0.150
35.0
45.0
45.0
55.0
65.0
17
18
18
20
23
26
27
27
29
32
710
710
710
710
21
17.6
17
13.6
33.8
40.3
41.8
52.2
0.150
0.150
0.150
0.150
3
3
3
3
400
460
480
580
0
0
0
0
15
15
15
15
0.150
0.150
0.150
0.150
45.0
55.0
55.0
65.0
17
19
19
22
26
28
28
31
800
800
800
800
21
17.6
17
13.6
38.1
45.5
47.1
58.8
0.150
0.150
0.150
0.150
3
3
3
3
440
510
535
650
0
0
0
0
15
15
15
15
0.150
0.150
0.150
0.150
45.0
55.0
55.0
65.0
18
20
20
23
27
29
29
32
900
900
900
21
17.6
17
42.9
51.1
52.9
0.150
0.150
0.150
3
3
3
490
570
595
0
0
0
15
15
15
0.150
0.150
0.150
55.0
65.0
65.0
19
22
22
28
31
31
21
1000
17.6
1000
17
1000
Tolerance
47.6
56.8
58.8
0.150
0.150
0.150
0.02
3
3
3
535
625
655
3
0
0
0
15
15
15
0.150
0.150
0.150
0.02
55.0
65.0
65.0
20
23
23
29
32
32
Outside
diameter
SDR
Soak Time
F.16
Cooling
Time in
Clamps
Min
Max
(Minutes)
35.0
45.0
45.0
55.0
65.0
(mm)
16
17
17
19
22
(mm)
25
26
26
28
31
Dual pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Outside
diameter
SDR
(mm)
Cooling
Interface
Stress
(after 10s)
Cooling
Time in
Clamps
(seconds)
Fusion
and
Cooling
Interface
Stress
(MPa)
(MPa)
Initial
Bead Size
(approx.)
Soak
Time
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
(MPa)
(mm)
(seconds)
(MPa)
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
(mm)
Typical Final
Overall Bead
Width
Min
(mm)
Max
(mm)
15
16
17
24
25
25
0
280
315
11
11
11
22.7
25.5
28.6
0.150
0.150
0.150
3
3
3
285
315
345
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
(Minute
s)
35.0
35.0
35.0
355
355
355
26
17.6
11
13.7
20.2
32.3
0.150
0.150
0.150
3
3
3
195
260
385
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
13
15
18
22
24
27
400
400
400
26
17.6
11
15.4
22.7
36.4
0.150
0.150
0.150
3
3
3
215
285
425
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
14
15
18
23
24
27
450
450
450
26
17.6
11
17.3
25.6
40.9
0.150
0.150
0.150
3
3
3
235
315
470
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
14
16
19
23
25
28
500
500
500
26
17.6
11
19.2
28.4
45.5
0.150
0.150
0.150
3
3
3
250
345
515
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
29.0
35.0
55.0
15
17
20
21
26
29
560
560
560
26
17.6
11
21.5
31.8
50.9
0.150
0.150
0.150
3
3
3
275
380
570
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
35.0
45.0
65.0
15
17
22
24
26
31
630
630
630
26
17.6
11
24.2
35.8
57.3
0.150
0.150
0.150
3
3
3
300
420
635
0
0
0
15
15
15
0.150
0.150
0.150
0.025
0.025
0.025
35.0
45.0
65.0
16
18
23
25
27
32
710
710
26
17.6
27.3
40.3
0.150
0.150
3
3
335
465
0
0
15
15
0.150
0.150
0.025
0.025
35.0
55.0
16
19
25
28
900
900
26
17.6
34.6
51.1
0.150
0.150
3
3
405
570
0
0
15
15
0.150
0.150
0.025
0.025
45.0
65.0
18
22
27
31
26
1000
17.6
1000
Tolerance
38.5
56.8
0.150
0.150
0.02
3
3
445
630
3
0
0
15
15
0.150
0.150
0.02
0.025
0.025
0.01
45.0
65.0
18
23
28
32
F.17
15.2
b)
Hydraulic/pneumatic unit
The unit shall be capable of actuating the clamp unit to provide adequate force
and speed of operation. A pressure monitoring device shall be provided to
monitor ram pressure.
Unless an automatic machine is used, a data plate permanently attached to the unit
setting out jointing and cooling pressures and times for specified sizes of pipe.
Note : It is very important that welding machine can control the secondary pressures
accurately as these will sometimes be only slightly greater than the drag pressure.
(c)
Trimming tool
The trimming tool shall be capable of being mounted securely within the frame of
the jointing machine, so that this equipment can produce accurately matched
planed faces.
Trimming blades of the planer shall be sharp and have defect free cutting edges to
provide continuous swarf of uniform thickness.
(d)
Heater Plate
The plate shall be electrically heated and shall be provided with a suitable
temperature controller to give a uniform surface temperature of 210 (+10 / 5)
o
C.
The plate surface shall have a permanent coat of anti-stick material. ADDITIONAL
SPRAY-ON RELEASE AGENTS SHALL NOT BE USED. The surface shall be free
from any contaminants.
The plate shall be fitted with an accurate temperature probe or indicator, accurate
to within 2 oC in the range of 200o 240oC. The temperature on both sides of
the circumference shall be measured using a digital thermometer with an
appropriate surface probe.
(e)
Control system
F.18
The control system shall be designed to carry out the operations as far as possible
automatically at the temperature, time and pressures indicated as required.
bead roll
over
bead roll
over
Interface
stress
(MP a)
Interface
stress
(MP a)
Initial
bead-up
COOLINGTIME
Initial
bead-up
COOLINGTIME
0.15
MP a
0.15
MP a
0.025
MP a
Heat Soak
Heat Soak
Time
Time
Heater plate
removal
Heater plate
removal
Shelter
A shelter shall be used to provide adequate protection for pipe, fittings and
equipment against adverse weather conditions and contamination.
(g)
(h)
Generator
The generator shall be selected to suit the butt fusion machine capacity and heater
plate rating. The specification of the generator shall be supplied by the machine
manufacturer
(i)
Ancillary equipment
The following equipment shall be made available on site :
(a) Pipe support rollers
(b) Pipe cutters
(c) Digital thermometer with probe
(d) Timer
(e) Indelible Marker pen for marking beads
(f)
Bead gauge
(g) Saw and saw guide
(h) Pipe end cover
(i)
Spirit level to ensure machine is level
(j)
Ground sheets or base boards
(k)
F.19
15.2.1
Definitions
Fusion pressure and cooling pressure : the pressure ( in bar ) required to provide,
on a given machine and for a given size and rating of pipe, an interface stress of
0.15MPa or 0.025MPa as appropriate. This pressure is a function of the ram
dimensions and the efficiency of the machine.
Butt-fusion welding machine shall capable of being programmed according to the
size and rating of the pipe and /or fitting.
Drag pressure : the minimum pressure ( in bar ) required to overcome the sliding
frictional drag of the pipe and the machine. This must be assessed accurately prior
to making each fusion joint and must be added to the ram pressure.
This operation is normally carried out automatically when fully automatic fusion
machines are used.
Bead-up pressure : the sum of fusion and drag pressures required to provide, on a
given machine and for a given size and rating of pipe, an interface stress of
0.15MPa to form the initial bead on the end of the pipe against the heater plate.
Heat soak pressure : the pressure required to maintain the pipe in contact with
the heater plate. This is normally the drag pressure.
Bead roll over pressure : the pressure required to provided, on a given machine
and for a given size and rating of pipe, an interface stress of 0.15MPa. This has the
same value as the initial bead-up pressure.
Plate removal time : the maximum time permitted for the opening of the carriage,
removal of the heating plate and closure of the carriage to bring the two hot pipe
ends together.
(b)
Preparation
(1)
(2)
F.20
Grease and oily films may be wipe with a clean, disposable lint-free cloth or
cleaning material dampened by a suitable solvent when necessary.
(3)
(4)
Dummy welds
In order to remove dust from the heater plate, a dummy weld should be
carried out at the start of each continuous jointing session, or at a change of
pipe size.
A dummy weld can be made using pipe cut-offs of the same size and
pressure rating and the pipe to be welded. It is not necessary to actually
make a joint, The procedure can be stopped after the full heat soak cycle as
specified in Tables.
(c)
Setting up
Operate the machine to open clamps and position the planer in its position.
Position pipes in the clamps with ends adjacent to planning tool and with pipe
markings aligned. This will assist in obtaining the best match in diameter. Pipes
should be jointed so that the pipe markings are uppermost when the pipes are in
trench.
Tighten pipe clamps to grip and re-round the pipes.
(d)
Trimming
Switch on the trimming tool. The pipe ends shall be moved against the trimming
tool until continuous shavings are produced from each pipe end.
Keep the trimming tool turning, whilst separating the pipe ends to avoid steps on
the trimmed surfaces. Switch off the planning tool and remove after it has come to
rest.
Remove loose shaving from the machine and inside the pipes. Do not touch pipe
or fitting ends, to prevent contamination of the clean surfaces.
Visually check that the pipe or pipe and fitting ends are completely planed and
repeat planning if necessary.
Bring pipe or pipe and fitting ends together and check there is no visible gap
between trimmed surfaces. The maximum permitted outside diameter mismatch
shall not exceed 10% of thickness of pipe / fitting.
F.21
If the mismatch is greater than that given above then the pipe or pipe and fitting
shall be realigned and re-planed.
(e)
Bead-up
Check that the heater plate has attained the operating temperature.
Insert and secure the heater plate into position in the machine.
Bring the pipe or pipe and fitting ends into contact with the heater plate using the
initial bead-up pressure equivalent to 0.15MPa interface stress.
The typical initial bead size is given in Tables.
(f)
Heat soak
After the initial bead-up, the pressure in the system shall be released so that the
pressure gauge registers between zero and the drag pressure to control bead
growth during heat soak time. Check that the clamps do no move. The pipe or
pipe and fitting ends shall be in contact with the heater plate.
(g)
Plate removal
During removal of the heater plate, no molten polymer should stick to the heater
plate. If it does, then the joint shall be aborted, the plate cleaned and the surface
quality of the plate examined. If the plate surface is damaged, the manufacturers
advice should be obtained on cleaning and / or replacement.
The maximum plate removal time, including the time to bring the hot ends
together, shall not exceed 10 seconds for pipe not exceeding 630 mm and 15
seconds for pipes exceeding 630mm.
(h)
Fusion jointing
Immediately after plate removal the hot pipe and fitting ends shall be brought
together in a smooth manner and the pressure raised in accordance to the Tables.
The fused material should roll back in a uniform manner and there should be no
sign of bubbles or contamination present.
The overall width of the bead is not critical and therefore the bead sizes quoted in
Tables are typical only. The uniformity of the bead size around the circumference
of the pipe is important as this indicates that the equipment is set up correctly,
therefore deviations beyond the limits detailed in Section Debeading should be
investigated in order to reduce the variation to within the recommended values.
(i)
Cooling
The joint should be allowed to cool in the clamps, whilst maintaining the joints at
the cooling pressure for at least the time given in Tables for the appropriate pipe.
At the end of the cooling time, the clamps may be released and the jointed pipe
or pipe and fitting removed. No handling of the pipe shall take place until the
F.22
Debeading
All external beads, and internal beads if required, shall be removed after the
cooling time using a suitable debeading tool. The bead removal tool shall not
induce any slits, gouges or defects in the pipe wall.
Butt fusion beads shall be uniform on both sides of the joint i.e. no wrinkles or
discontinuities.
The beads shall be bent back at several positions. No evidence of the bead
splitting shall be seen. If the bead is seen to split at any point then the joint shall
be cut from the pipeline and remade. If a similar defect recurs, all further
production jointing shall cease until the equipment has been thoroughly cleaned
and examined. New trial joints shall be made and shown to be satisfactory.
(k)
Records
Electronic or written records of appropriate joint procedure details shall be kept.
The minimum information to be recorded is given in Table below.
Butt Fusion Joint Record
Machine type :
Serial No. :
Time
:
Joint number :
Job No. :
Pipe or pipe and fitting size :
Joint cycle :
Parameter
Bead pressure ( no drag )
Joint pressure ( no drag )
Drag
Heater temperature
Bead-up pressure
Initial bead size
Heat soak time
Heat soak pressure
Dwell time (change-over
time)
Fusion pressure
(l)
Date :
Operator code :
Units
Actual Value
Permissible
Values
bar
bar
deg. C
bar
Mm
sec.
Bar
sec.
bar
F.23
The equipment shall be serviced and calibrated regularly. The frequency at which
this is carried out will be different for individual items of equipment and will also
depend on usage but should be at least once every 6 months.
15.3
15.3.1
General
With electro-fusion socket fusion, an electrical resistance element is incorporated in the
socket of the fitting which, when connected to appropriate power supply, melts and
fuses the material of the pipe and fitting together.
The effectiveness of this technique depends on the attention to cleanliness, in particular
the removal of the contaminated surface of the pipe over the socket depth.
Electro-fusion fittings are available in the range 20mm to 315mm although larger sizes
are now under development.
There are 2 control systems specified manual time selection and automatic time
selection. Both are described in this section.
15.3.2
Equipment
The control box input supply shall be from a nominal 220 volt generator.
NO EXTENSION LEADS SHALL BE USED ON THE CONTROL BOX OUTLET
CONNECTORS
WARNING : Control boxes are not intrinsically safe and shall not therefore be taken
into the trench.
Pipe surface preparation tool capable of removing the contaminated surface of the pipe
in excess of the insertion depth before welding is attempted. The tool shall remove a
layer 0.2 0.4mm thick from the outer surface of the pipe preferably as a continuous
strip of swarf over that length and round the pipe.
NOTE : Hand scrapers can be difficult to use effectively in trench conditions.
Pipe clamps or other approved method for restraining, aligning and re-rounding the
pipes during the weld cycle shall be used.
Pipe cutters including saw and saw guide.
15.3.3
Preparation
Check that the pipe ends to be jointed are cut square to the axis and any burrs
removed.
Wipe pipe ends using clean, disposable, lint-free material to remove traces of dirt
or mud, etc.
F.24
Mark the area over which the contaminated surface is to be removed, i.e. in
excess of the penetration depth, on each pipe to be jointed by placing the socket
of the bagged fitting alongside the pipe and. Trace a line round the circumference
at the appropriate distance from the pipe end using a suitable marker.
DO NOT REMOVE THE FITTING FROM ITS PACKING AT THIS STAGE
Connect the electro-fusion control box input leads to the generator.
Check that there is sufficient fuel for the generator to complete the joint.
Check that reset stop button, if fitted on the control box, is in the correct mode.
Using the pipe end preparation tool, remove the entire surface of the pipe
uniformly, preferably as a continuous swarf over the area identified, i.e. in excess
of penetration depth.
(b)
F.25
On completion of the heating cycle, the melt indicators should have risen. If there
is no apparent movement of the melt indicators, the joint should be cut out and a
new joint made.
If a satisfactory joint has been made, the joint shall be left in the clamps for the
cooling time specified on the fitting.
NOTE : If the fusion cycle terminates before completion of the countdown, check
for faults as indicated by the control box warning lights. Do not attempts a second
fusion cycle if countdown of the first cycle reached more than half of the total
time require and for at least one hour after the first attempt.
(c)
(d)
The equipment shall be serviced and calibrated regularly. The frequency at which
this is carried out will be different for individual items of equipment and will also
depend on usage, but should be at least once every 6 months. Guidance shall be
sought from the equipment manufacturer and a scheme of calibration and
servicing implemented. Particular attention shall be given to the control box and
generator.
Records
Written records of appropriate fusion procedure details shall be kept as required
using the format approved by the S.O.
15.4
15.4.1
General
With electro-fusion saddle jointing, an electrical resistance element is incorporate in the
base of the saddle which, when connected to an appropriate power supply, melts and
fuses the material of the pipe and fitting together.
The effectiveness of this technique depends on attention to cleanliness, in particular the
removal of the contaminated surface of the pipe over an area equivalent to the saddle
base.
Electro-fusion saddles are available to fit all commonly used main sizes with sizes 20,
25 or 32mm service connections. Outlet connections are also available up to nominal
size 180mm.
Two methods of holding the tapping tee saddle during the fusion cycle are used, top
loading and under clamping systems. However, because of the variations of equipment
used for each method, common procedures for holding the saddle during the fusion
cycle cannot be specified. For each type of fitting used, the manufacturers procedure
for holding the fitting during the fusion cycle should be followed.
F.26
15.4.2
Equipment
The control box input supply shall be from a nominal 220 volts.
NO EXTENSION LEADS SHALL BE USED ON THE CONTROL BOX OUTLET
CONNECTORS.
WARNING : Control boxes are not intrinsically safe and shall not be taken into the
trench.
Pipe surface preparation tool capable of removing the contaminated surface of the pipe
over the full area of the saddle base. The tool shall remove a surface layer 0.2 0.4mm
thick.
Pipe-clamp with suitable dimension for making service or branch connections.
15.4.3
Preparation
Expose the pipe onto which the tapping tee saddle is to be assembled.
Clean the pipe over the general area on which the saddle is to be assembled using
clean, disposable, lint-free material and use clean water only.
Without removing the fitting from its packaging, place it over the required
position on the main. Mark the pipe surface all round and clear of the saddle base
area.
Remove the surface of the pipe to a depth of 0.2 to 0.4mm over the full area
marked using a suitable tool. Remove the swarf.
Check that reset stop button on the control box, if fitted, is in the correct mode.
(b)
F.27
Press the start button on the control box and check that the heating cycle is
proceeding as indicated by the display count-down.
On completion of the heating cycle, the melt indicator should have risen. If there
is no apparent movement of the melt indicator, where incorporate, a new saddle
joint should be made. Cut the tee of the faulty joint from its base.
If a satisfactory joint has been made, the joint shall be left in the clamps for the
cooling time specified on the fitting label.
NOTE : If the fusion cycle terminates before completion of the count-down, check
for faults as indicated by the control box warning lights. DO NOT attempt a
second fusion cycle.
NOTE : DO NOT attempt to tap the pipe with the integral cutter for at least 10
minutes after completion of the fusion cycle.
(c)
(d)
Records
Written records of appropriate fusion procedure details shall be kept as required
using the format illustrated below.
ELECTROFUSION JOINT RECORD
Control Box Serial No. :
Operator Code
:
Time
:
Date :
Ambient Temperature :
Joint Number
:
Type of Fitting
:
Target Fusion Time
:
Achieved Fusion Time :
Joint Status
:
Power profile
:
Units
sec.
o
C
sec
sec
The following features indicate faults during the assembly / fusion operation:
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- High Density1.doc
F.28
15.5
Mechanical Joints
(a)
General
All mechanical fittings used shall be assembled in accordance with the
manufacturers instructions and all metal fittings should be suitably protected from
corrosion as stipulated in clause Metal Parts.
(b)
F.29
Nominal iron
Size (mm)
50
80
100
150
200
250
250
300
350
400
450
500
Standard Flanges
Bolts
No.
4
8
8
8
12
12
12
12
16
16
20
20
Torque Nm
( +/- 10% )
35
35
35
60
80
100
100
120
150
200
250
300
Branch connection
Normally, branch connections on the main are achieved by introducing fusion
tees during installation of the main.
A subsequent branch connection into an existing HDPE main can be achieved by
using :
16.0
16.1
Preparation Of Pipes
Generally HDPE pipes are joined to form a string above ground prior to snaking into the
trench. To prevent scoring, pipe rollers should be used.
Before lowering HDPE pipelines into the trench, a check should be made for cuts, deep
scratches or other pipe damage and in fusion jointed systems that the system has cooled
sufficient before stress is imposed upon any pre-made joints.
When lowering pipe into the trench, care should again be taken to avoid scoring of the
pipe by contact with the sides and bottom of the trench. Use should be made of planks
and ropes where appropriate but wire ropes or chains should not be used.
16.2
Laying Of Pipes
Gradual changes in direction of HDPE pipelines can be accommodated by pipe
deflection but every effort should be made to keep the pipe as central as possible within
the trench to enable adequate compaction of side-fill.
F.30
The bending of HDPE pipelines is permissible and the properties of fusion jointed
systems enable changes of direction without recourse to the provision of special bends
or anchor blocks. However, the pipe should not normally be cold bent to a radius less
than 25 times the outside diameter of the pipe. For push-fit or mechanical non end-load
resistant jointing systems, anchor blocks to withstand the resultant thrusts must be
provided. Under no circumstances should hot bending be attempted on site.
For installation of heavy flanged fittings, provision should be made for concrete support
both for the weight and to resist the turning moments associated with valves and
hydrants.
HDPE pipes and fitting may be partially or completely surrounded by concrete but they
should be protected by 3mm rubber membrane to avoid possible damage during
pouring or compaction to prevent high localized stresses.
After completion of an installation, pipe work and fittings should be inspected and
made ready for testing to ensure the safety and efficiency of the systems. The trench
may be backfilled prior to testing; but it is advisable to leave at least the joints exposed
throughout the test.
Complete and accurate records should be taken of the installation. It is useful for
records to be taken before the pipes are buried.
To assist the future location of the pipelines, a marker tape shall be laid along the line
of the main and connect at each end to either a sluice valve or hydrant. The
recommended position of the tape is 350mm below the surface directly above the
crown of the pipe.
17.0
17.1
General
This section gives details of installation of HDPE service pipes. A service pipe is that
part of the water supply system which conveys water from the distribution main to the
consumers premises and is subjected to water pressure from that main. It is considered
to comprise two sections:
17.2
The COMMUNICATION PIPE is that part of the service pipes from the main up to
the and including the consumers meter situated at the boundary of the
consumers property. The water supply authority is responsible for the installation
and maintenance of the communication pipe.
The SUPPLY PIPE is that part of the service pipe from the consumers meter into
the premises up to the storage cistern. The customer is responsible for the
installation and maintenance of the supply pipe.
F.31
Slight snaking of the communication pipe in the vertical plane is permitted without
overstressing the connection to the main. However, care must be taken not to kink the
pipe and/or impart excess bending moment to the saddle tapping.
The preferred method would seem to be the simple straight connection at right angles
to the main with changes in direction or level achieved by installation electrofusion
elbows to avoid overstressing of the communication pipe.
Where road and / or drain crossing is required, suitable GI ducting should be provided
to accommodate the communication pipe.
18.0
18.1
18.2
19.0
19.1
19.2
Care should be taken to ensure that all pipe jointing is adopted in accordance with the
manufacturers recommendations.
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- High Density1.doc
F.32
19.3
20.0
REPAIR METHODS
Whilst repairs to burst mains and services are usually carried out in difficult and dirty
conditions, every effort should be made to keep all pipe and joint surfaces clean and the
working area as dry and uncontaminated as possible through the operation.
The completed repair should be examined and approved under working conditions
before re-bedding, side filling and backfilling take placed. Special attention should be
given to the replacement and compaction of suitable material under and around the
repair.
20.1
20.1.1
General
The extent of the pipe defect or fracture should be determined to ensure that the
remainder of the pipe has not been weakened or damaged in any way. The inspection
should also ascertain the extent to which the bed and surround may have been
disturbed in the vicinity.
When repairing a burst it is recommended that a short length of pipe ( say 1 meter ) on
each side of the damaged, since the defect may extend on the inner surface of the pipe.
20.1.2
Emergency Repairs
The emergency temporary repair of a HDPE pipe may be carried out by using a split
collar in the normal way but a more permanent repair should be undertaken as soon as
possible.
20.1.3
F.33
20.1.4
20.1.5
20.1.6
Only specially designed equipment should be used with correct stops to avoid over
compression of the pipe.
Do not use within 5 pipe diameters of a fitting, fusion joint or a previous squeezeoff operation.
F.34
General
1.1
1.2
ABS pipe size above 200mm must be manufactured in accordance with ISO
161.1 and must be tested in accordance to AS 3518: 1988 Part 1 Appendix E.
Manufacturer must provide detailed dimensional specification on all the pipes
and fittings to be supplied.
1.3
The ABS pipes and fittings manufacturer must provide documentary evidence
that it has the facility in its manufacturing site to carry out the relevant tests as
stated MS 1419.
1.4
ABS pressure pipes and fittings compounds shall have a MRS (Minimum
Required Strength) value of 16 Mpa and shall comply with the scope,
designation of properties and test methods defined in ISO 7245. The resin
supplier shall submit data and test reports from independent and reputable test
bodies such as CSIRO Australia, Body Cote Germany or PSB Singapore on the
creep rupture regression curve on the material to show the pipes are conformed
to MRS 16 for 50 years service life. Test must be in accordance to ISO 9080 to
1,000 and 10,000 hours at 3 different temperatures, 20 0C, 40 0C and 60 0C. The
manufacturers shall submit invoices to SYABAS to substantiate that their resin
are sourced from the supplier whom resin has conformed to MRS 16 for 50
years.
1.5 The manufacturers shall NOT use recycle or their own re-processable material.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.1
1.6
The physical properties of ABS material to manufacture the pipe and fitting shall
be as follow:
PROPERTY
S.I. UNIT
OTHER UNIT
30 Mpa
4,350 lbf/in2
25%
25%
2,000 Mpa
290,000 lbf/in2
Compressive Strength at 20 0C
42 Mpa
6,100 lbf/in2
340 J/m
6.4 lbf/in2
1.05
1.05
104 0C
219 0F
5.6 x 10 ft/ft 0F
80 0C
176 0F
Poissons Ratio
0.35
0.35
Thermal Conductivity
0.25 W/m 0K
1.7 BTU/ft2/in/ 0F
Specific Heat
1.47 kJ/kg 0K
0.38 BTU/lbm/ 0F
3.5 x 1016 cm
3.5 x 1016 cm
Elongation at Break at 20 0C
Instantaneous Flexural Modulus at 20
0
C
Specific Gravity
Vicat Softening Point ASTM D1525
Coefficient of Linear Expansion
Volume Resistivity
1.7
ABS resin compounds will absorb moisture during storage in the factory and
caused an increase in moisture content. Since resin compounds with moisture
content higher than the permissible level will affect the quality of the end
products. As such, the manufacturer MUST reduce the moisture content of the
resin with dehumidifier machines.
1.8
All ABS pipes and fittings must pass the test of Effect of the Quality of the
Water under BS 6920. Manufacturer must provide documentary evidence from
the relevant standard testing authority confirming this conformance.
1.9
All ABS pipes, fittings and ABS Solvent Cement used for joining must be
manufactured and supplied by the SAME manufacturer to ensure material
compatibility, dimension accuracy and quality.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.2
1.10 ABS pipes and fittings manufacturer must provide documentary evidence to
demonstrate its expertise in the manufacturing and supply of ABS pipes, fittings
and ABS solvent cement. The ABS pipes and fittings manufacturer must arrange
for factory site audit by the owner/consultant prior to letter of award to confirm
product quality conformance.
1.11 All ABS fittings MUST be either injection mould or machine fabricated from
pressure pipes extruded by the same manufacturer. Rotor moulding or other
butt-welded low-pressure fittings are strictly NOT accepted. A factory audit is to
be conducted to ascertain capability of the manufacturer. All fittings supplied
using fabrication method must be fabricated using a single piece of Class 15
ABS pressure pipes extruded by the same manufacturer. All such fittings MUST
be subjected to 100% sample test at rated pressure conducted at the
manufacturers premises prior to acceptance for delivery. Test certificates MUST
be provided.
All pipes and fittings supplied must be accompanied by inspection and quality
reports issued by the manufacturer.
1.12 The manufacturer must provide a company profile among other information
indicating the relevant management personnels capability within the
organization in the manufacturing of ABS pipes and fittings.
2.0
Colour
The colour of ABS pipe shall be either dark blue or dark blue with navy blue stripes.
The minimum number of stripes shall be 4 spaced at 90 0 intervals and shall be of the
same type of resin as used in the compound for the pipe. The stripes shall not exceed
10% of wall thickness.
3.0
Scope of Supply
3.1
The Contractor shall manufacture, test, supply and transport to site as per
attached Bill of Quantities. All pipes shall be supplied with spigot on both ends
or socket on one end and plain on the other. Sockets shall be supplied loose for
site installation. All pipes supplied shall conform to the data in the following
Table 1.
Contractors shall submit a complete work programme on the schedule of
production and delivery.
3.2 SYABAS representatives reserve the right to visit the manufacturers pipe and
fittings manufacturing plant to witness Contractors capability in manufacturing the
pipes and specials. These visits will be notified earlier and will be done
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.3
during tendering and/or after tendering period is over. They can also request to visit
the plant anytime during the manufacturing period. All costs shall be borne by the
Contractor.
3.3
Contractor shall provide all necessary training and supervision to the pipe-laying
plumber at all time. These costs shall be included in the tender price.
TABLE 1 : ABS PIPE DIMENSION
PIPE SIZE
(DN/OD)
(DN15)
(DN20)
1 (DN25)
1 (DN25)
1 (DN25)
1 (DN32)
1 (DN32)
1 (DN32)
1 (DN40)
1 (DN40)
1 (DN40)
2 (DN50)
2 (DN50)
2 (DN50)
2 (OD75)
2 (OD75)
2 (OD75)
2 (OD75)
3 (DN80)
3 (DN80)
3 (DN80)
3 (DN80)
4 (DN100)
4 (DN100)
4 (DN100)
4 (DN100)
6 (DN150)
6 (DN150)
6 (DN150)
6 (DN150)
6 (DN150)
PIPE
CLASS
MAXIMUM
OPERATING
PRESSURE
(kPa)
OUTSIDE
DIAMETER
INSIDE
DIAMETER
WALL
THICKNESS
MASS
(mm)
(mm)
(mm)
(kg/m)
1500
1500
900
1200
1500
900
1200
1500
900
1200
1500
900
1200
1500
600
900
1200
1500
600
900
1200
1500
600
900
1200
1500
450
600
900
1200
1500
21.4
26.8
33.6
33.6
33.6
42.3
42.3
42.3
48.3
48.3
48.3
60.4
60.4
60.4
75.1
75.1
75.1
75.1
88.9
88.9
88.9
88.9
114.3
114.3
114.3
114.3
168.3
168.3
168.3
168.3
168.3
17.0
21.4
29.3
28.1
26.9
37.0
35.5
34.0
42.3
40.5
38.8
53.0
50.7
48.6
68.8
65.9
63.1
60.5
81.5
78.1
74.8
71.7
104.9
100.5
96.3
92.2
157.7
154.4
148.0
141.8
135.9
2.2
2.7
2.1
2.7
3.3
2.6
3.4
4.1
3.0
3.9
4.7
3.7
4.8
5.9
3.1
5.1
6.0
7.3
3.7
5.4
7.0
8.6
4.7
6.9
9.0
11.0
5.3
6.9
10.1
13.2
16.2
0.14
0.21
0.22
0.28
0.33
0.34
0.44
0.52
0.44
0.57
0.68
0.69
0.88
1.06
0.75
1.17
1.36
1.63
1.04
1.49
1.90
2.28
1.71
2.45
3.13
3.76
2.82
3.68
5.28
6.75
8.12
15
15
9
12
15
9
12
15
9
12
15
9
12
15
6
9
12
15
6
9
12
15
6
9
12
15
4.5
6
9
12
15
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.4
OD225mm
OD225mm
OD225mm
OD225mm
OD225mm
OD250mm
OD250mm
OD250mm
OD250mm
OD250mm
OD315mm
OD315mm
OD315mm
OD315mm
OD315mm
OD355mm
OD355mm
OD355mm
OD355mm
OD355mm
OD400mm
OD400mm
OD400mm
OD400mm
OD400mm
OD450mm
OD450mm
OD450mm
OD450mm
OD450mm
OD500mm
OD500mm
OD500mm
OD500mm
OD560mm
OD560mm
OD560mm
OD560mm
OD630mm
OD630mm
OD630mm
OD630mm
4.0
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
4.5
6
10
12
4.5
6
10
12
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
450
600
1000
1200
450
600
1000
1200
225.3
225.3
225.3
225.3
225.3
250.4
250.4
250.4
250.4
250.4
315.4
315.4
315.4
315.4
315.4
355.4
355.4
355.4
355.4
355.4
400.5
400.5
400.5
400.5
400.5
450.6
450.6
450.6
450.6
450.6
500.5
500.5
500.5
5005
560.6
560.6
560.6
560.6
630.7
630.7
630.7
630.7
214.6
211.4
202.8
198.6
192.6
238.6
234.9
225.3
220.8
214.1
300.6
295.9
283.9
278.1
269.7
338.8
333.5
320.0
313.5
304.0
381.8
375.9
360.6
353.3
342.6
429.5
422.9
405.7
397.4
385.4
477.2
469.8
450.7
441.9
534.5
526.2
504.9
494.9
601.3
592.0
564.7
556.8
5.3
6.9
11.2
13.3
16.3
5.9
7.7
12.5
14.7
18.1
7.4
9.7
15.7
18.6
22.7
8.3
10.9
17.6
20.9
25.6
9.3
12.3
19.9
23.5
28.9
10.5
13.8
22.3
26.5
32.4
11.6
15.3
24.8
29.4
13.0
17.1
27.8
32.9
14.6
19.3
31.2
37.0
3.85
5.00
7.92
9.29
11.22
4.72
6.16
9.77
11.45
13.84
7.47
9.76
15.49
18.17
21.96
9.48
12.39
19.66
23.06
27.87
12.02
15.71
24.95
29.26
35.37
15.19
19.86
31.55
37.01
44.75
18.74
24.51
38.95
45.69
23.48
30.72
48.83
57.28
29.70
38.86
61.78
72.48
Solvent Cement
The solvent cement designed for the bonding of ABS pipes and fitting shall have a
viscosity in the range of 0.6 Pa.s to 1.9 Pa.s when tested in accordance with Appendix
B of MS 1419 : Part 3 : 1997. The manufacturers shall provide recognised
documentary evidence that the solvent cement manufactured by them complied with
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.5
5.0
Jointing
5.1
All ABS joints shall be of cold solvent cement welded. The Contractor shall
provide sufficient ABS solvent cement for all pipe and socket joints under this
Contract. The Contractor shall ensure that the correct ABS solvent cement is
supplied for ABS pipes and fittings in accordance to the MS 1419. ABS solvent
cement and MEK Cleaner (Primary) fluids used in the jointing of ABS pipe,
fitting and in the fabrication of ABS fitting shall be in accordance with MS 1419.
uPVC cement or glue are strictly NOT allowed for use with ABS pipe and
fittings. Jointing techniques proposed by the Contractor shall be submitted to the
S.O. for approval at least two (2) weeks before the works commenced. Only
purpose-made ABS solvent cement and MEK cleaner manufactured and supplied
by the same pipes and fittings manufacturer are approved for used.
5.2
All pipes shall be cut square and swarf, etc. removed prior to jointing. Pipe
shall be inserted to full depth of fitting socket. Installed fittings which do not
have pipe inserted to full depth shall be considered below required standard
and shall be rectified at the Contractors expense. Backing ring shall be used in
all flanged joints.
5.3
The use of solvent cemented sockets; flange and shoulder style couplings are
permitted to join pipe and fittings as required. Equipment connections 50mm
and less may be threaded.
5.4
5.5
The use of hand operated lever winch or other suitable means of supplying a
steady effort sufficient to join fittings to pipes shall be made available when
jointing pipe sizes above 100mm. The used of hammers etc. to join fitting is
NOT permitted at anytime.
6.0 Support
6.1
The maximum distance between pipe supports shall be in accordance with the
manufacturer recommendation. The width of pipe supports shall be in
accordance with the manufacturer recommendations. Pipe support shall not
exert undue pressure on the pipe wall or deform the pipe wall against the clamp
or support. All clamps on horizontal pipe shall allow axial movement of the
pipe.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.6
6.2
6.3
ABS pipe may be connected directly to other pipe or equivalent using flange or
threaded connection. Flanges are the recommended method for all sizes,
however threaded connections may be used for size 50mm and below.
6.4
Horizontal pipe support centers for ABS pipe at various temperatures is given in
the Table 2. For vertical pipes, support centers may be increased by 50%. The
adjacent correction factor shown in Table 3 should be applied for other pipe
classes. Pipe at 80C must be continuously supported.
Table 2 : Horizontal Pipe Support Centre
PIPE SIZE
(mm)
15
20
25
32
40
50
80
100
150
225
250
315
355
400
450
500
630
CORRECTION FACTOR
0.88
0.92
1.00
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.7
7.0
Safety Precautions
The following requirements are in addition to any government safety legislation or
established company work practices.
Read safety precautions available on ABS solvent cement and MEK cleaner
containers.
As solvent cement and cleaner are flammable liquids, ensure work area is
clear of falling sparks or other sources of ignition e.g. smoking
To wear safety glass and protection glove at all times when using ABS
solvent cement and MEK cleaner
The contractor shall submit safety data sheets in their tender.
8.0
Jointing Procedure
The following procedure shall be observed and obliged at all times during pipeline
installation works.
Lightly abrade the gloss from the outer surface of the pipe and the inner surface of
the fitting using emery paper.
Clean the surface with clean rag moistened with MEK cleaner.
Mark the pipe distance back from the end equal to the depth of the socket plus
10mm. This is to allow you to ensure that the joint is fully home.
For sizes above 100mm, position the winch to pull the joint together after solvent
cement is applied.
Apply the solvent cement as quickly as possible first to the socket and to the pipe
using longitudinal brush strokes. For size 100mm and above, two coats will be
required on both the pipe and the fitting.
chamfer on the
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.8
9.0
Immediately after application of the solvent cement, push pipe fully home using
the mark on the pipe as a guide. Do not twist fitting on the pipe. If using a winch,
do not exert additional force once the pipe is fully home.
As all Malaysian Standard ABS fittings are a tapered interference fit, it is essential
the fitting be held in position for a time intervals of between 10 seconds to one
minute to prevent any movement. When using the winch on larger fittings, leave
the winch in position until winching is required for the next consecutive joint.
Wipe excess solvent cement from the joint. Care should be taken to avoid excess
deposits of solvent cement inside small diameter fittings as this can weaken the
wall of the pipe or fittings.
Notes on Jointing
The following precautions and notes shall always be observed by the Contractor.
Treat ABS solvent cement and MEK cleaner with care, as they are volatile
flammable liquids. Replace lids after use.
ABS pipe cannot be successfully cemented under wet conditions. Pipe must be
dry for effective jointing.
Use only clean rags and brushes. Brushed must be cleaned in MEK cleaner after
used.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.9
10.0
Cement may be removed from your hands with soap and water or industrial
hand cleaning soap. Do not use MEK cleaner to remove ABS solvent cement
from your skin.
Use only purpose-made ABS solvent cement and MEK cleaner from the same
manufacturer.
The key to fast efficient jointing particularly with large pipe diameter is
preparation. When using a lever winch, have everything ready before applying
cement. A canopy over the jointing area is desirable when working in full sun.
11.0
Ambient temperature.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.10
Whilst full rated pressure may not be applied for 24 hours, joints in smaller
diameters can often be put back into service within minutes of being made. An
approximate guide is to allow 1 (one) hour per 100kPa working pressure for size up
to 80mm. For size 100mm and above, the time should be increased to 1.5 hours
per 1 bar.
12.0
Sockets
Socket joints are permitted to be used for pipe and plains ended fittings.
Socket joints are permanent and cannot be disassembled.
13.0
Pipe Markings
All pipes must have the following markings:
14.0
Installation of Saddles
14.1 Drill the hole in the pipe wall with a small clearance to suit the spigot size
of the saddle. A hole-saw is useful for pipe size up to 100mm whereas a
jigsaw may be more effective for larger sizes.
14.2 Mark out the area on the pipe to be covered by the saddle.
14.3 Lightly abrade the area to be covered on the saddle and pipe to remove any
gloss.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.11
14.4 Feed into the pipe a minimum two worm drive (jubilee) style stainless steel
clips placing one either side of the saddle position. On the larger saddle
sizes (225-630mm) two or more clamps per side may be required.
14.5 Clean the abraded surfaces of the pipe and saddle using MEK cleaner.
14.6 Apply minimum of two coats of ABS solvent cement to pipe and saddle.
14.7 Immediately place the saddle in position, secure with the saddle in position,
and secure with the stainless steel clamps. The saddle must be pulled down
onto the pipe to ensure there is no gap between the pipe and the saddle.
This may require the use of a clamp. Leave worms drive clips in place for a
minimum of 48 hours. It is recommended to leave the stainless steel clamp
on at all times. Wipe off excess cement.
14.8 A minimum of 24 hours drying time must be allowed before applying full
pressure. On sizes 250mm and above a drying time up to 48 hours is
recommended.
15.0
16.0
Composite Unions
Flanges
Threaded adaptors
Flanged Joints
Two styles of flange jointing systems shall be used:
Full face flange for size to 6 and stub flange for size 2 to 630mm
Stub flange assemblies shall have the same pressure rating as full face
flanges assemblies
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.12
Backing rings must be used with both full face and stubs flanges available in
all standard-drilling configurations. Gaskets must be used with flanges.
ABS stub or full-face flange assemblies may be bolted directly to other pipe
systems of the same flange-drilling standard. Gaskets and backing rings must
be used at the joints. Torque values for flange face are as stipulated in Table
5.
Bolt Sizes
(mm)
M12 x 50
M12 x 50
M12 x 50
M12 x 50
M16 x 60
M16 x 65
M16 x 70
M16 x 80
M20 x 90
M20 x 100
M20 x 130
M20 x 150
M24 x 160
M24 x 170
M24 x 180
M24 x 190
M27 x 230
M27 x 240
Recommended
Torque (NM)
7
10
14
13
20
22
33
25
42
63
80
74
133
163
157
185
190
190
Standard butterfly valves shall be placed between ABS stubs or full-face flange
assemblies without modification. Valve should be checked for full and free movement
prior to final tightening of flange bolts.
17.0
Threaded Connection
The following table shows the class of pipe which shall be used for BSP treading.
When threading, sharp die shall be used and cut full thread depths, without
lubricant in one operation.
All threaded fitting shall be rated at 12 bar at 20C.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.13
For high-pressure installations it is preferable to use adaptors or fitting with male ABS
threads in preference to female threaded fittings.
Composite unions, available in male and female threaded configurations to 50mm are
recommended for joining ABS pipe to metal threads particularly in systems subject to
thermal cycling.
Tightening should only be done by hand with a maximum of an extra quarters turn
with a pipe wrench. There is often a tendency to over tighten threads however this
only causes distortion and leaks.
If leakage occurred at the threaded joint, disassemble the joint. If there is no damaged
at the thread, remake the joint and care shall be taken not to over tighten.
PTFE tape is the recommended thread sealant.
Do not use liquid thread sealant, e.g. Loctite or PTFE, as they contain chemicals,
which attack most plastic materials.
BSP Size (in.)
1
1
1
2
3
4
18.0
Pipe Class
T
T
T
T
T
T
T
T
Instrumentation Connections
Instrument connections may be made a combination of saddle and threaded reducing
bushes. In addition, for 80mm and larger pipe sizes, drilling and tapping directly in
the pipe at a fitting may be from these combinations. Maximum size tapping as
follows:
Pipe Size
(mm)
80
100 - 150
200
250
315
400 - 500
Maximum Instrument
Tapping Point Size
3/8
1
2
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.14
19. 0
Buried Pipes
19.1
Pipe Trench
Trenches should
requirements.
Where very heavy vehicle loads are anticipated, trench depths should be
calculated in accordance with SYABAS requirements.
19.2
be
constructed
in
accordance
with
SYABAS
19.3
Thrust Blocks
Thrust blocks may be installed for solvent cement jointed buried pipelines
at changes of direction, termination, changes in pipe diameter or tees.
Thrust blocks may be required where valve or other equipment is
positioned in the pipeline and are not independently supported.
19.4
Installing Pipe
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.15
19.5
Particular care must be taken to ensure pipes and jointing material are
clean and dry when making a joint.
Final Connections
Final connection, backfilling and tamping should be completed in the
coolest part of the day, i.e. early morning. This is to prevent undue tensile
loads being imposed on the pipe joints. If final joints or backfilling is
completed in the hotter part of the day, the pipe contracts during the
cooler hours of the night, excessive tensile loads may be placed on the
joints.
19.6
20.0
Times
(Hours)
24
36
48
For large installation split the system into several sections for testing.
Fill section with clean ambient temperature water (20C is ideal). Do not
pressurize.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.16
Allow the system to stand for one hour to allow temperature to stabilize and
equilibrium reached.
If there are no leaks remove any remaining air and increase pressure to 3 bar.
Leave at this pressure for 15 minutes and inspect for leaks.
All pipes shall be tested at a test pressure 1.5 times higher than the system
operating pressure less the allowance for temperature / pressure de-rating at the
current test temperature.
NOTE :
CAUTION :
If extended times are required to achieve the test pressure either leakage is
occurring or there is air trapped in the system. Inspects for leakage and if
apparent reduce the pressure and check for trapped air which must be
removed before the test and continue.
Under no circumstances should pressure tests be carried out using
pressurized gases. Such test could be extremely dangerous should a failure
occur.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.17
GENERAL
1.1
Scope
This Standard specifies the requirements for the design, materials, manufacturer and
testing of standard ductile iron ferrous saddles for uPVC, Ductile iron and Asbestos
cement pipes.
1.2
Referenced Documents
The following referenced documents contain provisions, which, through reference
in this text, constitute provisions of this Standard. For dated references, where there
are subsequent amendments to, or revisions of, any of these publications, the
Standard shall be amended or revised accordingly. For undated references, the latest
edition of publication referred to applies.
The titles of publications referred to in this Standard are listed below:Spesifikasi JKR
MS 628 :Part 1
MS 712
N1S 740
BS 21
BS 6681
BS 4190
BS 970 : Part 1
BS 3505
BS 4772
BS 2789
H.1
BS EN 1563
BS 1706
BS 2779
MS 672 : 99
BS 6920 : Part 1
BS 3643 : Part 2
BS 7079
BS 3900
BS EN 512
BS EN 10083-1
AS 1646
AS 4020
AS/NZS 4158
ISO 2531
H.2
1.3
SS 05 5900
AWWA C210
ASTM D570
ASTM D 4066
Definitions
For the purpose of this standard, the following definition applies.
1.3.1
Ferrous Saddle
Ferrous saddle is a device used in water works for making service connections and
tapping. It is used as a services clamp, which is, attached directly 360 around the
pipe or for pipe's wall which is too thin or too soft. The use of the ferrous saddle is
to provide support for the pipe without deforming it and distributes stresses away
from tapping hole as well as purchase for the threads of the ferrule.
1.3.2
Polyamide Adaptor
Polyamide (high strength plastic) adaptor provided with the tapping thread, is
integral with the boss of the saddle. The design of polyamide adaptor is to have
protection against corrosion. It replaces threading onto the ductile iron-boss/body of
the saddle that will also prevent galvanic effect (that will cause severe corrosion)
between ductile iron ferrous saddle and the brass ferrule.
1.4
1.4.1
Saddle Type A
Type A ferrous saddle is suitable for tapping Asbestos Cement Pipe complying with
MS 712 and BS EN 512 and Ductile Iron pipes complying with BS EN 545 : 2002
(previously known as BS4772 : 1933) and ISO 2531. (see Figure 1)
1.4.2
Saddle Type B
Type B ferrous saddle is suitable for tapping uPVC pipe complying with MS 628:
Part 1 and BS 3505 (see Figure 2)
NOTE : Both are designed to withstand same torque loads and bending moments,
H.3
1.5
Illustration
Ferrous saddle shall be of general form shown in Drawing.
1.6
Materials
The clamp ferrous saddle should be manufactured from compounded material
meeting the followings specification as below.
Table 1: Material for Ferrous Saddle
Components
Material
Symbol
Reference
Grade or
Designation
Ferrous saddle
body
Ductile Iron
DI
BS 2789
BS EN 1563 : 97
420/10, 500/7
400/15, 500/7
Bolts, Nuts,
Washer
Stainless Steel*
Carbon Steel
(Polymeric Coated)
SS
BS 970 Part 1
BS EN 10083-1
Sealing Gasket
(TOP)
Synthetic Rubber
EPDM
MS 672: 99/
AS 1646/BS EN 681
66-75 IRHD
Sealing Gasket
(Bottom)
Synthetic Rubber
EPDM
MS 672: 99/
AS 1646/BS EN 681
66-75 IRHD
Polyamide
Adaptor
Polyamide -11
PA
ASTM D 4066
PA321
NOTE : All casting shall have smooth, homogeneous and free from flaws, cracks blow
outs or other harmful defects. Grey cast iron, of BS 1457 Grade 220 and Malleable cast
iron BS 6681 Grade B30-06/W35-04 are not allowed to be used for this product.
* For coating refer Section Two - Protection against corrosion
All materials likely to contact with potable water should be incapable of permitting
bacterial growth. Non-metallic materials should comply with the requirement of the
effect of non-metallic materials on water quality as mentioned in specification.
H.4
1.6.1
Body
Body material shall be manufactured from the materials given as appropriate in
Table : Material For Ferrous Saddle.
NOTE : Body materials may be specified by the purchaser in his enquiry or order
1.6.2
1.6.3
Sealing Gasket
Gaskets shall be vulcanised, moulded or extruded elastomer and shall be free from
porous areas, foreign materials and visible defects. Reclaimed rubber shall not be
used
Sealing Gasket shall be made of EPDM complying with MS672 : 99, AS 1646:92 or
BS EN 681 for potable water applications, sealing gasket made of natural rubber is
not allowed. Materials complying with this standard shall meet the requirements of
BS 6920, which specifies the requirements for non-metallic materials in contact with
portable water.
Gaskets shall be manufactured from elastomeric compound of hardness (measured
in IRHD) such that the ferrous saddle shall perform satisfactorily in both short and
long term tests as specified. To meet this requirement gaskets shall fall within the
nominal hardness range of 66 -75 IRHD)
1.6.4
Polyamide Adaptor
The adaptor shall be made of injection moulded Polyamide 11 and shall comply
with ASTM D 4066 and shall follow the dimension and illustration in drawing.
1.7
1.8
Workmanship
1.8.1
Casting
All casting shall be homogeneous, smooth and shall be free from flaws, cracks,
blowholes, cuts or other harmful defects. All surfaces in close proximity to the pipe
and gaskets shall be smooth and free from sharp edges.
H.5
1.9
Nominal Sizes
Ferrous saddle shall be one of the following nominal sizes (DN) DN 80, DN 100,
DN 150, DN 200, DN 250, DN 300, DN 350 and shall be designated by the
nominal diameter of the pipes.
1.10
1.10.1
Boss Dimensions
The boss dimensions shall comply with table as appropriate. The boss shall permit
tapping within the size range " to 1" BSP.
1.10.2
Tapping Dimensions
The tapping hole shall be threaded in accordance with BS 21 with positive tolerance
deviation accordance with the requirements of BS 2779.
1.10.3
1.10.4
H.6
Saddle Type A
Sealing Gasket shall be contained within the recess between the boss and the pip.
The thickness of the rubber sealing gasket shall be not less than 4 mm while the
outside diameter shall be not less than 75mm.
Saddle Type B
The thickness of sealing gasket contained within the recess between the boss and
the pipes shall be not less than 4 mm while the rubber gasket contained under the
ferrous saddle body shall be not less than 1.5 mm.
2.0
2.1
Surface Preparation
This section specifies methods of protecting ferrous saddles against corrosion. It
covers internal and external protection by Fusion Bonded Epoxy powder (FBE) and
by Polyamide 11.
The surface to be protected shall be clean and free from porosity, cracks, scale,
loose rust, oil, grease or other foreign matter. Surface preparations shall be effected
by abrasive blast cleaning cold applied surface tolerant high solid epoxy with
AWWA C210 can be used as an alternative polymeric coating system. The surface
preparation, coating requirements and test methods for this coating system are
separately dealt with in Appendix : Surface Preparation, Coating Requirements and
Test Methods for Cold Applied Surface Tolerant High Solid Liquid Epoxy.
2.2
Degreasing
All items intended for coating shall be decreased to remove all oil, grease and
residual surface solids.
2.3
Abrasive Cleaning
Iron and steel surfaces of ferrous saddles shall be prepared by abrasive blast cleaning
to SA 2 quality of BS 7079.
NOTE : If a SA 3 surface quality is required, the purchaser shall specify this at
time of placing an order.
2.4
Pre-Treatment
After blast cleaning the resultant surface shall be free of loose dust, oil, grease,
soluble salts and other materials that may be deleterious to the final performance of
the coating. Water washing, degreasing and oil-free air blast shall be used as
necessary to ensure these contaminants are removed prior to proceeding with the
coating process.
H.7
2.5.
Coating
2.5.1
General
Coating shall be carried out using either fusion bonded epoxy powder or nylon 11
materials. The coating shall be applied using either the fluidised bed dipping process
or the electrostatic spray process and shall produce a finished coating which fully
complies with the thickness recommendations of the coating materials
manufacturer, though subject to the thickness limitation specified.
2.5.2
Body
The coatings on ferrous saddle body shall be not less than 250 m for Polyamide 11
or not less than 350 m thick for Fusion Bonded Epoxy as specified in AS/NZ 4158.
Particular attention shall be paid to either thinning or excessive build-up of coatings
at sharp edges especially at bolt - holes. Clearance between the pipe outside
diameter and the internal diameter of coated ferrous saddles shall be sufficient to
ensure satisfactory assembly of the ferrous saddle onto the pipe, without damage to
the coating.
2.5.3
Fasteners
Bolt, studs and nuts which are to be coated with epoxy or materials shall first be
zinc plated on all surfaces to BS 1706 Grade Fe/Zn 12 Threaded fasteners which are
to be Polyamide 11 coated shall use a self-adhesive grade of Polyamide 11.
The finished thickness of coating on threaded fasteners shall be between 75 m and
125 m. All surfaces of bolts, studs and nuts shall be coated, except that it is
permissible to leave uncoated the internal surface of coated nuts and the extreme
tips of coated bolts, provided that the resultant uncoated sections of bolts do not
form part of the tensile section of the bolt after tightening.
Fasteners shall be provided with washers under each nut. Washers shall be spun
galvanised to MS 740 and may in addition be further coated with either epoxy or
Polyamide 11.
H.8
2.6
Coating Application
The method of coating application shall comply fully with the recommendations of
the coating materials manufacturer and if required by the purchaser, the coupling
manufacturer shall submit full detail of the method of application for approval by the
purchaser. In case of epoxy coatings, which have limited shelf life, particular
attention shall be taken on products tracing.
The resultant coating shall be uniform in colour and texture and shall not exhibit
blisters, bubbles, crazed areas or contaminant inclusions. The coating shall be
completely fused to a smooth continuous film. No bare metal shall be visible except
for areas left deliberately uncoated No pinholes, tears, runs, sags or excessive
coating build-up shall be evident. All support points shall be touched up with a
compatible coating material recommended by the coating supplier
2.7.
2.7.1
Holiday Test
Ferrous saddle shall be tested for continuity of the applied coating protection using a
high voltage holiday detector set at a minimum 1,500 V or 5 m. Discontinuities
and pinholes indicated by the test shall be made good with an approved repair
material and the component re-tested satisfactorily.
2.7.2
Cure Test
Fusion bonded epoxy coatings shall be tested for proper cure of the coition by
rubbing the coating with MEK (methyl ethel ketone). If the coating becomes soft or
tacky, insufficient cure is indicated. In such case, post curing of the coating shall be
carried out by further heating in an oven until the necessary degree of cure is
achieved. Polyamide 11 coatings which are thermoplastic do not require this test.
NOTE. When working with MEK appropriate safety precautions must be taken. MEK
is flammable and must be kept away from open flames or other sources of ignition.
2.8
Repair
Any defective coatings shall be made good using methods approved by the coating
materials manufacturer.
2.9
Sampling
Two percent of each particular size and type of the ferrous saddles to be supplied
shall be tested. Any test piece, which fails to comply with dimensions, tests, or
showing signs of defect will render the whole batch to be rejected.
H.9
2.10
3.0
TESTING
3.1
Testing
3.1.1
Test Requirement
The manufacturer shall conduct a type test on each type and size of ferrous saddle
before dispatch to the site.
Type testing shall consist of the following tests in the sequence specified:
Strength Testing
Functional Testing
Corrosion Testing
Water Testing Test
Cathodic Disbondment Test
Adhesion Test
Chemical resistance test
Test results shall be recorded and retained by the manufacturer and shall include the
results of a visual examination of the ferrous saddle components after type testing.
3.1.2
Strength Testing
The ferrous saddle should be attached directly 360 around the test apparatus with
corresponding pipe OD in normal manner and gradually tightened the bolts with a
torque as specified in Table 2, in order to test the strength of the ferrous saddle body
There shall be no visible evidence of structural damage to the ferrous saddle body.
3.1.3
Functional Testing
The same ferrous saddle be attached directly 360 around the corresponding type
size of pipe with the insertion of sealing gasket under the boss (with tapping hole
c/w stop plug) and around a hole drilled in the pipe with a torque which shall not at
any point exceed the maximum functional test torque specified in Table 2 as
applicable. There shall be no visible evidence of structural damage to the boss and
ferrous saddle body and of leakage when subjected to an internal pressure of 16 bar
during the test duration as shown below.
H.10
3.1.4
220
120
Test Duration
(minimum)
(Min)
1
Corrosion Testing
The ferrous saddle should be coated in accordance with Clause 2.5 and shall
conduct a salt spray test complying requirement specified in BS 3900 : F4.
3.1.5
3.1.6
3.1.7
3.1.8
H.11
3.1.9
Visual Inspection
Ferrous saddles shall be clean and free from such defects as can be established by
visual inspection in accordance with this standard.
Ferrous saddles shall not deviate from roundness by more than +1mm. Ferrous
saddle body shall be smoothed and free from excessive burrs that might cause
damage to the gasket or might impair the pressure tightness of the joint.
Gaskets shall be moulded as specified in Sealing Gasket Dimensions.
3.1.10
3.2.
Production Testing
Steel saddles which are flash welded and expanded beyond the yield point of the
steel, need not be further mechanically or hydrostatically tested.
Steel saddles that are manufactured from previously pressure tested pipe or tubing
need not be further hydrostatically tested.
Ferrous saddles made from malleable or ductile iron shall be 100 % air tested under
water, either at the foundry or by the coupling manufacturer, to a pressure of at least
6 bar for a period of at least 5 seconds after static conditions have been obtained
after immersion in the water, without visible leakage. Castings which fail this test
shall be rejected.
4.0
MARKING
4.1
Marking
Each ferrous saddle shall be legibly marked (not on top of the boss of the saddle) in
accordance with the following requirements.
o
o
o
o
o
o
NOTE. Additional markings may be used at the option of the manufacturer and
purchaser provided that they do not conflict with any of the markings specified.
H.12
I : VALVES
1.0
General
1.1
1.2
Drawings
Typical Drawings are presented in the Schedule of Particulars.
Detailed engineering shop drawings MUST BE issued by the Contractor before
manufacture/fabrication. The Contractor shall prepare any additional drawings, which
the Contractor requires to interpret the Drawings for the use of his employee.
The Contractor shall be responsible for any discrepancies, errors or omissions in the
Drawings or other particulars supplied by him, whether such Drawings or particulars
have been approved by the S.O. or not.
1.2.1
I.1
(iv)
All detail drawings showing the installation of the valves and actuators where the
installation works is being carried out the Contractor.
The Contractor shall make such changes to the drawings as the S.O. may require and shall
resubmit the amended drawings to the S.O. for approval. These drawings and any
additional detailed drawing as the S.O. may require from time to time shall become the
Approved Drawings to be used for the manufacture and supply of the Goods. The
Contractor shall provide additional set(s) of the Approved Drawings as the S.O. may
require, without additional charge.
Unless specific instructions are given by the S.O. in writing, no drawings other than
Approved Drawings or drawings issued by the S.O. shall be used for the performance of
the Contractors obligations under the Contract.
Within 1 month of the despatch of any item of the Goods, the Contractor shall supply for
record purposes six (6) bound complete sets of the Manufactured Drawings amended as
necessary to show the Goods as manufactured.
After completion of installation, As-Built Drawings for installation works shall be
submitted within one (1) month of the completion of the Works.
Drawing format:
All drawings at each stage shall be submitted in the following formats:Approved Drawings: Five (5) sets in paper prints (A3 size);
Manufactured Drawings: Six (6) sets in paper prints (A3 size);
As-Built Drawings: Six (6) sets in paper prints (A3 size); and three (3) sets in CDROM.
All drawings must be signed and duly endorsed.
1.3
I.2
Maintenance instructions shall include charts showing lubrication, checking, testing and
replacement procedures to be carried out weekly, monthly and at longer intervals to
ensure trouble-free operations. Where applicable, fault location charts shall be included
to facilitate finding the cause of imperfect operation or breakdown.
The manuals shall contain detailed descriptions of the construction and operation of the
Goods with enlarged diagrams, lists of parts and procedures for ordering spares.
If in the opinion of the S.O. the information supplied is insufficient, the Contractor shall
supply further information as required. The manuals shall be printed in A4 size sheets
and suitably indexed and bound. A collection of manufacturers descriptive leaflets alone
will not be acceptable.
1.4
Quality Assurance
Within fourteen (14) days of the Letter of Acceptance, the Contractor shall produce and
submit to the S.O. for comment an outline Quality Assurance Plan. Within fourteen (14)
days thereafter, the Contractor shall submit to the S.O. for approval a detailed Quality
Assurance Plan that shall take proper account of the S.O.s comments on the outline
Quality Assurance Plan.
The approval by the S.O. of such Plan shall not relieve the Contractor of any of his duties
or responsibilities under the Contract. The Contractor shall implement the quality
assurance procedures in the Approved Quality Assurance Plan. The Quality Assurance
Plan shall set out the specific quality procedures, practices, resources and sequence of
activities to meet the requirements of the Conditions of Contract and Specifications and
shall include but not limited to:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
The Plan shall include organisation charts illustrating the main tasks and their sub-division,
the reporting structure and;
i.
I.3
ii.
iii.
The Contractor shall submit and receive approval of the Quality Assurance Plan before
starting manufacture of the Goods. The S.O. shall audit the Contractors quality plan and
its implementation. The Contractor shall submit a partial Quality Assurance Plan to the
S.O. to cover any work the Contractor will carry out within fourteen (14) days from the
date of the Letter of Acceptance. The Contractor shall not be entitled to commence the
manufacturing of the Goods prior to receipt of the S.O. approval of the Quality Assurance
Plan for that part. The S.O. may at his sole discretion, reject any of the works which in his
opinion have not been executed in accordance with the Quality Assurance Plan and the
Contractor shall re-execute at his own cost and without any entitlement to any extension
of time all such parts of the Works so rejected.
The Contractor shall adhere to the principles and procedures contained in the Approved
Quality Assurance Plan and any amendment or supplement thereof.
The Contractor shall deliver the goods by the dates and in the order of priority as he shall
have ascertained from the S.O. and included in the programme of delivery.
1.5
Notice of Deliveries
The Contractor shall notify the S.O. of the delivery date of each consignment at least
two (2) weeks in advance, and seek his instruction as to the point(s) of unloading. Every
consignment shall be accompanied by a detailed delivery note including the numbers of
each valve, fitting and/or actuator itemised as in the Bill of Quantities.
1.6
Marking
All valves shall bear the following marks on the outside of the valves:
(a)
The Manufacturer's distinguishing mark, manufacturing standard
(b)
The diameter (mm) and weight (kg).
(c)
The serial number and/on item number associated with the Bill of Quantities.
(d)
The pressure rating (PN)
(e)
Loading and duty at, which the valve has been designed to operate
Apart from all these markings, a bronze plate engraved with the word SYABAS (50mm
high) shall also be tied to each valve.
1.7
Inspection
All Goods to be supplied under the Contract shall be inspected by the S.O., the Engineer
or their appointed representative at the Contractor's premises or at the places of
manufacture, if manufactured at other premises.
The Contractor shall provide such office facilities, assistance, labour, materials, electricity
supply, fuel, stores, apparatus and instruments including X-ray or gamma ray equipment,
as may be necessary to allow a thorough and extensive inspection to be carried out.
I.4
The S.O., the Engineer or their appointed representative shall be entitled at all times
during manufacture to inspect, examine and test on the Contractors premises or at the
places of manufacture if manufactured at other premises, the materials and workmanship
of the Goods. Such inspection, examination or testing shall not relieve the Contractor
from any of his obligations under the Contract.
1.8
1.9
Site Conditions
The climatic conditions in Malaysia are generally hot, humid and tropical with maximum
air temperature in the shade exceeding 35C and relative humidity frequently reaching
98%. The Contractor shall take due considerations of the climatic conditions in the
design, transportation and storage of the Goods during the entire course of the works and
working life of the Goods.
1.10
Valve Agent
The Contractor shall assign a competent Valve Agent and such assistants as may be
necessary who must be capable of receiving instructions in Bahasa Malaysia and English.
The Valve Agent shall co-ordinate all submission until approval; co-ordinate the whole
stage of design, manufacture, shipping, delivery, installation, testing, commissioning,
I.5
prepare payment claims, settle any claims with regards to the Work, until issuance of the
Certificate of Making Good Defects and Final Accounts.
Any directions, explanations or instructions given to such Valve Agent by the S.O. shall be
deemed to have been given to the Contractor. Should the Contractor fail to provide such
Valve Agent, the S.O. shall appoint others as Valve Agent and all wages and other
expenses in connection with such employment shall be deducted from any monies due to
the Contractor.
2.0
2.1
(2) 20200-0050-99
(3) 20200-0083-00
JKR Standard Specification for Ductile Iron Type B Gate (Sluice) Valves
for Waterworks Purposes (DN 50 to DN 600
(4) BS 5163:1986
Predominantly key-operated cast iron gate valves for water works
purposes (part superseded by JKR specification)
(5) BS 5150:1990
(6) BS 4504:1989
(7) BS5155:1984 (1991) Specification for butterfly valves (part superseded by JKR specification)
(8) BS 5840:Part 1
(11) BS 2789:1985
(12) BS 970
(13) BS 1504:1984
(14) BS 3100:1991
(15) BS 1400:1985
Specification for copper alloy ingots and copper alloy and high
conductivity copper castings
I.6
(16) BS 2872:1989
Specification for copper and copper alloy forging stock and forgings
(17) BS 2874:1986
Specification for copper and copper alloy rods and sections (other than
forging stock)
(18) BS 4164:1967
Specification for coal tar based hot applied coating materials for
protecting iron and steel including suitable primers where required
(19) BS 2494:1990
Specification for elastomeric joint rings for pipe work and pipelines
(20) BS 6920:1988
Part 1
Part 2
(21) MS 672 : 1999
2.2
Materials
The term materials shall mean all materials and articles of every kind whether raw,
processed or manufactured to be supplied by the Contractor for the manufacture of the
Goods. Except as may be otherwise specified for particular parts of the Goods, the
provisions in this section of the Specification shall apply to materials and workmanship
for any part of the Goods.
All materials other than natural or pre-treated materials shall be new and of the kinds
and qualities described in the Contract and shall at least be equal to approved samples.
As soon as practicable after receiving the order to commence the manufacture of the
Goods, the Contractor shall inform the S.O. of the names of the suppliers from whom he
proposes to obtain any materials, but he shall not place any order, without the approval
of the S.O. which may be withheld until samples have been submitted and satisfactorily
tested. The Contractor shall thereafter keep the S.O. informed of orders for and delivery
dates of all materials.
Materials shall be transported, handled and stored in such a manner as to prevent
deterioration, distortion, damage or contamination.
2.3
I.7
Approval by the S.O. as to the placing of orders for materials, Goods or as to samples or
tests shall not prejudice any of the S.O.s power under the Contract nor relieve the
Contractor of any of his obligations under the Contract.
The S.O., the Engineer or their representatives will inspect and examine the Goods and
witness the test on the Goods at the Contractors premises in accordance with the
requirements of the Specification and the relevant standards.
2.4
Test Certificates
Certificates in duplicate shall be provided by the Contractor giving the process of
manufacture and the results of the specified tests as and when requested by the S.O.
Similar certificates in duplicate shall be provided by the Contractor in respect of materials
to be used in the manufacture of the Goods giving the process of manufacture, chemical
analysis (where relevant) and the results of the specified tests. The material shall be
suitably marked to enable it to be identified from reference on the certificates.
No materials subject to test shall be incorporated in the manufacture of the Goods until a
satisfactory test certificate has been received and approved by the S.O.
In case of any items which have not been inspected at the manufacturers works, the
Contractor shall obtain from the Manufacturer and supply to the S.O. certificates signed
by the Manufacturer giving the results of the tests as carried out and certifying that the
items have been manufactured in accordance with this Specification.
2.5
I.8
2.6
Testing Facilities
The Contractor shall at his own expense arrange with the suppliers or manufacturers to
supply the necessary gauges and prepare all test pieces and supply all labour and
apparatus for testing which may be required by the S.O., the Engineer or their
representatives for carrying out the tests to requirements of this Specification at the
Contractors premises or at the place of manufacture, and shall also provide all test pieces
required.
If the Contractor shall fail to perform any of the foregoing obligations, the S.O. shall be at
liberty to perform the said obligations or any of them, which the Contractor has failed to
perform, either at the Contractors premises, places of manufacture or elsewhere and
charge the costs and expenses thereof to the Contractor.
2.7
2.8
Rejected Materials
Any materials delivered to the Site, which have been rejected by the S.O., the Engineer or
their representatives shall IMMEDIATELY be removed from the Site.
Any Goods or materials, which have been rejected shall be marked in a distinctive
manner which will preclude any possibility of their use for the purposes of the Contract.
Such Goods may be submitted for re-test following the correction of any defects, where
such correction is permitted, subject to the approval of the S.O.
I.9
3.0
REQUIREMENT
3.1
GENERAL REQUIREMENTS
3.1.1
Materials
The valves, fittings and actuators (`Goods) shall be manufactured from materials
specified in the clauses appropriate to the particular item. Where the material to be
used has not been laid down in this Specification, the Contractor shall use only those
materials in such compositions as have been proved in actual service to be the most
suitable for the particular purpose.
All castings shall be reasonably smooth and free from flaws and defects. The valve trims
including pins, spindles and face rings, etc, shall be of corrosion resistant metals and
such parts that may show signs of corrosion or wear at the end of the Defects Liability
Period shall be replaced at no extra cost to the Contract or where allowed by the S.O.,
replaced by non-corrodible material of special quality at the Contractors expense. Care
shall be exercised in the selection of various types of metals for use in the valves to
reduce the effects of bi-metallic corrosion to the minimum.
Clauses on materials, standards, samples, tests and testing facilities under Section 3.2 of
the Specification shall be applicable where appropriate.
3.1.2
Grade of Materials
Materials used shall be of a quality not inferior to the following :-
3.1.3
Ductile Iron
Stainless
BS 970 Grade 316S16 and Grade 304S31 (in some cases only)
Cast Steel
Gunmetal
Phosphor Bronze -
BS 2870
Design
The Contractor shall design the valves to the S.O.s satisfaction and in accordance with
the Specification. The design shall be in accordance with the best modern practice and
shall be such as will facilitate inspection, cleaning, lubrication and repair to ensure
satisfactory operation under all service conditions.
The Goods may be of the Contractors standard design provided that such design is
generally in accordance with the Specification.
I.10
Approval by the S.O. of the Contractors design or drawings shall not relieve the
Contractor or any of his obligations or liabilities under the Contract except in so far as is
provided for by the Conditions of Contract.
3.1.4
Castings
The structure of castings shall be homogeneous and free from non-metallic inclusions and
other injurious defects. All castings shall be close-grained, sound, smooth, symmetrical
and shall be carefully cleaned and dressed off. No stopping or plugging will be permitted
in the case of holes or flaws appearing therein, and casting shall be made from first
running.
If any casting should prove defective, the S.O. shall have the power to reject it and the
Contractor shall replace it at no extra expense to the Contract.
3.1.5
Forgings
All major stress bearing forgings shall be made to a standard specification, which shall be
submitted if required to the S.O. for approval before work is commenced. Forgings shall
be subjected to non-destructive tests to detect flaws if any. Forgings shall be heat treated
for the relief of residual stresses. The name of the maker and particulars of the heat
treatment proposed for each such forging shall be submitted to the S.O.. The S.O., the
Engineer or their representatives may inspect such forgings at the place of manufacture
with a representative of the Contractor.
3.1.6
3.1.7
Lubrication
The Contractor shall submit full details of the method of lubrication to be employed for
Goods to be supplied under the Contract. The Contractor shall supply all necessary
lubricating equipment, including sufficient grease and other lubricants of each required
grade for setting valves to work and the cost of this shall be deemed to have been
included by the Contractor in the Contract rates.
3.1.8
I.11
Valve bodies, surface boxes and all other castings shall be coated in accordance with
Section 3.2.4 for tropical conditions. Machined surfaces shall be covered by a suitable
rust inhibitor, such as a high melting point grease of approved quality.
All submerged moving parts, or the pins, spindles and faces, etc in contact with them,
shall be of non-corrodible materials. Any parts that show signs of corrosion or wear
during the Period of Defects Liability shall be replaced by non-corrodible material of
special quality for the purpose at no extra expense to the S.O.. Care shall be exercised in
the choice of metals for use in the Goods to reduce the effects of bi-metallic corrosion to a
minimum. The foregoing shall apply also to the moving parts exposed to the weather.
3.1.9
Inspection
All Goods shall be inspected by the S.O., the Engineer or their representatives at the
Contractors premises or at the place of manufacture. The Contractor shall provide such
office facilities, assistance, labour, materials, apparatus and instruments as may be
necessary to allow a thorough and extensive inspection to be carried out.
The S.O. shall have free access to the Contractors plant or the manufacturers works at all
reasonable times, and shall be at liberty to inspect the manufacture of the Goods and
component parts at all stages. The charging of cupolas, melting, drawing off, conveying
and pouring of all metals shall be carried out in such a manner and at such time or times
that the S.O. desire to see that the work is carried out in accordance with this
Specifications, particularly but not limiting the following requirements/ conditions:
(a)
The manufacture of the Goods and component parts at all stages shall be
inspected and if found defective or inferior in quality to, or differing in form or
material, from the requirements of the Contract, may be rejected. The whole of
any consignment may be rejected if any of the Goods, or component part is found
not to conform in every respect to the requirements of the Contract.
(b)
The Contractor shall, if called upon to do so, obtain the S.O.s approval of the
manner in which the Contractor proposes to supply the Goods shall furnish such
drawings and information as the S.O. may require.
(c)
The Contractor shall notify the S.O. in advance of the date on which any of the
component parts, or Goods are ready for inspection.
(d)
The S.O. shall not be required to sign any form of waiver or indemnity concerning
his presence or actions at the place of inspection.
(e)
(f)
When independent tests and analyses, in addition to those made by the S.O. at
the Contractors or manufacturers premises, are considered necessary by the S.O.,
such tests, or analyses will be made by persons appointed by the S.O.. The
Contractor shall bear the cost of supply and carriage of samples and in addition
where the results of such tests or analyses show that the items are not in
accordance with the Specification, the cost of such tests or analyses.
I.12
(g)
The Contractor shall not deliver any of the Goods or report them as ready for
delivery until the S.O. shall have given his consent.
(h)
The inspection, examination or testing including the approval of the Goods by the
S.O. shall not release the Contractor from any of his obligations and liabilities
under the Contract.
The Contractor shall allow in his rates, where applicable and related expenses for
inspection of valves by the S.O..
3.1.10 Protection against damage during transit
All Goods shall be securely packed in crates or boxes for protection against damage
during transit. Valves of 450mm diameter and above shall be individually crated, battened
and bound with steel strip.
Flanges of valves shall be protected by wooden discs temporarily bolted on or secured by
steel strapping. Spindle caps of sluice valves shall be removed and secured to the inner
side of one of the wooden discs by means of a steel strip. Otherwise they shall be packed
in a case. The projecting end of the spindle shall be well wrapped with straw rope
covered by hessian cloth and secured in place by binding wire, which shall be carried
under the flange of the gland.
All plain ends shall be adequately protected by straw rope secured in place by binding
wire or strap. None of the packing will be returnable. The cost of packing shall be
included in the Contract rates.
3.1.11 Identification plates and labels
Each main and auxiliary item of the Goods shall, unless otherwise, specified, have
permanently attached to it in a conspicuous position an identification plate of weatherresistant material on which are engraved or stamped the Manufacturers name, service
rating, loading and duty at which the item of valves has been designed to operate, serial
number, weight and reference number as specified.
Additionally, each item shall have marked upon its body in raised letters the
manufacturers name, service rating, year of manufacturer and size of the Goods.
Details of proposed inscriptions shall be submitted to S.O. for approval before any labels
are manufactured.
3.2
3.2.1
General
All valves shall be designed to avoid cavitation and vibration in all positions, to minimize
head loss in the open position and to seal the water passage completely when shut. All
operating spindles and gears shall be provided with adequate points for lubrication.
Unless otherwise specified, all valves shall be closed in a clockwise direction. Lifting lugs
shall be provided for valves of sizes 600mm and above.
I.13
Head loss curves through the valves for throttled flow conditions shall be provided for
all valve sizes.
All protective coatings shall be non-toxic and shall not foster microbiological growth nor
impart any odour, taste, cloudiness or discoloration to the water.
After installation, the external surfaces shall be painted with two coats of cold applied
high solid liquid epoxy to AWWA C210-84. The minimum dry finished thickness shall
not be less than 350 micron.
The Contractor shall take note that all valves will normally be installed with one end fixed
and the other end to a flexible joints either a flange adaptor or mechanical coupling joint.
Unless otherwise stated, all valves shall be double flanged.
Unless otherwise specified, the bodies and discs of sluice valves, butterfly valves, and
non-return valves shall be manufactured from ductile iron to BS 2789/BS EN 1563 Grade
Grade 500/7.
3.2.2
Flanges
All valves are to be installed on steel pipes with flange details as per BS 4504. All flanges
shall be cast integral with the valve, add-on flanges by other means is not acceptable.
All valve flanges shall be designed to withstand the stresses of the valve ratings. They
shall be at right angles to and concentric with the bore axes. They shall be of the raised
face type, truly faced over their whole width and drilled in accordance with BS 4504 to
match with the flanges for the steel pipes. Bolthole shall be drilled off centre lines and
shall be truly in line end to end with the longitudinal axis.
3.2.3
Works Test
After completion of assembly each valve shall be shop operated from the fully open
position to the fully closed position and return to fully open under no flow condition to
demonstrate that the assembly is working smoothly. The torque required on each valve
shall be ascertained. Where electric motor actuators are provided, the complete assembly
of valve and actuator shall be tested.
All valves shall be hydrostatically tested at the place of manufacture to the pressures
specified and shall satisfactorily pass the specified tests before they are packed for
delivery.
All valves shall be body tested to one and a half (1 ) times the valve rating pressure.
Seat tests to 1.1 times the valve rating pressure and shall be carried out on all valves.
All valves shall be subjected to open end test in accordance with B.S. 5163 and each
valve shall be subjected to separate hydrostatic tests as follows:(a)
Seat tests
The tightness of seats shall be tested as follows:-
I.14
(b)
(i)
with the wedge or disc closed and with the valve fixed at one end only
and the other end free, the test pressure shall be applied to that face of
the wedge or disc, the other face being at atmospheric pressure. There
shall be no visible leakage past the wedge or disc at the hydrostatic test
pressure (gauge) specified;
(ii)
The above procedure shall be repeated but with the valve fixed at the
other end and with the pressure applied to that end of the valve.
Body test
With the wedge or disc open the test pressure (gauge) specified shall be applied to
the whole body of the valve. There shall be no visible leakage through the body,
the flanged joint or the valve packing gland nor shall any part be permanently
deformed.
The test durations for all tests shall be as in the table below:Minimum test duration (minutes) for
Nominal Diameter
(mm)
(c)
Body
Seat
200 to 300
The S.O. requires the Contractor to comply with the following additional tests, as
per JKR Standard Specification (JKR 20200-0083-00):
I.15
Functional Test
The valve shall be fully opened and then closed, using the same number
of turns, as specified in the Schedule of Particulars, with a torque not
exceeding the maximum functional test torque during any time in its
travel.
Then the test shall be repeated in the closed position.
Durability test (for elastomer on the wedge or for resilient seated valve)
The valve shall be fully closed and subjected to the working pressure of
the valve. Then, it is opened to 1/3 of the fully open position and fully
closed again. Each closure is considered as one cycle.
Each valve shall be subjected to 50 cycles whilst the working pressure of
the valve is maintained.
After the durability test, the elastomer shall be inspected to ensure no
visual cracks, tear or chipping off.
(d)
A test certificate must be supplied with each valve. It shall contain a statement by
the manufacturer confirming that the valve has been tested, the test results, the
standard adopted, pressures used, test medium and duly signed by an authorized
personnel. The serial number on the certificate shall be the same as on the valve.
The cost of these additional tests shall be included in the Contract rates for factory
testing.
3.2.4
I.16
3.2.5
All gate valves shall be of resilient seat (50mm to 300mm); metal seat (350mm to
600mm), Type B, PN 16(bar) rating (unless otherwise specified), cap operation
with non-rising spindle/stem, conforming to JKR Specification 20200-0083-00: JKR
Standard Specification for Double Flanged Ductile Iron Type B Gate Valve for
Waterworks Purposes and BS 5163:1986 or better. The range of valve sizes
covered is DN50 to DN600.
(b)
All gate valves of 300mm dia. and up to 600mm dia. shall be supplied complete
with spur gearing. Where gear box is specified, the status of the valve open/close
position shall be provided.
(c)
(d)
All flanges and boltings shall comply with BS4504 or BS EN 1092-2: 1997.
(e)
Ductile iron conforming to BS 2789/BS EN 1563 with Grade 500/7 for the
following:
(i)
(ii)
(iii)
(iv)
Body
Bonnet
Stuffing Box
Grand/Seal housing
(v)
(vi)
Wedge
Cap/Handwheel/ torque limiting/stem cap
(b)
( c)
Stem nut and wedge ring/body (not applicable for resilient seat) shall be of
gunmetal LG2 conforming to BS 1400 or stainless steel 431S29 or 304S31
conforming to BS 970.
(d)
Dust seal/excluder and spindle seal shall be of rubber O-ring made of EPDM or
Nitrile conforming to MS 672:99 or AS1646:92. Stuffing box and bonnet gasket
shall be not less 3mm thick gasket made of EPDM or Nitrile conforming to MS
672:99 or AS1646:92 with 66-75 IRHD. Gland Packing shall be of asbestos free
teflon braided packing or rubber O-ring made of EPDM or Nitrile conforming to
MS 672:99 or AS 1646.
I.17
(e)
The wedge for resilient seat shall be vulcanised with rubber made of EPDM or
Nitrile conforming to MS 672:99 or AS 1646:92. The entire wedge gate shall
form an axial and butt seal against the valve body, giving a tight shut-off at all
pressures up to the full rating or the required test pressure. The method of butt
sealing at the bottom of the wedge shall give smooth straight-through bore in the
body without seating recess.
The valve shall be designed so that the gate may be removed without removing
the body from the connecting pipe work. The gate guides shall be cast integrally
with the valve body and be of adequate strength and of sufficient length to guide
the gate throughout their full travel. In the fully open position, the gate shall be
withdrawn well clear of the flow stream and the spindle shall not protrude into
the bore of the valve.
(f)
(g)
Bolts, nuts, washers and setscrews shall be of stainless steel 316S16 for
corrosion resistance for the following:
(i)
(iii)
(h)
(i)
Ductile iron caps shall be supplied to fit the spindles or operating gears for all
the valves and these shall be secured by brass set screws with the direction of
closing indicated on the caps.
(j)
(k)
An identification plate marking the serial no. of the valve, dimension, type of
valve, etc. shall be permanently attached to the valve body.
I.18
ITEM
COMPONENTS
MATERIAL
GRADE
STANDARD
1
2
3
4
5
6
7
Stainless steel
Stainless steel
Ductile iron
Ductile iron
Ductile iron
Stainless steel
Asbestos free teflon braided packing
Or
Rubber O-Ring
304S31
304S31
500/7
500/7
500/7
304S31
-
BS 970
BS 970
BS 2789 or BS EN1563
BS 2789 or BS EN1563
BS 2789 or BS EN1563
BS 970
-
Nitrile or EPDM
8
9
10
Stuffing box
Stuffing box gasket (3mm thick) (min)
Stem/Spindle
11
12
13
14
Bonnet
Bonnet bolts & nuts
Bonnet gasket (3mm thick) (min)
Stem nut/Spindle nut
15
16
Wedge
17
18
19
20
Body
Dust seal/excluder
Seal cartridge
Stem seal/Spindle seal
Ductile iron
Rubber
High tensile brass
Or
Stainless steel
Ductile iron
Stainless steel
Rubber
Gunmetal
Or
Stainless steel
Gunmetal
Or
Stainless steel
Ductile iron (400mm dia. only)
Or
Ductile iron vulcanized with rubber
500/7
Nitrile or EPDM (66-75 IRHD hardness)
CZ116, CZ114
MS 672 : 1999 or
AS 1646 : 1992
BS 2789
MS 672
BS 2872/BS 2874
431S29
500/7
304S31
Nitrile or EPDM (66-75 IRHD hardness)
LG2
BS 970
BS 2789
BS 970 : Part 4
MS 672
BS 1400
431S29 or 304S31
LG2
BS 970
BS 1400
316
500/7
BS 970 : Part 4
BS 2789
Nitrile or EPDM
Ductile iron
Rubber O-ring
Gunmetal/acetal resin
Rubber O-ring
500/7
Nitrile or EPDM
LG2
Nitrile or EPDM
MS 672 : 1999 or
AS 1646 : 1992
BS 2789
MS 672 : 1999
BS 2872
MS 672 : 1999
S3-19
24 July 2007
All sluice valves shall be Works Tested in accordance to Clause 3.2.3 and site
tested where deemed necessary.
(b)
Durability test for elastomer on the wedge of the resilient seated valves shall be
tested in accordance to JKR Specification 20200-0083-00.
(c )
A test certificate shall be issued for each valve tested with details of the standard,
pressures used, type of tests conducted, medium used, duration of tests, serial
number of valve, date of tests, certified by a qualified tester, etc.
(b)
(c)
(d)
(e)
(f)
(g)
Year of manufacture.
(h)
(i)
Apart from all these markings, a bronze plate engraved with the word SYABAS (50mm
high) shall also be tied to each valve.
3.2.6
Butterfly Valves
3.2.6.1 General
(a)
The butterfly valves shall conform generally to JKR Specification 202000050-99 or BS 5155 or better. The valve shall be selected as follow:CONCENTRIC DISC DESIGN is suitable for dual flow operation;
SINGLE or DOUBLE ECCENTRIC DISC DESIGN WITH RESILIENT
SEAT, TIGHT SHUT-OFF TYPE is suitable for single way operation.
I.20
All valves shall be suitable for waterworks purposes in a tropical country. All
butterfly valve shall be rated at PN16 (bar) unless otherwise specified. The
range of valve sizes covered is DN50 to DN2000.
(b)
(c )
(b)
I.21
Valves will be installed with the disc shafts horizontal. Valves of 450mm
diameter and above shall be provided with suitable reducing gears. Quadrant
worm reducing gear totally enclosed in a ductile iron gear box and secured to
the valve body shall be provided for the smooth operation of the valves.
The worm shaft shall be vertical and square at the top for operation with a mild
steel/stainless steel key held in a vertical position. The gearing shall be suitable
for operation of the respectively valves by a mild steel/stainless steel tee key and
bar with a force of 270 Newtons applied on each side simultaneously from a
distance 750mm from the centre of the key against the full unbalanced pressure
of the valve rating. Suitable means shall be provided to prevent overstressing of
the valve seat in the close position.
The gearing and bearings shall be protected by suitable water-tight enclosures
permanently packed with grease. The Contractor shall provide details of the
type of gearings in the Schedule of Particulars and shall state in his Tender the
type of test to be carried out to demonstrate the water tightness of the assembly
under a head of 3.5 metres of water column.
(d)
Ductile iron caps shall be supplied to fit the spindles or operating gears of all the
valves and these shall be secured by brass set screws with the direction of
closing indicated on the caps.
(e)
All butterfly valves shall be Works tested in accordance to Clause 3.2.3 and site
tested where deemed necessary.
(b)
Durability test for elastomer on the wedge of the resilient seated valves shall be
tested in accordance to JKR Specification 20200-0050-99.
(c )
A test certificate shall be issued for each valve tested with details of the standard,
pressures used, type of tests conducted, medium used, duration of tests, serial
number of valve, date of tests, certified by a qualified tester, etc.
(b)
I.22
(c)
(d)
(e)
(f)
(g)
Year of manufacture
(h)
(j)
Apart from all these markings, a bronze plate engraved with the word SYABAS (50mm
high) shall also be tied to each valve.
Table 2 : Components and materials for butterfly valve
Component
Body
Body with integral seat
Disk
Handwheel
Shaft/Spindle
Material
Ductile Iron
Ductile Iron
Stainless steel
BS Reference
BS 2789
BS EN 1563
BS 2789
BS EN 1563
BS 970
Grade or
designation
500/7
420/12
431S29
Carbon steel
Internal fastenings
Stainless steel
3.2.7
Phosphor bronze
Aluminium bronze
BS 2870, BS 2873
BS 2872, BS 2874,
BS 2875
PB102
CA103,
CA104, CA106
BS 3076
NA13
Non-return Valves
Non-return valves shall be of an approved non-slamming, tilted disc or recoil type to
PN 16 (unless otherwise specified), capable of withstanding severe transient surge shall
be mechanically and hydraulically designed to ensure rapid closure before reversal of
flow under high velocities and surge conditions especially when an air surge vessel is
incorporated and/or when two or more pumps are running in parallel. The valves shall
be adequately sized so that under normal flow conditions the velocity shall not exceed
2.0m per second and the friction losses not greater than 0.5m. Valves of diameter
greater than 460mm shall be of the multi-door type. Friction curves and dynamic
performance test for non-slam features MUST be submitted with the tender. These
curves must be endorsed and signed by both the manufacturer and agent/sole
I.23
distributor, without which their tender will not be accepted. In this instance, an
endorsement means that the manufacturer and agent/sole distributor warranties the
results of the tests and that each of the valves manufactured will meet these minimum
standard.
The body, door and cover shall be of spheroidal graphite iron to BS 2789/BS EN1563;
minimum Grade of 500/7.
The door shall be hinged on an aluminium bronze or stainless steel pin and supported
in gun metal bearing blocks. The body seat and door facing rings shall be gun metal or
aluminium bronze. For horizontal valve, the seating shall be inclined at an angle of not
greater than 50 degrees from the flow axis. All internal parts shall be renewable. All
non-return valves exceeding 450 mm diameter shall incorporate a by-pass complete
with isolating valves.
The flow are through the valve body, inlet and outlet, shall be equal to the pipe size and
gradually increased to as area 40% greater that pipe size through the valve seat.
Non-return valves for installation in vertical pipes delivering upward flows shall be
suitably modified where necessary to achieve the above design criteria.
Conventional check-valves are unsuitable for the above duties and will not be
acceptable for use in delivery mains of the pumps.
During normally open position, headloss must be at the minimum possible and in the
close position, there shall be NO LEAK. Certified test reports must be submitted.
The Contractor shall guarantee that the valve supplied complies with the NON-SLAM
Characteristics. This feature shall be specified in the test certificate and verified on site.
Should the valve fail to prove this, the Contractor shall provide a replacement and/or
alternative, at no additional cost to the Contract.
All check valve shall be provided with a position indicator of the disc, visible from all
positions. All check valve shall be surface prepared in accordance to Clause 3.2.4 and
BS 6920.
I.24
Air Valves
3.2.8.1 General
All air valves shall generally conform to JKR Specification 20200-0043-99 (or better) for
ductile iron air valves.
Double orifice air valves shall be of the `Aerokinetic type incorporating hydrodynamic
principles suitable for air exhausting during charging or venting when emptying of the
main. The ball-sealed orifice shall always remain open while air is discharged and shall
be immediately closed when the water rises in the valve to lift the ball and seal the
orifice.
The escaping turbulent air or a mixture of air and water spray (even at the critical
velocity of 300 m/sec) shall not cause the ball to be thrown into the discharging air
stream and be blown shut prematurely during the filling of the water main a high rate.
Under no circumstances shall the large orifice ball blow shut prematurely.
Standard double orifice air valves shall have a minimum pressure rating of 16 bars
(unless otherwise specified) and in all cases shall be supplied with PN 16 flanges to BS
4504:1989.
The ball of the large orifice shall bear a calculated mathematical relation with the inlet
diameter of the valve i.e. average cross-sectional area of escaping air stream, so that the
ball will be blown shut by a stream of water but held down by a stream of air. The
buoyancy of the ball shall be such that it will ensure effective sealing of the large orifice
even at low pressure. The weights of each ball of the same size and type shall be not
differ by more than 2%.
Single small orifice air valves shall be reliable in action and shall operate such that the
ball cannot be held against orifice by air pressure alone.
The design of the valve shall be such as to allow maximum free air discharge and inflow
at pressure differentials of plus 0.5 bar and minus 0.2 bar respectively. The Contractor
MUST submit with his tender, curves for free air discharges and inflow against various
air pressures at valve inlet. These curves must be endorsed and signed by both the
manufacturer and agent/sole distributor, without which their tender will not be
accepted. In this instance, an endorsement means that the manufacturer and
agent/sole distributor warranties the results of the tests and that each of the valves
manufactured will meet these minimum standard.
Each air valve shall be supplied with horizontally positioned isolating sluice valve of the
same size with bevel gearing arrangement for vertical operation and a set of flange
jointing materials including nuts, bolts, washers and joint gaskets for insertion between
the air valve and sluice valve. The gear box shall be greased pack, concealed
permanently and water-tight. The isolating sluice valve is specified in Clause 3.2.5. The
bevel gear pinion shall be of corrosion resistant steel. A pressure tapping insertion into
a suitably designed short piece as shown in the Drawings shall be supplied with each air
valve tee. The flange diameter of the insertion short piece shall be the same to suit the
air valve.
I.25
All air valves shall be made insect proof by providing stainless steel screens at the vents
leading into the atmosphere. The floats shall be ABS plastic balls or stainless steel
Grade 316.
The orifice shall be either gunmetal or stainless steel, not less than 3mm and tapering to
10mm suitable to release accumulated air within the pipe. The profile of the orifice
shall be such as to avoid damage to the ball surface. The orifice shall be protected by a
suitable plug of stainless steel.
The low pressure cover shall be massive and designed to withstand full operating thrust
in working condition. The neoprene seat ring shall be held securely in place under the
low pressure cover by a joint support ring to prevent it from sagging when the ball is not
sealing the orifice.
After completion of machining but before assembly the valve body shall be
hydraulically tested to one and a half (1.5) times the valve rating pressure for a period a
5 minutes and thereafter compressed air at a slightly higher pressure shall be released
through the valve inlet to check the function of the ball.
Subsequently, the hydraulic pressure shall be reduced to 0.5 bar and there shall be no
leakage through any of the orifices.
Materials used shall not be inferior to the following:
(a)
Ductile Iron
(b)
BS 1400 LG2
(c)
Brass/Gunmetal for
plugs and spindles
(d)
(e)
ABS Plastic *
ISO 2580
(f)
Stainless Steel
Note :* ABS plastic float shall be counter weighed such that the seam/joint of the ABS ball will always
remain horizontal, it will seal against the seat of the air valve in one position only.
(b)
A test certificate shall be issued for each valve tested as follows: Type tests
Performance test
The certificate shall be complete with details on pressure used, type of test conducted,
medium used, serial number of valves, date of test, certified by a qualified tester.
I.26
b)
c)
d)
Year of manufacture
e)
Apart from all these markings, a bronze plate engraved with the word SYABAS (50mm
high) shall also be tied to each valve.
3.2.9
Control Valves
I.27
A visual valve position indicator shall be provided to indicate the valve piston position.
The visual shall be capable of operating in any position and shall incorporate a single
flanged cover at the top of the valve. All parts shall be accessible and serviceable
without removing the valve from the pipeline.
3.2.9.2 Float Control Valves
The float/level controlled valve supplied shall be of the full bore, one way flow, pilot
controlled, diaphragm or piston actuated, hydraulically operated globe type valve.
The main valve modulates to maintain a constant tank level.
The valve supplied shall be suitable for side mounting and/or at ground level. It may or
may not operate together with another external float, plunger, level, etc.
The control shall be a modulating, remote mounted type of simple but sensitive design,
requiring minimum head to open the valve and responsive to water level variation.
The construction material of this valve is similar to the Altitude Control valve in Section
3.2.9.1.
3.2.10 Fittings
Extension spindles of galvanised mild steel/stainless steel shall be provided for operating
of valves. The bottom end of the spindle shall be in the form of a socket to fit the cast
iron cap and the top end squared to suit the valve key.
Extension spindles shall be of suitable cross section to prevent buckling or permanent
distortion under all operating conditions and shall be capable of withstanding at least
twice the rated output torque of the electric motor actuator or at least twice the torque
developed at the stem created by a maximum force of 340 N at the rim of the hand
wheel.
The length of the spindle required between the top of the valve and the horizontal axis
of the hand wheel, both in the case of hand wheel operated valves and electric motor
actuated valves, shall be as shown on the Drawings. The spindle shall be supported
such that the L/R (L= length or span between supports, R = radius of gyration) for the
unsupported part of the spindle shall not exceed 200.
Where spindles are furnished in more than one piece, the different sections shall be
joined together by rigid couplings. The couplings shall be threaded and keyed or
threaded and bolted, and shall be of greater strength than the spindle.
The threads of the spindle shall be machine cut and of the square or ACME type. The
number of threads per decimetre shall be such as to work most effectively with the
actuator.
Rising spindles shall be provided with adjustable limit nuts or stop collars above and
below the pedestal lift nut to prevent over-travel of the sluice or disc gate in either
direction.
I.28
Bracket-mounted and floor-mounted spindle guides, including both the guide housing
and the bracket, shall be constructed so that when properly spaced they will hold the
stem in alignment and yet allow it enough play to permit easy operation. The inside
diameter of the guide shall not be more than 3mm larger than the outside diameter of
the spindle. The guides shall be spaced in accordance with the manufacturers
recommendations for each spindle size.
The guide shall be adjustable with regard to the bracket to provide concentric alignment
with the spindles and shall be lined, and provisions shall be made to hold the lining
rigidly in place so as to prevent loosening while in service.
Brackets shall be fixed to the concrete walls with sufficient anchor bolts to prevent
twisting or sagging under load. Valve keys shall be of galvanized mild steel/stainless
steel suitable to operate the extension spindles.
Cast iron surface boxes shall have square openings with top supporting flanges and be
100mm deep suitable for heavy traffic. The covers shall be of the chained type.
The Contractor shall obtain from the S.O. confirmation of the exact length of extension
spindles required before manufacturing them.
3.2.11 Electric Actuators
Electrically operated actuators for valves shall be sized to guarantee closure at the
maximum possible differential pressure across the disc. The safety margin of motor
power available for unseating the door shall be at least 50 percent in excess of
maximum closing torque at the nominal supply voltage. For valve sizes 300mm or
greater, the closing and opening shall take approximately 2 minutes for each operation
unless otherwise specified. For valve sizes less than 300mm, the operating speed for
closing and opening shall be 300mm per minute.
The electric motors shall be Class F insulated and tropicalised and with a time rating of
15 minutes or twice the valve stroking time, whichever is longer. Duty rating shall be S2
or S4.
Motor burn-out protection shall be provided by direct sensing of motor temperature by a
thermostat embedded in the motor winding. A changeover volt-free contact (monitor
relay) for remote indication of motor tripped shall be provided.
A space heater shall be provided in the electric actuator. The heater shall be suitable for
use on a single phase A.C. supply and wired to the terminals compartment. The heater
shall be sufficiently rated to maintain the temperature above dew point when the
actuator motor is stationary.
The actuators gearbox shall be of totally enclosed grease lubricated type, suitable for
operation at any angle. The gearbox shall be designed to be leak proof and without
further re-greasing throughout its operating life. The drive shall incorporate a lost
motion hammer blow feature. The output shaft shall be hollow to accept a rising stem.
Thrust bearings of the ball or roller type shall be provided in such a way that the gear
case can be opened for inspection or disassembled without releasing the stem thrust or
taking the valve out of service.
I.29
A hand wheel shall be provided for emergency operation and shall be arranged such
that when engaged the motor shall be automatically disconnected mechanically and
electrically and the drive being restores to power only after disengaging the hand wheel
and by starting the motor. The hand wheel and any gearing shall be such as to permit
emergency manual operation in a reasonable time and in any case shall not exceed one
hour. Clockwise operation of the hand wheel shall give closing movement of the valve
unless otherwise stated.
The actuator shall be furnished with a drive bushing easily detachable for machining to
suit the spindle or gearbox input shaft. The drive bushing shall preferably be positioned
to enable standard length stems to be used. The valve manufacturer shall furnish stem
details so that the actuator manufacturer can machine the drive bushings to suit the
valve extended spindles. Unless otherwise specified, extended spindles, wherever
required, shall be of hot dipped galvanised mild steel construction coated with coal tar
epoxy paint. Where the length of the extended spindle exceeds 1.5m length, universal
couplings shall be incorporated.
Electric actuators shall be provided with open and close torque and position limit
switches with separate changeover volt-free contacts at each end of travel for remote
indication and inter-locking. Means shall be provided to prevent the open torque switch
tripping while the initial unseating hammer blow effect is applies. Two extra sets of
limit switches shall be provided, as required, with at least three switches per set, each
set independently adjustable to any valve opening or closing position.
A mechanical dial indicator (indicating 0-100 percent marking) shall be provided to
show continuous valve movement. In addition, a 4 20 mA analogue signal output
shall be provided for continuos remote position transmission.
The reversing contactor starter and local controls shall be integral with the actuator,
suitably housed to prevent breathing and condensation build-up.
Static or solid state controls will not be accepted.
The starter shall be suitable for 60 starts per hour, and shall comprise mechanically and
electrically interlocked reversing contactors of appropriate rating to the motor size with
coils fed from a 110 volt control transformer of 40 VA minimum rating. The common
connection of the contactor coils at the transformer shall be earthed so that the
contactors drop out in the event of leakage to earth. The primary winding shall be
separated from the secondary by an earthed screen and the secondary output shall be
protected by an easily replaceable cartridge type fuse.
When the distance between the actuator and the remote control point exceeds 500
metres, the remote control voltage shall be 24V DC, derived from a rectified supply
from the remote control point. The required DC interposing relays shall be incorporated
in the actuator and shall be suitable for satisfactory operation within 80-110% of the
nominal DC voltage.
A phase discriminator shall be incorporated to ensure correct rotations.
Local controls shall comprise pushbutton switches to Open, Close and Stop and a
Local/Off/Remote selector switch pad lockable in any one of three positions:Local control only.
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\I-Valves.doc
I.30
I.31
I.32
I.33
General
1.1
This specification briefly specifies the requirement for the standard 100mm and 150mm
pillar hydrants.
1.2.
Pillar hydrants will be of ductile iron material conforming to BS 750 : 1984 or JKR
Specification 202000-0042-99.
2.0
2.1
2.2
The 100 mm pillar hydrant shall be designed with 65 mm diameter outlets as shown
in Appendix 1 & 2.
The pressurized 100 mm pillar hydrant shall be equipped with landing valves as in
Appendix 3.
The 150 mm pillar hydrants is provided with two 65 mm diameter outlets and one
100 mm diameter outlet as in Appendix 4.
3.0
Materials
3.1
The body and cap of the pillar hydrants shall be made of ductile (spheroidal graphite) iron at least
of quality conforming in all respect to the requirements specified in BS 2789:1985 of Grade
421/12.
3.2
Outlets
The material for outlets shall be made of die-cast brass which must comply with the
standard BS 1400 Grade DCB1 with minimum tensile strength of 210 N/mm.
The screwed outlets shall be provided with caps to cover the outlet thread.
_____________________________________________________________________________________________
J.1
3.3
The caps shall be securely attached to the hydrant by galvanized steel chain.
The screwed outlets shall be locked to prevent theft by using pins as shown.
Landing Valve: -
The materials used for all the components of the landing valve are as shown and must comply with
BS 5041 Part :1987.
4.0
Dimensions
4.1
Body
4.1.1
4.1.2
Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.
Overall height
875 mm 10 mm
213 mm 3 mm
Internal diameter
Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.
4.2
Outlet
4.2.1
65 mm diameter Outlet
150 mm 3 mm
This outlet is used as the standard outlets for the 100 mm diameter pillar hydrant and as the
side outlets of the 150 mm diameter pillar hydrant.
_____________________________________________________________________________________________
J.2
4.2.2
4.2.3
Outlet diameter
Internal 64mm
+ 0.0 mm
- 1.5 mm
External 75 mm
+ 0.8 mm
- 0.0 mm
Length of outlet
122 mm 1.0 mm
Diameter of flange
96 mm 1.0 mm
Length of thread
35 mm 1.0 mm
Diameter of thread
(External)
35 mm 0.4 mm
Type of threads
V - Threads
5 1/3 Nos
Outlet Diameter
Internal
95 mm + 0 mm
- 1.5 mm
External
112 mm + 0.8 mm
- 0 mm
(ii)
Length of Outlet
126 mm 1.0 mm
(iii)
Thickness of Flange
12 mm 1.5 mm
(iv)
Diameter of Flange
140 mm 1.0 mm
(v)
Length of thread
50 mm 1.0 mm
(vi)
(vii)
Type of threads
Threads per 25.4 mm
Round Threads
3 Nos.
_____________________________________________________________________________________________
J.3
4.2.4
Landing Valves
All landing valves shall comply with BS 5041 Pt 1:1987 to be used for the pressurized
100mm pillar hydrant as well as the side outlets of the pressurized 150 mm pillar hydrant.
4.3
Caps
Cap dimension are as follows:
4.4
4.3.1
Width of cap
External diameter of cap
Internal diameter
Rubber gasket
4.3.2
Width of Cap
51 mm 1.0 mm
External diameter
210 mm 3 mm
Internal diameter
112 mm 0.5 mm
Rubber gasket
42 mm 1.0 mm
100 mm 2.0 mm
81 mm 0.5 mm
Min. 3 mm thick
Min. 3 mm thick
Chain
The total minimum length of chain used for 100 mm pillar hydrant.
Link of galvanized steel chain can be fixed either by attaching to the ear with a 100
mm drill hole or embedding in lug formed in casting.
5.0
Coating
5.1
All machined surfaces shall be thoroughly cleaned and shall be treated with a protective
composition before they become affected by rust.
_____________________________________________________________________________________________
J.4
5.2
The outer surface of the body shall be coated of either fusion bounded epoxy powder or
approved fire hydrant yellow with minimum thickness 250 m conforming to AS / NZ
4158.
6.0
Testing
6.1
Hydrostatic Test
7.0
The hydrant is subjected to a hydraulic pressure of not less than 24 bar for a period of not
less than 24 bar of a period of not less than 1 minute.
The hydrant shall deliver not less than 210 liters / min at a constant pressure of 1.7 bar at
the inlet to the hydrant (Results may be obtained by interpolation by referring to the
pressure versus flow curve as in Appendix 7).
Markings
Each hydrant shall have the following markings in raised letters of minimum 50 mm high cast on
the body.
Made in Malaysia
8.0
Accessories
8.1
Valves
_____________________________________________________________________________________________
J.5
8.2
All fittings such as double-flanged duck-foot 90 () bends and pipes with cast-on flanges,
Class K 12 connecting to the pillar hydrants shall be made of ductile iron.
8.3
All ductile iron fittings shall have the tensile strength of 421 Mpa and minimum elongation
of 5%.
8.4
All fitting shall be coated with fusion bonded epoxy powder of not less than 350 m
thickness.
All bolts, nuts and washers made of hot dipped galvanize zinc plated carbon steel
coated with Rislan Nylon with the finished thickness of coating between 75 m and
125 m.
9.0
Flanged joints
9.1
The dimensions and tolerances of the flanges of pipes and fittings shall comply with PN 16
requirement for ductile iron.
9.2
Each fitting shall be supplied with a set of flange jointing materials, which shall be
completed with nuts, bolts, washers and joint rings.
9.3
Joint rings shall be of flat section 5 mm thick, medium rubber reinforced with two-ply
flexible fabric and shall not extend beyond the bolt circle.
10.0
10.1
It is the responsibility of the Contractor to inform SYABAS Sdn. Bhd. for inspection purposes
during manufacturing and before delivery.
10.2
SYABAS reserved the rights to inspect and witness the testing of product offered.
10.3
At any time, when requested, the Contractor is to provide SYABAS a sample of the product
offered for evaluation purposes. All costs shall be borne by the Contractor.
10.4
If at any time the Contractor fails to deliver the required sample, the product is deemed fail
to meet the specifications.
11.0
Certification
11.1
The Contractor is required to provide a copy of the certificate and testing report from SIRIM,
IKRAM or other recognised certification body.
11.2
Tests report required should be those tests conducted within a year period.
_____________________________________________________________________________________________
J.6
11.3
SYABAS reserved the rights to refuse offer or reject supply if the documents required are not
enclosed.
12.0
Packaging
All pillar hydrants shall be individually packed with proper methods and protected from
damage during transit.
_____________________________________________________________________________________________
J.7
_____________________________________________________________________________________________
J.8
_____________________________________________________________________________________________
J.9
_____________________________________________________________________________________________
J.10
_____________________________________________________________________________________________
J.11
_____________________________________________________________________________________________
J.12
_____________________________________________________________________________________________
J.13
Appendix 5
Cold Applied High Solid Liquid Epoxy Coatings
On Casting Surfaces (Both Internally and Externally)
1.
Surface Preparation
All surfaces to be coated shall be clean and dry and free from porosity, crack, sand, rust,
oil, grease and other foreign matter. They shall be prepared by abrasive blast cleaning to Sa
2 Standard (ISO 85011). Only dry abrasive blasting procedures shall be used.
Any clean surface left overnight without coating shall be reblasted before application of
coating. In the event rusting occurs after completion of surface preparation due to bad
weather, the surface shall again be cleaned in accordance with the specified standard.
Cleaning shall be discontinued each day in sufficient time to permit the surfaces cleaned to
be coated before rust booming.
2.
Coating Application
Coatings shall be applied in accordance with Section 3.3 of AWWA C210-84. Application
of coating shall be by spraying to a total dry film thickness of more than 356 microns but
less than 635 microns.
The coating shall not have coating imperfections such as blisters, cracks, bubbles,
underfilm voids, mechanical damages, holidays, pinholes or discontinuities.
3.
Coating Repair
Areas requiring coating repairs due to coating imperfections shall be cleaned using hand
and power tool to minimum St 2 Standard (ISO 8501-1). The adjacent coating shall be
roughened. All dust shall be wiped off.
Same coating material shall be applied to the prepared repair areas immediately to the
required thickness. Repairs shall be electrically inspected using a holiday detector.
4.
Coating Procedure
a.
b.
Application Condition :
_____________________________________________________________________________________________
J.14
Surfaces shall not be coated in rain, wind, fog, mist or in areas where airborne elements
exist; when the steel surface temperature is less than 30C above dewpoint; when the
relative humidity is greater than 85%. Blast-cleaned surfaces shall be coated as soon as
practical, not later than rust booming.
c.
Apply a wet coat in even parallel passes. Overlap each pass 50% to avoid bare
areas pinholes or holidays.
Thinning normally not required. Thin only for workability with not more than 10%
by volume of thinner.
Check thickness of dry coating with non-destructive dry film thickness gauge.
It is recoatable provided that the existing surface is cleaned from oil or other foreign
contamination. Prior to recoating all irregular surfaces are to be sand paper abraded.
5.
Inspection
a.
Surface Preparation :
recoating
time
shall
follow
paint
manufacturer
Surface Profile :
The profile height shall be spot checked with Elcometer Profile Gauge or KeaneTator Comparator with reference to5a. above.
c.
Paint Material
_____________________________________________________________________________________________
J.15
Metal Temperature
The magnetic metal temperature gauge should be used. Metal temperature must be
30C above the dew point.
e.
f.
g.
Visual Inspection
Coats shall be smooth, free from dry spray, pinholes, blisters, craters and excessive
sagging.
6.
6.1
All pipes shall be checked for continuity of the applied protection in accordance with
ASTM G62-87. Discontinuities and pinholes indicated by the test shall be made good as
per the manufacturer recommendation.
6.2
Adhesion Test
When an adhesion test is carried out, it shall comprised one of the following methods :
a.
b.
_____________________________________________________________________________________________
J.16
made through the protection on the metal pipe. Sudden impact that would cause
ultimately separation shall be avoided. The blades shall be worked under the
protection and an attempt made to peel it from the metal. The adhesion shall be
considered satisfactory if removal of the protection causes cohesive failure and the
protection does not peel cleanly from the primer or the pipe surface.
c.
d.
_____________________________________________________________________________________________
J.17
BEFORE BLASTING
1. Condition of Rust
- Grade A, B, C, D
INSPECTION OF
CASTINGS
To check
2. Oil or grease solvent wipe in
accordance with SSPC-SP1
3. Sharp edges, wedge slag
- grind off
1. Grade / Mesh size
INSPECTION OF
ABRASIVE
To check
2. Salt free and general utility
To check
_____________________________________________________________________________________________
J.18
B.
DURING BLASTING
MEASURE AND
RECORD WEATHER
CONDITION
INSPECTION OF
CASTINGS
To check
1. Measure and record weather
condition dew point, relative
humidity, steel surface
temperature. No blasting shall be
allowed if steel temperature is not
at least 30C above dew point
To check
Note :
1.
2.
3.
Blasted surfaces left uncoated overnight shall receives a complete light blasting the
next day before priming.
_____________________________________________________________________________________________
J.19
C.
AFTER BLASTING
CHECK WEATHER
CONDITION
INSPECTION OF
CASTINGS
To check
No coating to be applied if casting
temperature is less than30C above
dew point
To check
1. Sharp edges to be removed by
sanding down
2. Dust free surface to blow off
dust
Within 4 hours
PAINT APPLICATION
_____________________________________________________________________________________________
J.20
Dimet
Manufacture Description
Courtaulds Coatings
(International Paint)
Intergard Potable
Interline 925
Water Tank
Coating
Nippon Paint
Coppon EA-9
Finish HB
Jotamastic 87
Naviguard
Amerlock 400
Amercoat 395
Coating System
AWWA C210 84
by COT
10 Dec 92
1 or 2 coats
AWWA C210
84/92 by COT
27 Sep 94
1 or 2 coats
1 or 2 coats
2 coats
Multicoat System
Multicoat System
2 coats
Colour
Varieties
Varieties
Varieties
White, Pink
Cream, White
Varieties
Solids Volume
DFT per Coat
Recommended Total DFT
82% 2%
150 - 400
400
Airless or
Conventional
Spray
100%
150 - 400
400
Airless or
Conventional
Spray
83% 3%
100 - 210
400
Airless or
Conventional
Spray
56%
125
400
100%
300 - 600
400
Airless Spray
Airless Spray
55%
150
400
Airless or
Conventional
Spray
BS 3900 C2 & C3
(350C)
BS 3900 C2 & C3
(350C)
ASTM D1640
(320C)
ASTM 1640
(210C)
(350C)
(350C)
2.5 hrs
5 hrs
3 days
2.5 hrs
4 hrs
3 days
4.5 hrs
12 hrs
4 days
6 hrs
24 hrs
7 days
1 hrs
3 hrs
-
4 hrs
8 hrs
-
Certification
Application Method
Drying Period
Touch Dry
Hard Dry
Curing
_____________________________________________________________________________________________
J.21
(250C - 350C)
2 hrs
16 hrs
9 days
Appendix 6
Polymeric Coating
1.
Pipes and fittings shall be coated with either a thermoset or thermoplastic polymeric
coating material. The coating shall be applied using either the fluidized bed dipping
process or the electrostatic spray process. The minimum thickness of polymeric coating
material shall be not less than those specified below :
Coating Type
Thermoplastic
200 450
Thermoset
350 650
Note : A coating manufacturer may specify higher minimum coating thickness than those
specified above
2.
Performance Testing
Water Quality
All coating material in contact with or likely to come in contact with potable water
shall meet the requirements of BS 6920 Part 1.
3.
a.
Holidays
Coating shall be tested in accordance with AS 3894.2. Only pinhole-free coated test
piece shall be used in subsequent performance test.
b.
_____________________________________________________________________________________________
J.22
c.
Water Absorption
d.
Flexibility
When tested in accordance with AS 3682 at 00C, the coating shall not crack when
strained at 1.0% as calculated in the following equation :
Strain
where
e.
Sc
R
100 Sc
2R Sc
Sample Thickness
Radius of Mandrel
Impact Resistant
When tested in accordance with ASTM G14 at 230C, the impact resistant shall be
equal to or greater than 2.0 J. The test may either be conducted on pipe with an
outside diameter of 110mm to 125mm and wall thickness from 5mm to 7mm (6mm
for flat plate). If cast plate is used, the side in contact with the anvil shall be
machined flat prior to testing.
f.
Abrasion Resistance
The abrasion resistance test shall be undertaken according to ASTM D4060 with
CS18 wheel, 1000 cycles at 230C 21C. The weight loss shall be equal to or less
than 40mg.
g.
Cathodic Disbondment
Coated test piece shall be tested according to sections 5, 6, 7, 8 and 9 of BS 3900 :
F 11. The coating when subjected to an impressed current at a negative voltage of
1.5V, shall not disbond more than 5mm radially from the end of the damaged
coating after 28 days.
h.
Cure Test
This test applied only to thermosetting coatings, including liquid thermosets. After
an appropriate combination of time and conditions (both to be defined prior to the
test by the manufacturer) from the point of coating application, thermosetting
coating on coated test pieces shall be demonstrated to have been cured within
_____________________________________________________________________________________________
J.23
declared limits. The method used shall also be declared. Whenever practicable, the
method chosen should produce quantitative results.
Thermoplastic coating do not required this test.
i.
Adhesion Test
Adhesion testing shall be carried out to determine the adhesive strength of the
coating to the substrate. It does not prove cohesive strength of the coating. Testing
shall be by means of a V-cut test. Toughness of the film and visual evidence of
coating in the anchor pattern valleys will give good indication of satisfactory
adhesion.
The test shall be carried out using a sharp knife. Two cuts are made in the coating at
an included angle of approximately 300. Using the sharp point craft knife or similar,
the knife shall be used to attempt to lift the point of V in a single action levering
against a fulcrum. Not more than 2mm of the V shall be removed by this method
by adhesive failure to the substrate or the adhesion shall be considered to be
unsatisfactory.
The purchaser shall state his requirement for an adhesion test and the frequency of
testing at the time of enquiry and order.
j.
_____________________________________________________________________________________________
J.24
_____________________________________________________________________________________________
J.25
J.26
J.27
GENERAL
This section of this specification covers necessary information on the
dimensions and various material requirements for Stainless Steel Water Meter
(15mm) Positions connected to public mains.
Specifications and material requirements for commonly used plumbing
materials are also covered in this section.
They are made up of the following components:
For three to five meter stands, the incoming pipes are 50mm I.D.
Brass gate valve or ball valve (full bore) for two to f i v e meter positions
(optional, depending on the respective State Water Authority) - ,
Brass or stainless steel fittings (e.g. nipple, coupling, elbow, jam nut, tee
etc);
Other jointing combinations for single and multi meter stands are as shown in
Drawing (Please refer to Standard Drawing).
Typical details of standpipe taps and kitchen sink tap are shown in Standard
Drawing
K.1
2.0
MATERIAL
2.1
K.2
(Note : G.I. pipes and fittings are not allowed to be used in contact with
potable water supply.)
2.2
K.3
8078 and DIN 16962 Part 5-8. All metal fittings moulded integrally shall be
dezincification resistant brass with BSP threads to CZ 132 of BS 2872 or BS
2874 and Nickel & Chromium plated to BS 1224, service condition no.3
classification number Cu/Ni 10b Cr r. The minimum wall thickness and
pressure rating for cold water system, unless otherwise stated or shown in
the drawing is PN 10 or SDR 11 according to DIN 8077.
Where stainless steel pipe (suitable for cold and hot water) is stated or
shown, all service pipes, pump delivery pipe works, plumbing works at
below and above ground level shall be welded austenitic stainless steel
pipes (using Schedule 40S pipes for sizes ranging f/2" to 2" Diameter and
threaded, and Schedule 10S pipes for 2" to 8" Diameter pipes by way of
welding) manufactured according lo ASTM A.312/A312M together with
stainless steel butt welding fittings manufactured according to ASTM
A403/A403M or stainless steel screwed fittings manufactured according to
ASTM A351/A351M.
However for pipe work in plumbing above ground level (which include
service pipes, pump delivery pipe works ), as an option, stainless steel tubes
manufactured according to BS 4127 : 1994 specification for light gauge
stainless steel tube, primarily for water application, may be used. It shall be
made of stainless steel material grade 304 S15 of BS 1449 Part 2 : 1983
Compression fittings and capillary fittings to be used for joining the stainless
steel tubes shall be made of copper and shall comply with BS 864.
Where copper pipe is shown, it shall be to B.S. EN 1057:1996. Fittings to be
used for joining copper pipe shall be to B.S. 864 :Pt. 2.
Unless shown or stated otherwise, service pipes and distribution pipes
except those buried under ground level, shall be concealed or protected
with metal sleeve made of stainless steel or G.I. pipes. The contractor shall
execute the work In such a manner so as to avoid cutting into finished work
in walls, aprons, beams, etc. where practicable as the work proceeds.
Pipework to be buried or concealed shall not be covered or plastered before they
are examined, tested and approved by the State Water Authority,
notwithstanding any approval given by the S.O.
Saddles used for tapping to public main shall conform to one of the following
standards;
JKR Standard Specification for Ferrous Saddles (revised edition 1999) Spesifikasi JKR 20200-0044-99.
JKR Standard Specification for Polyamide/polypropylene Alloy (PA/PP)
Clamp Saddles to Be Used with uPVC; Ductile Iron, CIOD and AC Pipes
(revised edition 1999) - Spesifikasi JKR 20200-0046-99.
K.4
2.3
Concreting
As shown in Drawing, 1:2:4 concrete slab casted with BRC 10 of minimum
dimensions 640mm x 600mm x 50mm shall be provided for single or multi
meter stands if they are placed in the open ground.
3.0
Wall thickness
ANSI Class 1 5 0 / A N S I B 1 6 3 4
Threaded ends
BS 21 ( BSPT )
All stainless steel pipes and fittings (including brass) shall be threaded to BS21.
4.0
5.0
K.5
L CONCRETE WORK
1.0
CONCRETE
1.1
Scope
This section covers the supply of materials for concrete, design of concrete mixes,
quality control of concrete, mixing, transporting, placing and curing of concrete,
and testing of concrete.
The standard of materials and workmanship shall not be inferior to the
recommendations of the current:
British Standard 8110 : Structural Use of Concrete
British Standard Code of Practice BS 8007 1987: Design of Concrete
Structures for Retaining Aqueous liquids.
Appropriate Malaysian Standards approved by the S.O.
Unless otherwise specified, all reinforced concrete for retaining aqueous liquids
shall comply with BS 8007 and shall be of Grade C35A designed to resist Class 2
Sulphate Conditions as defined in BS 5238: Part 1 Table 7.
1.2
1.3
(a)
Plant proposed;
(b)
(c)
(d)
(e)
(f)
Striking times for formwork and procedure for temporary support of beams
and slabs.
Test Certificates
Unless otherwise directed by the S.O., manufacturer's test sheets shall be supplied
with each consignment of cement and admixture certifying compliance with the
relevant standard.
L.1
The Contractor shall also submit to the S.O. certificates of calibration for the
weighing and dispensing equipment on the concrete batch mixing plant, certified
test results for all tests carried out on aggregate, water, fresh concrete and hardened
concrete, all as specified.
1.4
Aggregate Samples
Prior to the commencement of the trial mixes of concrete the Contractor shall
submit for approval samples 50 kg in weight of each aggregate which he proposes
to use.
The source of each aggregate shall be clearly marked on the container of each
sample.
Certified test results demonstrating compliance with the relevant quality standard
shall be submitted at the same time. Samples approved by the S.O. shall remain
preserved at site for reference.
1.5
Records of Concreting
An accurate and up to date record showing dates, times, weather and temperature
conditions when various sections of the works are concreted shall be kept by the
Contractor and shall be available for inspection by the S.O. The Contractor shall
also record the results of all tests of concrete and shall identify these results with the
parts of the works of which the samples material is representative.
For each grade of concrete, the Contractor shall submit to the S.O., not later than
twenty-four hours after concreting, a daily return of the number of batches mixed,
the number of batches and total volume of concrete placed, the number of batches
wasted or rejected and the weight of cement used.
The return shall also include specific details of each location in the works where
concrete is placed, together with the grade of concrete, total volume of concrete
placed and the number of batches used for each location.
1.6
Concrete Mixes
At the commencement of the works the Contractor shall design a mix for each grade
of concrete which will be required for use in the works and shall submit full details
of the mix designs to the S.O. for his approval. Each mix design shall be according
to the requirements of BS 5328.
1.7
L.2
Rebates, keys or notches shall be formed and waterstops inserted as the S.O. may
require. The position of construction joints and the size of formwork panels shall be
so coordinated that where possible the line of any construction joint coincides with
the line of a formwork joint and that in any case all construction joint lines and
formwork joint lines appear as a regular and uniform series.
For all exposed horizontal joints and purposely inclined joints, a uniform joint shall
be formed with a batten of approved dimensions to give a straight and neat joint
line.
1.8
Cement
The cement used for any particular mix shall comply with whichever of the
following standards is relevant :Ordinary Portland cement
BS 12
BS 4027
MS 1227
MS 1389
For water retaining structures, the cement used shall be a blended cement
comprising ordinary portland cement from an approved source and conforming to
BS12 and containing 25%, by mass, of pulverised fly ash (PFA) to the requirement of
MS 1227, or containing 50%, by mass, of ground granulated blast furnaced slag
(GGBS) to the requirement of MS 1389. The cement used shall be an approved
brand of Malaysian manufacture unless otherwise approved.
In addition to the requirements for soundness of cement given in the relevant British
Standard for the type of cement being used, the cement shall also be tested for
soundness in accordance with ASTM C151-77 `Standard Test Method for Autoclave
Expansion of Portland Cement'. The expansion of the cement bar resulting from this
test shall not exceed 0.8 percent.
The Contractor shall provide from each consignment of cement delivered to the site
such samples as the S.O. may require for testing. Any cement which is, in the
opinion of the S.O., lumpy and partially set shall be rejected and the contractor
shall promptly remove such cement from the site. Cement which has been stored
on the site for more than forth days and cement which in the opinion of the S.O. is
of doubtful quality shall not be used in the works unless it is retested and the test
results show that it complies in all respects with the relevant standard.
1.9
Storage of Cement
Immediately upon arrival at the site, cement shall be stored in silos designed for the
purpose or in dry weather-tight and properly ventilated structures with floors raised
500 mm above ground level with adequate provision to prevent absorption of
moisture. All storage facilities shall be subject to approval by the S.O. and shall be
such as to permit each access for inspection and identification. Each consignment of
L.3
cement shall be kept separately and the Contractor shall use the consignments in the
order in which they are received.
Cement of different types and from different sources shall be kept in clearly marked
separate storage facilities. Cement delivered to the site in drums or bags provided
by the supplier or manufacturer shall be stored in the unopened drums or bags until
used in the works.
Any cement in drums or bags which have been opened on the site shall be used
immediately or shall be disposed of.
1.10
Aggregates
Aggregates for concrete shall be obtained from an approved source and shall
conform with the requirements of BS 882.
Sampling and testing of aggregates shall be carried out as required by S.O in
accordance with the requirements of the appropriate clauses of BS 812. Water
absorption of aggregates when tested in accordance with the standard procedure
prescribed in Part 2 of BS 812, shall not exceed 3%.
The aggregates to be supplied shall not give rise to any alkali reaction with the
cement, whether silica or carbonate. Potential reactivity or otherwise of aggregates
shall be determined in accordance with ASTM C 289.
In addition, the soluble chlorides and sulphates content of the aggregates shall be
such that the concrete mix as a whole complies with the specified limits of salt
content.
Tests for chlorides and sulphates and for potential alkali reaction shall be carried out
when required by the S.O.
Notwithstanding any provisions contained herein, limestone aggregates shall not be
used in underground and water retaining structures.
1.11
Storage of Aggregates
The Contractor shall provide means of storing the aggregates at each point where
concrete is made such that :
(i)
Each nominal size of coarse aggregate and fine aggregate shall be kept
separated at all times;
(ii)
(iii)
L.4
The Contractor shall ensure that graded coarse aggregates are tipped, stored and
removed from store in a manner that does not cause segregation.
Wet fine aggregate shall not be used until, in the opinion of the S.O., it has drained
to a constant and uniform moisture content of the fine aggregate continuously and
adjusts the amounts of fine aggregate and added water in each batch of concrete
mixed to allow for the water contained in the fine aggregate. If necessary to meet
the requirements of this clause, the Contractor shall protect the heaps of fine
aggregate against inclement weather.
1.12
Water
Water for washing aggregates and for mixing concrete and curing shall be clean and
free from harmful matter and shall satisfy the recommendations in the Appendix to
BS 3148. When required by the S.O. the Contractor shall take samples of the water
being used for which it is proposed to use for mixing concrete and test them for
quality, including determining the concentration of sulphates and chlorides, which
shall be such that the concrete mix as a whole complies with the specified limit for
salt content.
1.13
Admixtures
Admixtures shall mean material added to the concrete materials during mixing for
the purpose of altering the properties of the concrete mix.
Admixture containing calcium chloride shall not be used.
Admixtures shall not be used unless the S.O. has given his prior approval in writing
for each instance. Both the amount added and the method of use shall be to the
approval of the S.O. who shall also be provided with the following information :(i)
The typical amount added and the detrimental effects if any, due to an
increase or decrease in this amount;
(ii)
(iii)
Whether or not the admixture leads to the entrainment of air when used at the
amount the manufacturer recommends.
BS 5075 Part 2
BS 5075 Part 1
Retarding admixtures
BS 5075 Part 1
ASTM C 618
L.5
1.14
Test Equipment
The contractor shall furnish all equipment and materials necessary for collecting
samples and carrying out field laboratory tests on materials for concrete and on fresh
and hardened concrete. Laboratory equipment shall be housed in a suitable
laboratory building on the site, which shall also incorporate space for storage of
field test equipment, and for curing of concrete test cubes in an orderly manner so
that they are readily accessible for testing on the due date. The contractor shall also
furnish all weights, containers and other equipment necessary for testing the weightbatching equipment for concrete materials and the dispensers for admixtures.
1.15
Grades of Concrete
Grades of concrete for use in the work shall be as shown in the table below:Maximum
Cement
content
(kg/cu.m)
Maximum
free
water/cement
ratio
325
550
0.55
35
325
400*
0.55**
40
35
300
550
0.60
C30
20
30
275
550
0.65
C25
20
25
250
550
0.70
C20
20
20
225
550
C15
20
15
205
550
Characteristic
Minimum
strength at 28 days
cement
(N/sq.mm)
content (kg/cu.m)
Concrete
grade
Maximum
aggregate
size (mm)
C40
20
40
C35A**
20
C35A**
**
Maximum free water cement ratio is 0.55 where OPC or cement containing
GGBS is used. Maximum free water cement ratio is 0.50 where cement
containing PFA is used.
***
Concrete grade is that number which represents its 28 day characteristic strength
expressed in N/sq.mm.
Characteristic strength is that value of cube crushing strength below which none of
all test results fail. This condition shall be deemed to be satisfied when test results
comply with the specified test requirements.
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\L-Concretework 1-new1.doc
L.6
Maximum free water/cement ratios shall be based on aggregates being in a surfacedry condition.
1.16
1.17
b)
c)
d)
1.18
Chlorides in aggregates
ASTM D 1411
Sulphates in aggregates
BS 1377 Test 9
ASTM D 512
ASTM D 516
Workability
The workability of each grade of concrete shall be such that satisfactory compaction
can be obtained when the concrete is placed and vibrated and that there is no
tendency to segregate when it is handled, transported and compacted by the
methods which the contractor proposes to use in the works.
For reinforced concrete, the compacting factor, determined by the method
described in BS 1881, shall not be less than 0.85 nor greater than 0.92. For
unreinforced concrete the compacting factor shall be not greater than 0.85. Where
L.7
The aggregate shall comprise both fine aggregate and coarse aggregate. The
maximum size of coarse aggregate shall be 20 mm or 40 mm as approved by
the S.O.
(ii)
The cement content shall not be below the minimum specified for the grade of
concrete.
(iii)
(iv)
(v)
Where sufficient data can be produced by the contractor to show that the
standard of acceptance for characteristic strength can be maintained using a
lower margin, the mix may be redesigned to have such reduced margin.
Sufficient data shall consist of cube test results from at least 40 separate
batches of concrete produced over a same plant under similar supervision.
The reduced margin shall be 1.64 times the standard deviation of the test
results considered, but not less than 5 N/sq.mm for Grade 15 and 7.5
M/sq.mm for Grades 20, 25, 30, 35A and 40.
For any concrete containing admixtures, the strengths shall not be less than those
specified but the mixes for the grade of concrete shall be separately designed to take
account of the effects of the admixtures, and shall have separate trial mixes made
and tested.
1.20
Trial Mixes
As soon as the S.O. has approved each of the concrete mix designs, two batches
from a trial mix for each grade shall be produced in laboratory using cement and
surface dry aggregates known to be typical of the proposed source of supply. The
proposed mix proportions of each grade shall be approved only if both batches have
the correct cement content and free water cement ratio at or below the maximum
value for the proposed degree of workability.
When mix proportions have been approved by the S.O., three further batches of
concrete for each grade shall be made at site under full scale production conditions
using the same mixing time and handles by means of the same plant which the
Contractor proposes to use in the works.
L.8
Material Batching
All cement used in the manufacture of concrete shall be measured by weight either
with an approved weighing machine or by making the size of each batch of
concrete such as to require an integral number of complete bags or drums of
cement.
L.9
For concrete of Grades 20, 25, 30, 35A and 40, the fine aggregate and the several
nominal sizes of coarse aggregates shall be measured singly or cumulatively by
weight using weight-batching machines.
For concrete of Grade 15, the fine and coarse aggregate shall be measured
separately either by weight using weight-batching machines or by volume in gauge
boxes.
Weight-batching machines shall provide facilities for the accurate control and
measurement of the aggregates either singly or cumulatively and shall be capable of
immediate adjustment by semi-skilled operators in order to permit variations to be
made to the mix. All weigh dials shall be easily visible from the place at which
filling and emptying of the hoppers is controlled.
Every concrete mixing machine shall be fitted with a device to measure added water
by weight and shall be so constructed that the water inlet and outlet valves are
interlocked so that either one of them cannot be opened unless the other is fully
closed. The weighing device shall be provided with an overflow with a crosssectional area at least four times that of the inlet pipe and with its discharge point
clear of the mixing plant. The entire water system shall be maintained free of leaks
at all times and the measuring device shall be fitted with a drain pipe which allows
the full quantity of water being measured to be drained off for checking the
measurement. The outlet arrangement of the measuring device shall be such that
between five and ten percent of the water enters the mixer before the other
materials and further five to ten percent of the water enters the mixer after the other
materials. The remainder of the water shall be added at a uniform rate with the
other materials. The water measuring device shall be readily adjustable so that the
quantity of water added to the mixer can, if necessary, be varied for each batch.
Where volume batching is permitted by the Specification, gauge boxes shall be
soundly constructed of timber or steel to contain exactly the volume of the various
aggregates required for one batch of each mix. They shall have closed bottoms and
shall be clearly marked with the mix and aggregate for which they are intended.
When calculating the size of the gauge box for fine aggregate, an allowance shall be
made for the bulking of the fine aggregate due to the average amount of moisture
contained in the stockpiles on the site. Before the contractor puts any gauge box
into use on the site he shall obtain the approval of the S.O. of the size and
construction of such gauge box.
Any admixtures which may be used shall be measured separately in calibrated
dispensers.
All mixing and batching plants shall be maintained free of set concrete or cement
and shall be clean before commencing mixing. The accuracy of calibration of any
weighing plant, water measuring plant and admixture dispenser, shall be checked
before carrying out trial mixes, before mixing concrete for inclusion in the work,
after each service or adjustment to the mixing plant, and in any case at least once
per month.
L.10
1.22
Mixing Concrete
Concrete shall be mixed in batches in plant capable of combining the aggregates,
cement and water (including admixtures, if any) into a mixture uniform in colour
and consistency, and of discharging the mixture without segregation.
On commencing work with a clean mixer, the first batch shall contain only half the
normal quantity of coarse aggregate to compensate for the adhesion of the other
materials to the drum.
The moisture contents of the aggregates shall be determined before the
commencement of each day's concreting and at such intervals during each day as
may be necessary. The Contractor shall make due allowance for the water
contained in the aggregates when determining the quantity of water to be added to
each mix, and shall adjust the amount of water added to each mix to maintain
constant the approved free water/cement ratio of the mixed concrete.
1.23
Ready-Mixed Concrete
Ready-mixed concrete shall not be used in any part of the works without the S.O.'s
written approval, which may be withdrawn at any time.
The Contractor shall satisfy the S.O. that ready-mixed concrete complies with the
Specification in all respects, add that the manufacturing and delivery resources of
the proposed supplier are adequate to ensure proper and timely completion of each
concreting operation.
The specified requirements as to the sampling, trial-mixing, testing and quality of
concrete of various grades shall apply equally to ready-mixed concrete which shall
furthermore be made and delivered in accordance with BS 5328 : 1981.
Any additional facility, which the S.O. may require for the supervision and
inspection of the batching, mixing and transporting of ready-mixed concrete shall be
allowed to be used after 45 minutes of initial mixing.
1.24
L.11
1.25
1.26
Transporting Concrete
Concrete shall be conveyed from the mixer to its place in the works as rapidly as
possible by methods which will prevent segregation or drying out and ensure that
the concrete is of the required workability at the time of placing. If segregation has
nevertheless occurred in any instance, the materials shall be remixed or rejected.
1.27
Placing Concrete
Concrete shall be placed and compacted before the initial set has occurred and, in
any event, not later than 45 minutes from the time of mixing.
When pneumatic placers are used, if the end of the placer pipe is not equipped with
an energy absorbing device, it shall be kept as close to the work as practicable.
Mortar or water used at the beginning or end of a run shall be discharged outside
the formwork..
When pumps are used, the end of the supply pipe shall be kept immersed in the
concrete during placing to assist compaction. Mortar and water used at the
beginning or end or a run shall be discharged outside the formwork.
1.28
Cool the mixing water and replace part of the water by chipped ice. The ice
shall be completely melted by the time mixing is completed.
(ii)
Spray clean cool water over the aggregate stockpiles. The Contractor shall
carry out regular tests on the aggregates to ensure that concentrations of
sulphates or chlorides do not rise to unacceptable levels, and to ensure that
moisture content determinations allow for such spraying.
(iii)
L.12
1.29
(iv)
Apply a fine moisture (fog) spray of clean cool water to shaded areas
immediately prior to placing concrete.
(v)
Compaction
All concrete placed in-situ shall be compacted with power driven internal type
vibrators supplemented by hand spading and tamping except as otherwise approved
by the S.O. The vibrators shall at all times be adequate in number, amplitude and
power to compact the concrete properly and quickly throughout the whole of the
volume being compacted. Spare vibrators shall be readily on hand in case of
breakdown.
Vibrators shall be inserted into the uncompacted concrete vertically and at regular
intervals. Where the uncompacted concrete is in a layer above freshly compacted
concrete the vibrator shall be allowed to penetrate vertically for about 100 mm into
the previous layer. In no circumstances shall vibrators be allowed to come into
contact with the reinforcement or formwork nor shall they be withdrawn quickly
from the mass of concrete but shall be drawn back slowly so as not to leave voids.
Internal type vibrators shall not be placed in the concrete in a random or haphazard
manner nor shall concrete be moved from part of the work to another by means of
the vibrators.
The duration of vibration shall be limited to that required to produce satisfactory
compaction without causing segregation. Vibration shall on no account be
continued after water or excess grout has appeared on the surface.
1.30
1.31
Curing of Concrete
Concrete shall be cured by protecting the surface from the effects of sunshine,
drying winds, frost, rain, running water or mechanical damage for a continuous
period of four days when the cement used in the concrete is sulphate-resisting
Portland cement, Portland Pulverised-Fuel Ash cement or Portland Blastfurnace
Cement. The protection shall be applied as soon as practicable after completion of
placing by one or more of the following methods as approved by the S.O.:
(a)
(b)
(c)
L.13
(d)
Liquid curing membrane (d) shall not be used on Class U1 surfaces where laitance is
to be removed and aggregate exposed to provide a satisfactory bond for placing
further concrete or mortar screeds or on surfaces where the S.O. is of the opinion
that the appearance of the concrete surface will be affected.
1.32
Construction Joints
A construction joint is defined as a joint in the concrete introduced for convenience
in construction at which special measures are taken to achieve subsequent
continuity without provision for further relative movement.
Concrete placed to form the face of a construction joint shall have all laitance
removed and the large aggregate exposed prior to the placing of fresh concrete.
The laitance shall wherever practicable be removed when the concrete has set but
not hardened by spraying the concrete surface with water under pressure or
brushing with a wire brush sufficient to remove the outer mortar skin and expose
the large aggregate without being disturbed. Where the laitance cannot be removed
due to hardening of the concrete, the whole of the concrete surface forming the
joint shall be treated by high pressure water jet, sand blasting, use of a needle gun
or a scaling hammer to remove the surface laitance.
Before concreting is resumed, all loose matter on the existing concrete surface shall
be removed and the surface slightly wetted.
1.33
L.14
1.34
Class of
finish
Line and
level
Abrupt
irregularity
Gradual
irregularity
Dimension
U1
+/-12
+/ -6
U2
+/ -6
+/ -3
U3
+/ -6
+/ -3
F1
+/-12
+/ -6
+12, -6
F2
+/ -6
+/ -6
+12, -6
F3
+/ -3
+/ -3
+6/ -6
Unformed Surfaces
Finishes to unformed surfaces of concrete shall be classified as U1, U2, U3, spaded'
or `bonded concrete' or such other special finish as may be particularly specified.
Where the class of finish is not specified, the concrete shall be finished to Class U1.
Class U1 finish is the first stage for Class U2 and U3 finishes and for a bonded
concrete surface. Class U2 finish shall be a leveled and screeded, uniform plain or
ridged finish, which (unless it is being converted to Class U2, U3 or bonded
concrete) shall not be disturbed in any way after the initial set and during the period
of curing, surplus concrete being struck off immediately after compaction.
Where a bonded concrete surface is specified, the laitance shall be removed from
the Class U1 finish surface and the aggregate exposed while the concrete is still
green.
A spaded finish shall be a surface free from voids and brought to a reasonably
uniform appearance by the use of shovels as it is placed in the works.
Class U2 finish shall be produced by manual or mechanical floating of the concrete
surface after the initial set has taken place and the surface has hardened sufficiently.
The concrete shall be worked no more than is necessary to produce a uniform
`sandpaper' finish free from screedmarks.
Class U3 finish shall be a hard smooth steel-trowelled finish. Trowelling shall not
commence until the moisture film has disappeared and the concrete has hardened
sufficiently to prevent excess laitance from being worked into the surface. The
surface shall be trowelled under firm pressure and left free from trowel marks.
The addition of dry cement, mortar or water will not be permitted during any of the
above operations.
L.15
1.36
L.16
Length
+/-6 mm
Cross-section
Straightness
L.17
Dry-pack mortar jointing for packing shall consist of one part of volume ordinary
Portland cement and two and half parts by volume of fine aggregate passing a 1 mm
sieve. The mortar shall be mixed with only sufficient water to make the materials
stick together when being moulded in the hands. The mortar is thoroughly
compacted.
Any pre-cast concrete structural member which is found to be cracked, damaged or
otherwise inferior in quality either before or after erection shall be rejected and
replaced by the Contractor.
1.38
Pr-Sstressed Concrete
The Contractor shall submit to the S.O. for approval his proposed method of carrying
out all operations connected with pre-stressed concrete work and his proposals for
handling, hoisting and placing a position any pre-cast pre-stressed concrete units.
Pre-stressed concrete work whether pre-cast or cast in-situ shall be as detailed on the
Drawings and the Contractor shall provide full details of his proposed method of
carrying out all operations connected with pre-stressing including :(a)
(b)
(c)
Procedure for pre-stressing and method of checking and recording the prestress, wire extension and anchorage slip.
(d)
(e)
Grouting of ducts
All tendons, duct forming devices, anchorages and other components shall be kept
free of mud, oil (except water soluble oil applied for protection), paint, retarders,
loose rust, or other foreign matter. They shall be placed with a tolerance of +/-3
mm in concrete dimensions of 300 mm of less or 6 mm in concrete dimensions
over 300 mm.
1.39
No-Fines Concrete
No-fines concrete shall be made using a coarse natural aggregate conforming with
BS 882 and cement to BS 4027. No fine aggregate shall be used. The grading of
the coarse aggregate shall be;
Not less than 95% by weight passing a 19 mm BS sieve;
Not more than 5% by weight passing a 10 mm BS sieve.
The proportion of aggregate, cement and water shall be determined by trial mixes
by the Contractor starting with a cement : aggregate particles ratio of one to eight by
volume.
L.18
The trial mix shall be considered suitable when all the aggregate particles are coated
with a film of cement grout. The water content shall be just adequate. The concrete
when placed shall contain no layers of laitance.
No-fines concrete shall not be mixed by hand.
Vibration shall not be used to compact the concrete. Three test cubes of no-fines
concrete shall be made of each trial mix. The minimum crushing strength of the
chosen mix shall be 3 N/sq,mm at 28 days.
1.40
Standard
Concrete blocks
BS 6073 : Pt 1 : 1981
Concrete flags
BS 7263 : Pt 1 : 1990
Concrete sills
BS 5642
Concrete lintels
BS 5977
The concrete shall comply in every aspect with the provisions of the
Specification whether such products are manufactured on the site or
obtained from other manufacturers.
(b)
1.41
L.19
1.42
Each set of cubes (six cubes per set) shall be made from a single sample taken from
a randomly selected batch of concrete. Three cubes shall be tested 7 days after
manufacture and three cubes 28 days after manufacture.
1.43
The average 28 days strength determined from any group of four consecutive
sets of three test cubes exceeds the specified characteristic strength by not less
than 7.5 N/sq.mm for Grade 15 concrete and 10 N/sq.mm for Grades 20, 25,
30, 35A and 40.
(ii)
The average of each set of three test cube results is greater than 100% of the
specified characteristic strength.
If only one set of three cube results fails to meet the second requirement, those
results may be considered to represent only the particular batch of concrete from
which the cubes were taken, provided that the average strength of the group satisfies
the first requirement.
If more than one set of three cube results in a group fails to meet the second
requirement or if the average strength of any group of four consecutive sets of three
test cubes fails to meet the first requirement then all the concrete in all the batches
represented by all such cubes shall be deemed not to comply with the strength
requirements.
1.44
Non-Compliance
When the average strength of four sets of three consecutive test cubes fails to meet
the first requirement, no further concrete from that mix shall be placed in the work
and the contractor shall establish the cause of the failure and apply such remedies as
are necessary. The Contractor shall demonstrate by trial mixes and test cube results
that the revised mix is in accordance with the specified requirements.
L.20
The Contractor shall within 24 hours of the date of test make proposals for
agreement with the S.O. about action to be taken in respect of any concrete
represented by test cubes which fail to meet either of the requirements. These
proposals may include, but shall not be limited to, cutting and testing cores.
Concrete which is ultimately found not be comply with any of the requirements of
the Specification shall be rejected and shall be broken out and replaced or
otherwise dealt with as agreed with the S.O.
1.45
1.46
Inspection Procedures
Before any concrete is placed, the Contractor shall carry out an inspection to ensure
that all preparations are complete, including the provision of the necessary
equipment and personnel, and shall ensure that sufficient materials are available to
complete the work proposed.
After completion of this inspection the work shall be offered for inspection by the
S.O., sufficient time being allowed for inspection and correction of any defects. no
concrete shall be placed until the S.O. has inspected and approved the surfaces
upon which the concrete is to be placed the formwork and the reinforcing steel.
Where required by the S.O. the Contractor shall institute a `pour card' system in
which a card is made out for each lift of concrete and is initialed by the Contractor
and S.O. indicating that the inspections have been carried out.
The `pour card' shall include spaces to identify the concrete being placed and to
signify completion of the inspections by the Contractor and S.O. of the following
items:
Preparation of surface on which concrete is to be placed;
Formwork;
Reinforcement;
Ready for concrete placing;
Inspection after removal of formwork (any remedial work shall be agreed and
noted);
L.21
Curing procedures;
Completion of remedial work (if any)
1.47
(b)
L.22
Surface
Coat
Application rate
(sq.mm/litre)
Horizontal
1st (priming)
2nd
3rd
7
1
1.5
Vertical
1st (priming)
2nd
3rd
4th
7
2
2
2
Over-coating shall take place as soon as the previous coat has dried.
Immediately the final coat has been applied to vertical surfaces, bitumenized
building paper shall be applied to the fresh emulsion and pressed into close
contact over the whole area of the protection.
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\L-Concretework 1-new1.doc
L.23
Polyethylene sheet
250 micron polyethylene sheet shall be placed against vertical or sloping
surfaces of excavated ground before placing concrete directly against such
surfaces.
Backfilling with sand against protected surfaces shall be carried out in such a
manner that the protection is not damaged. Nevertheless, if such damage
occurs, the damage shall be made good to the satisfaction of the S.O.
1.48
1.49
L.24
No separate payment will be made for complying with the provision of this clause
and all cost shall be deemed to be included elsewhere in the Bill of Quantities.
1.50
Any purpose made hole or opening which has an average cross-sectional area
less than 1600 sq cm or which has a volume of 0.1 cu metre of less;
(ii)
Any portion of chases, rebates, channels, pipes, ducts or the like whose crosssectional area in 1000 sq mm or less;
(iii)
(iv)
The space occupied by any steel reinforcement, rails, joints or the like
embedded in the concrete.
L.25
1.52
1.53
1.54
L.26
At each joint rebates shall be formed to receive sealing compounds as shown on the
Drawings.
Each segment of the wall footing and haunch defined by the floor and wall joints
shall be concreted in one continuous operation. Segments shall be concreted
alternately and an interval of at least 7 days shall elapse before intervening segments
are concreted.
1.55
1.56
(a)
The structure shall be cleared of all debris and shall be brushed down on all
internal faces with a stiff broom while still dry, and all resulting debris
removed; all associated reservoir pipework shall be cleaned in accordance
with the specification requirements.
(b)
No leaks or damp patches on the backs of walls are discernible during period
of the test (if the backs of walls are wetted by rainfall or any other cause the
test must be delayed until they are dry for at least 72 hours). In the case of
individual parts of a structure being tested independently, the division walls
also must be watertight.
(ii)
The floor under drainage system of the structure (if any) remains dry, or the
flow in it before the test is not increased as a result of filling the structure with
water;
(iii)
The recorded change in level of the water in the structure minus the loss of
water by evaporation gives a figure which does not exceed 1/2000 of the
depth of water originally in the structure.
L.27
During the 72 hour test period referred to above the loss of water by evaporation
shall be determined by measurement of the loss of water from a shallow watertight
tray of 0.4 sq.m in area containing not less than 75 mm depth of water and
positioned to float on the surface of the water in the structure.
The roofs and manhole covers of the closed reservoirs shall be tested for watertightness before the laying of any roof membrane by general observation from
within the reservoir for damp patches or leaks over a period of heavy and prolonged
rain but should such a suitable occurrence fail to happen, the roof and fittings shall
be hosed down vigorously and this shall be repeated in such a way as to keep the
roof wet for 3 successive days.
The roof and fittings shall be deemed satisfactory for water-tightness if there are no
discernible leaks or damp patches from inside the reservoir. Remedial measures
and retesting shall be carried out at the Contractor's expense until satisfactory.
Should any parts of the structure fail the above tests in any respect, the Contractor
shall immediately take steps to ascertain the nature and positions of any defects or
leakages, shall empty the structure, and remedy the defects in an approved manner.
Note that a damp patch appearing on the outside of the wall must be rectified from
the water face, a repair making the outer face only watertight shall not be approved;
this applies to bobbin holes also.
When the remedial work has been completed in an approved manner, the testing
and if necessary rectification shall be repeated until a satisfactory test is achieved.
If necessary, in extreme cases of lack of water-tightness, the structure or any member
or section of a member thereof may be rejected.
Any expense in materials (including the supply of water), plant labour and all other
costs including overheads and profit involved in the satisfactory water-tightness
testing of all the water retaining structures in the works shall be included in the rates
entered by the Contractor in the Bill of Quantities.
Any costs, incurred by the Contractor in remedial or replacement work necessary to
achieve the satisfactory testing shall be entirely at the expense of the Contractor.
1.57
L.28
The Contractor shall provide evidence to the satisfaction of the S.O. that the
chlorine dosage proposed for sterilisation will not adversely affect joint sealant
materials.
Chlorination shall be carried out by Method 1 or Method 2 as set out below. The
Contractor shall submit details of his proposed method of working to the S.O. for
approval before commencing disinfection of any structure.
Method 1
The structure shall then be filled to the overflow level with potable water to which
enough chlorine is added to provide a free chlorine residual throughout the
structure of not less than 10 mg/l at the end of the appropriate retention period.
This shall be not less than 6 hours when the water entering the structure has been
chlorinated uniformly by gas-feed equipment or chemical pump or not less than 24
hours when the structure has been filled with water which has been mixed with
calcium hypochlorite or sodium hypochlorite within the structure. The procedure
set out in AWWA C652 shall be followed.
At the end of the retention period the free chlorine residual shall be reduced to not
more than 2 mg/l by draining and refilling or blending with potable water having a
low chlorine concentration, after which the water within the structure shall be
sampled to determine the free chlorine residual and for bacteriological analysis to
check for the absence of coliform organisms of faecal origin. If the results are
unsatisfactory the structure shall be drained and the disinfection procedure shall be
repeated. The costs of any re-testing shall be borne by the Contractor.
Method 2
A solution of 200 mg/l available chlorine shall be applied directly to all surfaces of
the structure which would come into contact with water by suitable brushes or
spray equipment. The disinfected surfaces shall remain in contact with the strong
chlorine solution for at least 30 minutes after which potable water shall be admitted
and the structure shall be filled and tested for bacteriological quality as in Method 1.
1.58
L.29
Sealing Compounds
Sealing compounds for horizontal construction joints shall be hot applied
bituminous sealants complying with the requirements of BS 6213. Sealing
compounds for vertical and inclined construction joints shall be bituminous putty of
a quality approved by the S.O.'s Representative. Both sealing compounds shall be
capable of expanding to 110% of their original thickness between parallel faces
without separation.
Horizontal floor joints and vertical and inclined joints to be filled with the sealing
compound shall first be thoroughly cleaned and dried and an approved primer
compatible with the sealing compound shall be applied. Each primer and sealing
compound shall be applied in accordance with the manufacturer's
recommendations for tropical climates.
Sealing compounds for expansion and contraction joints shall be polyuretane or
polysulphide liquid polymer sealants complying with BS 6213 obtained from
approved manufacturers. The sealing compound shall be capable of expanding to
133% of its original thickness between parallel faces without extruding and of
contracting to 67% of its original thickness without separation.
Expansion and contraction joints to be filled with the sealing compound shall first
be thoroughly cleaned and dried and an approved primer compatible with the
sealing compound shall be applied. Both primer and sealing compound shall be
applied in accordance with the manufacturer's recommendations for tropical
climates.
1.60
Joint Fillers
Joint filler shall either cork joint filler or cellular joint filler.
Cork joint filler shall be waterproof and rotproof and shall not extrude as a result of
compression. Cork joint filler shall compress to less than 50% of its original
thickness with immediate recovery to 80% or more of its original thickness.
Cellular joint filler shall be preformed low-compression joint filler made from foam
rubber. Cellular joint filler shall recover to its original thickness after each loading
and unloading.
L.30
1.61
Waterstops
Waterstops shall be of rubber or PVC and shall be of a type and manufacture
approved by the S.O. The Contractor shall carefully follow the manufacturer's
instructions in any work involving the incorporation of waterstops into structures.
Waterstops shall be fully continuous when laid and site joints shall be limited to
simple butt joints which are to be made with the manufacturer's fusing jig. A
careful check shall be made on all joints after completion to ensure that no
imperfections exist.
Waterstops shall be securely held in position by the formwork or by means to be
approved by the S.O. and the concrete shall be carefully worked around the
waterstops to ensure that they are completely embedded and that no air pockets will
exist.
1.62
Movement Joints
Movement joints are defined as all joints intended to accommodate relative
movement between adjoining parts of a structure, special provision being made
where necessary for maintaining the water tightness of the joint. The Contractor
shall comply with the instructions of manufacturers of proprietary jointing materials
and shall, if required by the S.O., demonstrate that the jointing materials can be
applied satisfactorily.
The Contractor shall submit to the S.O. for his approval, as soon as practicable after
the acceptance of his Tender and not less than three weeks before the
commencement of concreting, details of his proposals for the installation of
waterstops. These shall show where joints are to be located and details of the
intersections and changes of direction to a scale that shows the position of any joint
or shape of any moulded section.
As far as possible jointing on Site shall be confined to the making of butt joints in
straight runs of waterstops. Where it is agreed with the S.O. that it is necessary to
make an intersection or change of direction or any joint. Other than a butt joint in a
straight run, on Site, a prefabricated joint intersection or change of direction piece
shall be made and submitted to such tests as the S.O. may require.
Flexible waterstops shall be fully supported in the formwork, free of nails and clear
of reinforcement and other fixtures. Damaged waterstops shall be replaced and
during concreting care shall be taken to place the concrete so that waterstops do not
bend or distort.
The surface of set concrete in a movement joint shall, where specified on the
Drawings, be painted with two costs of bituminous paint and fresh concrete shall be
placed against it only when the paint is dry. Expansion joints shall be formed by a
separating strip of approved preformed joint filler.
L.31
Caulking grooves shall be provided as shown on the Drawings. At all joints where a
caulking groove is formed, immediately prior to caulking, the groove shall be wire
brushed and loose material removed and blown out by compressed air. After the
groove has dried it shall be primed and caulked with approved jointing compound
applied in accordance with the manufacturer's instructions. At all caulked joints,
the face of the caulking strip and 25 mm width of concrete on either side shall be
painted with two coats of paint having the same base as the caulking compound.
1.63
Structural Tests
The S.O. may, if required, call for loading test on the structure, and for floors, roofs
and similar structures. The test load shall be up to 1 times the design
superimposed load for the areas to be tested. The test load shall not be applied
within 84 days of the casting of the appropriate concrete, and temporary timber
supports, in case of failing, must be immediately available. The test shall be
satisfactory if upon removal of that load the residual deflection does not exceed one
quarter of the maximum deflection after 24 hours loading. If the residual deflection
exceeds this amount, the test is to be repeated and if residual deflection is as above,
this may be considered satisfactory. All measurements and levels of the second test
are to be entirely independent of the first test.
The S.O. may deem tests necessary because :(a)
(b)
(c)
(d)
(e)
(f)
If the loading test be made wholly or in part for reason (a), the test shall be at
Contractor's own cost; if for reason (b) to (e) inclusive, then if the test be satisfactory
the Contractor shall be reimbursed for the cost of the test; if for reason (f) Contractor
shall make the test and be reimbursed for the cost of same, whatever the test result.
If the result of the loading test be unsatisfactory the S.O. may instruct that the part of
the works concerned be taken down or removed and reconstructed to comply with
this Specification, or that such remedial measures shall be taken as to make the
works secure. If the test was made for one or more of the reasons (a) to (e)
inclusive, as detailed above, the Contractor shall take down or remove and
reconstruct the works or take such remedial measures as the S.O. may instruct, all at
his own cost.
L.32
M FORMWORK
1.1
FORMWORK
1.1
Scope
This section covers the supply, erection and removal of formwork, the finishes
to be attained and the remedial action to be taken to the finished concrete after
removal of formwork.
1.2
Submissions
When required by the S.O., the contractor shall submit calculations and designs
for formwork including of layout of panels, before fabrication commence.
1.3
Materials
Formwork shall be constructed of timber, sheet metal or other approved
materials. The Contractor shall also furnish all struts, braces and ties to
withstand the placing and vibrating of concrete, all construction loads and the
effects of weather.
Form ties shall be rod and cone or other approved proprietary type. They shall
be designed so that no part remaining embedded in the concrete after formwork
has been removed shall be nearer than 50 mm from the surface in the case of
reinforced concrete and 150 mm in the case of unreinforced concrete.
Form ties for use in water-retaining structures shall incorporate a diaphragm not
less than 50 mm diameter welded to the mid point of the tie, designed to
prevent water passing along the tie.
1.4
M.1
1.5
1.6
Erection of Formwork
All formwork shall be soundly constructed, firmly supported, adequately
strutted, braced and tied to withstand the placing and vibrating of concrete,
construction loads and the effects of weather. Formwork shall not be tied to or
supported by reinforcement.
Faces of formwork in contact with concrete shall be free from adhering foreign
matter, projecting nails and the like, splits or other defects, and all formwork
shall be clean and free from standing water, dirt, shavings, chippings or other
foreign matter. Joints shall be sufficiently watertight to prevent the escape of
mortar or the formation of fins or other blemishes on the face of the concrete.
All exposed exterior angles on the finished concrete of 90 deg. or less shall be
given 20 mm by 20 mm chamfers.
M.2
Formwork shall be provided for the top surfaces of sloping work where the
slope exceeds 15 deg. from the horizontal (except where such top surface is
specified as spaded finish) and shall be anchored to enable the concrete to be
properly compacted and to prevent air being trapped.
Formwork in contact with the concrete shall be treated with a suitable nonstaining mould oil prior to reinforcement and concrete placement to prevent
adherence of the concrete. Care shall be taken to prevent the oil from coming
in contact with reinforcement or with concrete at construction joints. Surface
retarding agents shall not be used unless specified.
Where ties are built into the concrete for the purpose of supporting formwork,
the whole or part of any such supports shall be capable of removal so that no
part remaining embedded in the concrete shall be nearer than 50 mm in the
case of unreinforced concrete. Holes left after removal of such supports shall be
neatly filled with well rammed dry-pack mortar.
Openings for inspection of the inside of the formwork, for the removal of water
used for washing down and for placing concrete shall be provided and so
formed as to be easily closed before or during placing concrete. Before placing
concrete all bolts, pipes or conduits or any other fixture which are to be built in
shall be held fast by fixing to the formwork or otherwise. Holes shall not be cut
in any concrete without prior approval of the S.O.
1.7
Removal of Formwork
Formwork shall be so designed as to permit easy removal without resorting to
hammering or levering against the surface of the concrete.
The periods of time elapsing between the placing of the concrete and the
striking of the formwork shall be as approved by S.O after consideration of the
loads likely to be imposed on the concrete and shall in any case be not less than
the periods shown in the following table. Where soffit formwork is constructed
in a manner that allows the removal of the majority of the formwork and the
retention during and after such removal of a sufficient number of adequate
supporting props in an undisturbed condition, the Contractor may with the
agreement of the S.O. remove the formwork at the earlier times listed below
provided that the props are left in position and are not disturbed during removal
of the majority of the formwork.
M.3
Position
Props to slabs
14
10
Props to beams
21
Notwithstanding the foregoing, the Contractor shall be held responsible for any
damage arising from removal of formwork before the structure is capable of
carrying its own weight and any incidental loading.
1.8
Building in Plant
The Contractor shall erect all formwork, struts and other temporary work to
enable plant to be built in, and such formwork shall be designed to allow
placing of the concrete, mortar or grout so as to fill the voids completely, and to
enable air to escape from any cavities during filling.
The formwork shall be sealed against pipework and other items of plant to
prevent leakage of grout.
Formwork shall be supported independently of all plant and pipework. The
Contractor shall use such templates and moulds as are necessary to achieve the
accurate positioning of such items.
1.9
Dry-Pack Mortar
Dry-pack mortar for filling holes and repairing surface blemishes shall be made
from one part by weight of cement and three parts fine aggregate passing a 1
mm sieve. The colour of the mortar shall match that of the surrounding
concrete. The mortar shall be mixed with only sufficient water to make the
materials stick together when being moulded in the hands.
The dry-pack material shall then be placed and packed in layers having a
thickness not greater than 15 mm. The compaction shall be carried out by use
of hardwood stick and hammer and shall extend over the full area of the layer,
particular care being taken to compact the dry-pack against the sides of the hole.
After compaction the surface of each layer shall be scratched before further
loose material is added. Holes shall not be over filled and the surface shall be
M.4
finished by laying the hardwood block against the dry-pock fill and striking the
block several times. Steel finishing tools shall not be used and water shall not
be added to facilitate finishing.
1.10
M.5
The Contractor shall thoroughly clean up any hole or defective area that is to be
filled and where the surface has been damaged the Contractor shall break out
any loose, broken or cracked concrete or aggregate.
Where the remedial work is to be carried out using dry-pack mortar or concrete,
the concrete surrounding the hole shall be thoroughly soaked after which the
surface shall be dried so as to leave a small amount of free water on the surface.
The surface shall then be dusted lightly with cement by means of a small dry
brush until the whole surface that will come into contact with the dry-pack
mortar has been covered and darkened by absorption of the free water by the
cement. Any dry cement in the hole shall be removed.
Dry-pack mortar shall be mixed and placed as specified.
Where concrete is to be used, the concrete mix shall be approved by S.O and
shall be placed and compacted into the hole, using formwork as necessary.
Where the remedial work is to be carried out using epoxy resin mortar or other
specialist material, the surface of the cleaned hole shall be prepared and primed
and the repair material placed, compacted and finished in accordance with the
manufacturer's instructions.
Where in the opinion of the S.O., the defect is too extensive to permit
satisfactory repair, either from the point of view of structural integrity or
appearance, the concrete containing the defect shall be broken out and
replaced.
1.11
Movement Joints
Movement joints for expansion and contraction shall be constructed in
accordance with the details and to the dimensions shown on the Drawings or
where otherwise ordered by the S.O. and shall be formed of the elements
specified.
The Contractor shall pay particular attention to the effects of climatic extremes
about the works on any material which he may desire to use in any movement
joint and shall submit for approval by the S.O. his proposals for the proper
storage handling and use of the said materials having due regard for any
recommendations in this connection made by manufacturers.
Waterstops shall be incorporated into all expansion and contraction joints in
units which retain or exclude liquids.
Different types of waterstop material shall not be used together in any complete
installation. Waterstops shall be fabricated into the longest practical units at the
supplier's works and shall be continuous throughout the structure below highest
water level. Intersections and joints shall be factory made where possible.
M.6
M.7
when in contact shall give a coefficient of friction of not more than 0.2 when
subjected to a load of 270 kN/sq.m.
Where formed in concrete structures the lower joint bedding surface shall be
steel float finished to a smooth true surface.
1.13
1.14
Measurement of Formwork
Formwork and all work in connection therewith as specified for each surface
finish of classes F1, F2 and F3 shall be valued by measurement of only such
items as are provided in the Bill of Quantities under the following categories :Vertical formwork
Battered formwork
Soffit formwork
Top-face formwork
Curved formwork
M.8
Main formwork shall be measured as the net area of formwork in contact with
the surface of concrete it is required to support. Formwork for special features
of any kind including fillets, shall not be measured for payment except to the
extent that separate items for such features are provided in the Bill of Quantities.
Provided that in the case of a fillet or chamfer which is being measured under
an item for main formwork and whose width on the splay is less than 150 mm
the measurement shall be calculated from dimensions extending to the point of
the intersection of the concrete faces as if the angle had been formed without
fillet or chamfer.
No deduction from the measurement of formwork shall be made in respect of;
(i)
The area occupied by in-situ pipes or ducts of any size passing through the
formwork.
(ii)
M.9
Joint filler shall be measured as the net area (or length) fixed in place. Joint
sealing of caulking grooves shall be measured as the net length of joint sealed
and shall include for cleaning, priming and caulking over the joint.
Painting surface of set concrete shall be measured once as the net area painted
with two coats.
M.10
O STEEL REFORCEMENT
1.0
1.1
GENERAL
Scope
This Specification covers detailing, fabricating, supplying and placing of
reinforcing steel and accessories for all cast in place and pre-cast concrete.
The Contractor shall be entirely responsible for the correctness of bar schedules
before arranging for the supply, cutting and bending of steel reinforcement.
1.2
Submission
The following submissions are required to be submitted by the contractor:
(1)
Test Certificates
Manufacturer's test certificates for each delivery of reinforcing steel. Each
certificate shall show the country of origin and test.
(2)
Data
Manufacturer's data on accessories and mechanical couplings.
1.3
Steel Reinforcement
Steel for reinforcement shall be of the following kinds as may be specified or
detailed on the Drawings :
Type R -
Type Y -
welded hard drawn steel wire and other cold worked high bond
bar fabric conforming with BS 4483.
Fabric
1.4
Cold drawn wire or cold drawn and stress relieved wire conforming with
BS 5896.
(b)
O.1
(c)
1.5
Cold worked high tensile alloy steel bars conforming with BS 4486.
Accessories
The Contractor shall supply all accessories such as reinforcing steel supports,
hold-downs, spreaders, hangers, tie wire and all other incidentals necessary to
complete an acceptable installation of all steel reinforcement. All accessories
shall be of steel with the exception of spacers to maintain concrete cover to
reinforcement against formed or blinded surfaces which shall be of concrete of
same texture, colour and composition as cast-in-place concrete. Concrete
spacers shall be in the form of a truncated cone or pyramid and shall be used
with the larger face towards the reinforcing steel. The smaller face of a
truncated cone or pyramid shall have a maximum dimension of 50 mm.
1.6
Detailing
1.7
1.8
1.9
O.2
1.10
Fixing of Reinforcement
All reinforcement shall be securely and accurately fixed in positions shown on
the Drawings using approved spacer blocks or chairs. All intersections of bars
shall be secured with No. 16 gauge (1.60 mm) soft iron wire, the ends being
turned into the body of the concrete. The contractor shall ensure that all
reinforcement is maintained in position at all times, particular care being taken
during placing of concrete.
Concrete cover to reinforcement shall be as specified or detailed on the
Drawings, and shall be maintained in accordance with the tolerance specified in
BS 8110. Correct concrete cover to reinforcement shall be maintained with the
aid of approved spacer pieces. Top reinforcement in slabs shall be maintained
in position by means of chairs, the diameter and quantity being sufficient to
ensure security of the reinforcement in shape and positioO.
No part of the reinforcement shall be used to support formwork, access ways,
working platform, or the placing equipment or for the conducting of an electric
current.
1.11
1.12
O.3
O.4
N - PILING WORK
1.0
1.1
GENERAL REQUIREMENTS
General
Unless otherwise specified, all pilings shall comply in all respects to CP 2004. All
materials and workmanship for piling shall be in accordance with the appropriate
sections of this specification.
1.2
1.3
Handling of Piles
All piles shall be handled with great care. Any piles cracked or damaged during
handling shall not be used in the works and shall be replaced by the Contractor at
no extra cost to the Government.
1.4
1.5
N.1
The plant used for pile driving shall be of such type and capacity with the approval
of the S.O.
1.6
Extension of Piles
As the result of measurements of the driving resistance or load bearing capacity of
piles driven, the S.O. may order the lengths of piles to be modified either by
lengthening in-situ or by providing a longer initial length of pile.
Where piles have to be further extended with extension piles, they shall be brought
up to the required length by addition of an extension pile as shown on the Drawing.
The extension pile shall be placed in alignment and jointed as shown on the
Drawing.
1.7
Piling Programme
The Contractor shall submit to the S.O. his proposed programme for the execution
of the piling work at least seven days before commencement of the work. In
addition, the Contractor shall inform the S.O. daily of the programme of the piling
for the following working day and shall give adequate notice of this intention to
work outside working hours, if this has already been approved by the S.O.
1.8
Records
The Contractor shall maintain a record of driving of all piles giving sets and other
data listed below or as required by the S.O. to whom the records shall be submitted.
All piles shall be driven to such final sets or depths as may be approved by the S.O.
Piling Records shall include the following details:
Contract particulars.
**Pile type.
Pile reference number (location).
Nominal cross-sectional dimensions or diameter.
Length of preformed pile.
Date and time of starting and finishing and redriving.
Ground level at commencement of installation of pile.
Cut - off level
Type, weight, drop and mechanical condition of hammer and equivalent
information for other equipment.
Number of types of packing used and type and condition of dolly used during
driving of the pile.
**Pile driving log.
*Set of pile in mm per blows or number of blows per 25mm of penetration.
*If required, the sets taken at intervals during the driving.
*If required, temporary compression of ground and pile from time of marked
increase in driving resistance until pile reaches its final level.
All information regarding obstructions, delays and other interruptions to be
sequence of work.
N.2
**
compression
Immediately after a pile has been completely driven a record shall be made of the
reduced level of the pile head and further checks shall be made on the level of the
pile head and further checks shall be made on the level of each pile head after the
driving of adjacent piles. Should any pile heave upwards it shall be re-driven to its
original level or, if necessary, until its specified set is again obtained.
Any unexpected driving conditions shall be noted in the records.
1.9
1.10
Safety Precaution
The Contractor shall take safety precautions throughout the piling operations in
accordance with the requirements of the relevant laws and by-laws and to the
approval of the S.O.
1.11
Definition
A preliminary pile is a pile installed before the commencement of the main piling
works for the purpose of establishing the driving criteria for subsequent working
piles and for conforming the adequacy of the design, dimensions, and bearing
capacity. The pile shall be treated as a working pile unless otherwise directed by the
S.O.
A working pile is a pile which is installed as part of the permanent foundation
works.
Where a pile test is carried out, the ultimate load is defined as the constant load at
which the pile continue to settle at a steady rate or the load at which the maximum
settlement of the pile test during one continuous loading cycle is one tenth of the
pile base diameter or least dimensions, which ever is the lesser.
N.3
Where a pile test is not carried out, the ultimate load is defined as the calculated
ultimate load, derived from appropriate static bearing capacity calculations.
The design load shall be defined in relation to pile loaded in isolation, without
nearby piles being loaded except those providing test reaction.
Where the ultimate load is measured by means of pile tests, the design load is the
ultimate load divided by the specified factor of safety.
Where the ultimate load is not measured by means of pile tests, the design load is
the lesser of the following:
The calculated ultimate load for the pile divided by the specified factor of
safety.
The calculated load of the pile base together with the calculated shaft
adhesion, as derived from appropriate static bearing capacity calculations
divided by a factor of safety of 3.0
Unless otherwise specified, the factor of safety shall be taken as not less than 2.0 for
piles in compression and not less than 3.0 for piles in tension.
The working load is the design load modified to allow for group effect, pile spacing
or any other factors changing the efficiency of the total foundation from that of a
single isolated pile and is at least equal to the dead plus imposed loads on the pile
together with down drag or up lift loads appropriate.
2.0
2.1
General
The materials to be used and workmanship for pre-cast reinforced concrete piles
shall be as specified under concrete works. The type of mix used shall be as those
shown in the Drawings.
2.2
Reinforcement
The main reinforcing bars in piles not exceeding 12m in length shall be in one
continuous length unless otherwise approved by the S.O.
In the piles exceeding 12m long, joints will be permitted in main longitudinal bars
at 12m nominal intervals. Joints in adjacent bars shall be staggered at least 1m apart
along the length of the pile. Joint shall be butt-welded as specified in concrete work.
Other means of jointing reinforcement, such as by means of mechanical couplings
shall be to the approval of the S.O.
2.3
Pile Shoes
The type of pile shoes to be used shall be as shown in the Drawings and shall
comply with the following as relevant :
N.4
Chilled-hardened cast iron shoes as used for making grey iron casting to BS
1452, Grade 10; or
Mild steel to BS 4360, Grade 50B; or
Cast steel to BS 3100, Grade A.
Mild steel straps cast into the shoes shall be as shown in the Drawings. Rock shoes
where required shall consist of wrought iron shoes and mild steel straps cast into
chilled-hardened cast iron blocks, as shown in the Drawings.
2.4
2.5
2.6
N.5
deviate by more than 12mm from the straight line connecting the centroids of the
end faces of the pile.
2.7
Length of piles
The length of a pile shall be taken to the mean overall length measured from the tip
of the shoes to the top of the head. The length of the piles to be cast shall be to the
approval of the S.O. Based on the results of piles driving resistance and/or load tests
carried out on piles driven on the site, the S.O. may from time to time order the
lengths of piles to be modified.
2.8.
N.6
The exposed part of the pile shall be in good condition, without damage or
distortion;
The dolly and packing shall be in sound condition;
The hammer blow shall be in line with the pile axis and the impact surfaces
shall be flat and at right angle to the pile and the hammer axis.
The hammer shall be in good condition and operating correctly;
The temporary compression of the pile shall be recorded if required.
Piles shall be driven in an approved sequence to minimize the detrimental effect of
heave and lateral displacement of the ground. When required, levels and
measurement shall be taken to determine the movement of the ground or any pile
resulting from the driving process. If any pile rise occurs as a result of adjacent piles
being driven, the contractor shall submit to the S.O. his proposal for correcting this
and to avoid the same in subsequent work.
If preboring is specified the pile shall be pitched into a hole prebored to the depth
shown on the Drawings, unless otherwise instructed by the S.O.
Jetting shall be carried out only when the Contractors detailed proposals have been
approved and not for the last 3m of the required depth of penetration.
2.9
N.7
remainder of the pile, and be properly cured and allowed to harden sufficiently to
develop the strength necessary for further driving.
Pile which has been repaired/lengthened by adding cast-in-situ concrete as
described in 2.9 and shall not be driven until the added concrete has reached the
specified strength of the concrete for the pile.
2.10
3.0
3.1
3.2
Straightness of Piles
For standard rolled sections the deviation from straightness in millimetres shall not
exceed 1.04 (L- 4.5) where L is the length of pile in metres.
For proprietary sections made up from rolled sections the deviation from straightness
shall not exceed 1/1000 of the length of the pile.
3.3
Strengthening of Piles
Unless otherwise approved by the S.O. the strengthening of the toe of the pile in
lieu of the shoe or the strengthening of the head of a pile shall be made from
material of the same grade as the pile and to the details as shown in the Drawings.
3.4.
Marking of Piles
Each pile shall be clearly marked with indeletable marking at the flanged head
showing the following:
Reference Number
Overall Length
In addition, each pile shall be marked at interval of 300mm along its length before
being driven.
N.8
3.5
3.6
3.7
Lengthening of Piles
Where lengthening of piles are required, the piles shall be joined by butt-welding
stiffened with plates fillet-welded on all four sides as detailed in the Drawings. All
welding shall be continuous and complying with BS 4449. The type and size of
welding shall be detailed in the Drawings.
3.8
4.0
4.1
Species of Timber
Unless otherwise approved by the S.O only Kempas (Keempassla Malaccensis) of
approved manufacture shall be used for the Works.
4.2
Definitions
The timber terms used in this specification shall have the meaning assigned to them
in CP 112:1967 on Malayan Grading Rules for Sawn Hardwood Timber (2168)
whichever is applicable.
4.3
Quality
The timber used for the piles shall not be of a lesser quality than the selected
Structural Grades Specified in section J (Stress Grading) of part III of the Malayan
Grading Rules for Sawn Hardwood Timber. The timber shall be free from rot, fungal
or pest attack and any other defects not permitted for its grade.
N.9
4.4
Sizes
The tolerance allowed for the pile shall be as for U.K Standard of CP 112:1967. The
dimension of sawn timber piles shall be within the range of 2mm less and 6mm
greater than their specified cross sectional dimensions. The centroid of any crosssection of sawn timber pile shall not deviate by more than 25mm from the straight
line connecting the centroids of the end faces of the standard length of pile.
4.5
Workmanship
The standard of workmanship shall comply with CP 112:1967 where applicable.
4.6
Preservative Treatment
The method of treatment shall be the full-cell process as described in MS 3.38. The
composition of preservative shall be Type 2 of MS 3.38. The depth of penetration of
preservative when determined by the method described in Appendix H of MS
3.38, shall be a minimum of 25mm. The net dry salt retention in the treated part of
the timber as determined by the method described in Appendix K of MS 3.38 shall
be a minimum of 16kg/cu.metre.
4.7
4.8
Marking
The treated timber piles shall be permanently marked with an identification which
indicates that they comply with this specification, manufacturers trade mark, charge
number and date of treatment, and the length of the pile.
4.9
Warranty
Before commencement of work the Contractor shall nominate the supplier who shall
be approved by the S.O.
The supplier of the treated piles shall issue a warranty which provides that for ten
years period the treated piles shall be free from, such fungus and insect attack which
may render the supported structure structurally unsound. If it is established that the
defects in the supported structure are due to wood destroying organisms in the pile,
the supplier shall remedy the defect in the structure and its foundation at his own
cost. Subject to the provision of this clause, the actual form of the warranty shall be
approved by the S.O. before the treated piles are accepted for the incorporation
work.
N.10
4.10
4.11
Pile Head
The pile head shall be adequately protected during driving, so that brooming does
not occur.
The pile head shall be fitted with toothed metal plates as approved by the S.O. for
protection against brooming and splitting during normal driving.
In case of hard driving, unless otherwise approved by the S.O. a metal helmet shall
be fitted to the top of the pile. The top of the pile shall first be trimmed to fit closely
into recess of underside of the helmet. A hardwood dolly and, if necessary, a
packing piece shall be used above the helmet.
If during driving the head of the pile becomes excessively broomed or otherwise
damaged, the damaged part shall be cut off, and the helmet refitted.
4.12
4.13
Lengthening of Piles
Piles shall be provided in one single length of 6.0m each unless otherwise
approved. Any pile driven to the required set at a depth of 6.0m or less shall be one
continuous length.
If jointing is required, piles joints shall be made by using mild steel welded boxes
450mm long fabricated from 5mm thick plates unless otherwise shown in the
Drawings. The internal dimensions of the box shall be 3mm undersize of the pile
cross-sectional dimensions. The joints and the ends of the piles to be jointed shall be
constructed, so that the necessary strength and stiffness are developed at the joint.
4.14
N.11
4.15
5.0
PILE TESTING
5.1
General
5.1.1
5.1.2
Safety Precautions
When preparing, conducting and dismantling a pile test the Contractor shall carry
out the work in a safe manner and shall in addition make such other provisions as
may be necessary to safeguard against any likely hazards.
5.2
Definitions
5.2.1.
Compression Pile
A pile which is designed to resist an axial force such as would cause it to penetrate
into the ground.
5.2.2
Anchor Pile
A pile which is designed to resist an axial force such as would tend to cause it to be
extracted from the ground.
5.2.3
Test Pile
Compression pile to which a load is applied to determine the load versus settlement
characteristics of the pile and the surrounding ground.
5.2.4
Reaction System
The system of kentledge, piles or anchors that provides a resistance against which
the pile is tested.
5.2.5
Kentledge
The dead weight used in loading test.
N.12
5.2.6
5.2.7
5.3
Supervision
All tests shall be carried out only under the direction of an experienced and
competent Contractors Supervisor with approved test equipment and test procedure
as specified hereinafter.
All Contractors personnel operating the test equipment shall have been trained in its
use. Test shall be carried out only in the presence of the S.O.
5.4
Reaction System
5.4.1
General
Compression test shall be carried out using a kentledge, anchor piles or specially
constructed anchorages as reaction system. The reaction system used shall be
designed to transfer safely to the test pile the maximum load required for testing.
Full details of the reaction shall be submitted to the S.O. prior to any work related to
the testing process being carried out on the Site.
5.4.2
Kentledge
Where kentledge is to be used it shall have adequate weight to resist load up to 1.2
times the maximum test load. The kentledge shall be supported on cribwork, beams
or other supporting structures disposed around the test pile so that its centre of
gravity is on the axis of the pile. Kentledge shall not rest directly on the pile head.
The bearing pressure under the supports shall be such as to ensure stability of the
kentledge stacks and shall not impair the efficiency of the testing operations. The
distance from the edge of the test pile to the nearest part of the support to the
kentledge stack in contract with the ground shall not be less than 1.3m.
5.4.3
N.13
The Contractor shall ensure that when the test load is applied, the load is correctly
transmitted to all the bolts and tie rods. The extension of rods by welding shall not
be permitted unless it is known that the steel will not be reduced in strength by
welding. The bond stress of the rod in tension shall not exceed normal permissible
bond stresses of the type of the steel and mix of concrete used.
Where anchor piles are used the centre to centre spacing of the piles from the test
pile shall be not less than three (3) times the diameter of the test pile or the anchor
piles or 2m whichever is the greater. Under-reamed tension piles shall not be used.
Where permanent working piles are approved by the S.O. to be used as anchor
piles, their levels shall be observed during application of the test load to ensure that
there is no residual uplift.
Where ground anchors are used, no part of the section of the anchor transferring
load to the ground shall be closer to the test pile than three (3) times the diameter of
the test pile. Furthermore, no part of the ground anchor shall be closer to a working
pile than one-and-a-half times the diameter of the test pile along the unbounded
length of the anchor, and three (3) times the diameter of the test pile along the
bonded length of the anchor. Under-reams on ground anchors shall not exceed
180mm in diameter.
5.5
Testing Equipment
The Contractor shall ensure that when the hydraulic jack and load measuring device
are mounted on the pile heads, the whole system will be stable up to the maximum
load to be applied.
The test loads shall be applied by means of a hydraulic jack of adequate capacity
fitted with a load measuring device.
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
operated under hydraulic pressure shall be capable of withstanding and test pressure
equivalent to one an a half times the maximum test load without leakage.
Where the C.R.P test is required the jack pump capacity shall be adequate to
maintain the required rate of penetration. The permissible extension of the jack shall
be such that the pile can be moved continuously and without repacking for distance
of at least 50mm.
The measuring device shall be of the type approved by the S.O. capable of
registering loads in increments not exceeding 21KN.
The hydraulic jack and measuring device shall be calibrated together to the approval
of the S.O. before and after each series of test whenever adjustments are made to
device or at intervals appropriate for the type of equipment used. Certificates of
calibration shall be submitted to the S.O.
The loading equipment shall be capable of adjustment throughout the test to obtain
a smooth increase of load or to maintain each load constant at the required stages of
maintained loading test.
N.14
5.6
5.6.1
General
If a test is required on a working pile the Contractor shall prepare the pile for testing
to the approval of the S.O.
5.6.2
Driving Records
For each working pile which is to be tested a detailed records of driving shall be
made and submitted to the S.O. daily not later than noon on the next working day.
5.6.3
Cut-off Level
The pile shall terminate at the normal cut-off level or at a level required by the S.O.
However, where necessary the pile shall be extended above the cut-off level of
working piles so that gauges and other apparatus to be used in the testing process
will not be damaged by water or falling debris. If the cut-off level is below ground
level, the pile is not extend and there is a risk of the borehole collapsing, a sleeve
shall be left in place or inserted above the pile, or other approved action shall be
taken.
Adequate clearance shall be given between the top of the pile and the bottom of the
sleeve to permit unrestricted movement of the pile.
5.6.4
5.6.5
Notice of Test
The Contractor shall give the S.O. at least 24 hours notice of the commencement of
test.
5.7
Settlement Measurement
An independent reference frame shall be set up to permit measurement of the
vertical movement of the test pile. The support for the frame shall be located not
closer than 2m from the test pile, and shall be rigidly fixed to the ground to a depth
of not less than 1m of concrete surround. In addition, the elevation of the supports
shall be checked frequently with reference to fixed benchmark.
The entire measuring assembly shall be protected against rain, direct sunlight and
other disturbances that might affect its reliability. Temperature readings shall be
taken when requested by the S.O. The measurement of pile movement shall be
made by four dial gauges rigidly mounted on the reference frame that bear on
machined metal or glass surfaces normal to the pile axis fixed to the pile cap or
head. Alternatively the gauges may be fixed to the pile and bear on surfaces on the
N.15
reference frame. The dial gauges shall be placed in diametrically opposite positions
and be equidistant from the pile axis. The dial gauges shall enable readings to be
made to within an accuracy of 0.1mm and shall have minimum travel of not less
than 50mm.
The Contractor may submit other methods of measuring the movement of pile heads
fro approval.
5.8
Test Procedure
5.8.1
General
Throughout the test period all equipment for measuring load and movement shall be
protected from the effects of weather. Construction equipment and persons who are
not involved in the testing process shall be kept at sufficient distance from the test to
avoid disturbance to the measurement apparatus.
5.8.2
5.8.3
N.16
5.9
Presentation of Results
5.9.1
Submission of Results
Result shall be submitted as a signed summary in duplicate to the S.O. immediately
on completion of the test, which shall give:
For the Maintained Load Test for each stage of loading, the period for which the
load was held, the load and the maximum settlement. These are to be plotted as
time-settlement graphs.
For the CRP test, the maximum load reached and a graph of load against
penetration.
5.9.2
Site Location
Contractor Identification
Proposed Structure
Main Contractor
Piling Sub-contractor (if any)
Site Office
Clients Name
Maintained Load or CRP Test
Date of Test
Test Procedure
Weight of Kentledge
Tension of Pile, Group Anchor Details
Plan of Test Arrangement showing position and distance of Kentledge
Supports, Tension Piles and reference frame to Test Piles
Jack Capacity
Method of Load Measurement
Method(s) of Penetration Measurement
Relevant Dates and Times
Test Results
In Tabular Form
In Graphical Form : Load Plotted against Settlement, with Times
Ground Heave (if any)
Effect on Adjacent Structure (if any)
N.17
Site Investigation
5.10
5.11
Completion of Test
5.11.1
Measuring Equipment
On completion of a test all equipment and measuring devices shall be dismantled,
checked and either stored so that they are available for use in further tests, or
removed from the Site.
5.11.2
Kentledge
Kentledge and its supporting structure shall be removed forthwith from the Site on
completion of all tests.
5.11.3
5.12
5.12.1
General
In general, all relevant clauses stated herein before shall apply to the load testing of
bakau piles, except that what is understood as single test pile in these clauses shall
mean a group of test piles for bakau piles.
5.12.2
N.18
5.12.3
Pile Cap
An approved reinforced concrete pile cap with a column stump shall be cast
centrally over the group of piles to be tested. The column stump shall be short to
ensure stability, and it shall have an approved mild steel bearing plate cast on top.
The loads shall be applied centrally on to the steel plate.
5.12.4
Test Procedure.
The bakau pile shall be tested to failure by the Maintained Load Test as described
herein before. The load on the pile group shall be applied in 6 to 8 equal
increments until failure load is reached. Failure load (i.e. ultimate load) is that load
at which the piles continue to settle at a constant rate without further increase of
load.
For each increment of load, the settlement readings shall be recorded at various time
intervals until the rate of the settlement is less than 0.25mm per hour. The load at
each increment shall be maintained at a constant value throughout the test.
(Note : for a group of 9 (nine) bakau piles, the increment of load is generally about
4 tonnes).
The process of applying the next increment of load and taking the settlement
readings against various times intervals shall be repeated until the ultimate load for
the pile group is reached. The test load shall than be gradually released. No further
settlement readings or rebound readings need to be taken on release of load.
5.12.5
Interpretation of Results
The allowable load on the pile group shall be obtained by applying an appropriate
factor of safety to the ultimate load determined from the load test. The factor of
safety is applied chiefly to offset against the possibility of settlement due to
consolidation. A factor of safety from 3 to 6 shall be applied depending on the
strength of the soil. As a guide, a factor of safety of 6 shall be applied to very soft
soil and a factor of safety of 3 shall be applied to medium strength soil.
N.19
:3
: 30 NOVEMBER 2006
P BRICKWORK
1.0
GENERAL
Unless otherwise specified all brickwork shall comply with the requirements of CP
121 : Part 1:1973.
2.0
MORTAR
2.1
General
Mortar to be used for the work shall be in accordance with CP 121: Part 1: 1973 and
consists of either:
o
Cement : sand
All mortar shall be used within 45 minutes of mixing and no remarking up of mortar
shall be permitted thereafter.
Mortar for brickwork and plasterwork below ground level shall be in the proportion
of 1 part of cement or masonry cement and 3 parts of sand.
Mortar for brickwork and plasterwork above ground level shall be in the proportion
of 1 part of cement and sand, with the addition of an approved mortar plasticizer or
1 part of masonry cement and 6 parts of sand.
The ingredients for mortar shall be measured in proper gauging boxes and shall be
mixed on a clean boarded platform or in the approved mechanical batch mixer. The
mixture shall be thoroughly mixed dry after which only sufficient water shall be
added with fine roses and the mass thoroughly mixed again to produce a uniform
material of good consistency. No remaking up of partially set mortar shall be
permitted.
2.2
Cement
The cement to be used, unless otherwise specified shall be Ordinary Portland
Cement complying with MS 522:1977 and masonry cement shall comply with MS
794:1982.
2.3
Admixtures
Mortar plasticizers shall comply with the requirements of BS 4887:1973 and used
strictly in accordance with the manufacturers instructions.
P.1
2.4
:3
: 30 NOVEMBER 2006
Sand
Sand for mortar shall comply with BS 1210:1976 and shall be natural sand obtained
from rivers or approved pits. Sand shall be hard, durable, clean, and free from
adherent coatings such as clay, and from any appreciable amount of clay in pellet
form. It shall not contain harmful materials such as iron pyrites, salts, coal or other
organic impurities, mica, shale or similar laminated materials or flaky or elongated
particles in such a form or sufficient quantity to affect adversely the hardening
strength or durability of the mortar or as might attack the reinforcement in reinforced
brickwork. The S.Os decision as to the suitability of any sand shall be final. The
grading of the sand when determined as described in MS 30:1971 shall be within
the following limits:
BS Sieves
(mm)
2.5
6.3
5.00
2.36
1.18
Type S
100
98 100
90 100
70 100
Type G
100
98 100
90 100
70 100
m
600
300
150
75
40 100
5 70
0 15
05
40 100
21 90
0 25
08
Water
The water to be used shall be as specified under Concrete Work.
3.0
BRICKS
The bricks to be used for the work shall be solid common fired-clay bricks
complying with MS 76:1972 and of approved manufacture. They shall be regular in
size and shape, with good-faces and clean arises, undamaged, and free from all
defects. Before any bricks are ordered, samples shall be submitted to the S.O for the
approval and all deliveries of bricks shall be up to standard of samples approved and
kept on the site. All rejected bricks shall be removed from the site forthwith at the
Contractors own expense.
4.0
BRICKWALLING
The whole of the brickwork shown upon the drawings unless otherwise specified,
shall be constructed with standard size clay brick in the mortar and leave surface
ready for plastering.
All bricks shall be soaked in a suitable tank or pit to be provided by the Contractor
for at least half an hour before being laid and shall be kept wet whilst being laid.
The top of the walls left off shall be thoroughly wetted before work is resumed. All
P.2
:3
: 30 NOVEMBER 2006
constructed walling must be left wet and properly protected from the direct sunlight
during the following day. The Contractor shall provide sufficient means to ensure
that this is done.
All bricks shall be properly bedded in mortar. All joints shall be thoroughly flushed
up and raked out to a depth of 13mm as the work proceeds. No joint shall exceed
10mm in thickness.
Brickwork shall be carried perfectly true and plumb in a uniform manner. No one
portion being raised more than 1m above another at one time. No overhand work
shall be permitted and scaffolding shall be carried up as work proceeds. The vertical
points of every alternate course shall be kept perpendicular over one another, and
all perpends, quoins etc, shall be kept strictly true square.
All intersections and angles of walls shall be properly bonded together, and all walls
and piers of lengths and widths not multiples of brick sizes shall be cut and bonded
in the best approved manner. No broken bricks shall be used except where required
to form bond.
All half brick (113mm) walls shall be reinforced at every fourth course with
approved brick reinforcement commencing two courses above base level.
All brickwork adjacent to reinforced concrete shall be bonded to the concrete
structure properly with wrought iron cramps of approved size and pattern set at
900mm centres.
All arches, cuttings, sinkings, setbacks and projections shall be properly formed.
Chases and holes through walls for the passage of pipes, and the like shall be neatly
cut and formed.
5.0
BOND
All half brick-walls shall be built in stretcher bond.
All other brickwork shall be built in English bond or as shown in the Drawings.
P.3
Q PAINTING WORK
1.0
GENERAL
All paints to be used shall be those supplied by the manufacturers approved by
SIRIM. The brand name of the paint to be used shall be as stated by the Contractor
at the time of tendering and agreed upon by the S.O. The quality of paints shall
comply with M.S. 124 : 1989 in respect of emulsion paint and M.S. 125 : 1995 in
respect of oil/enamel paint. The paint manufacturer shall provide SYABAS written
warranty from the date of the certificate of Practical Completion.
Paints shall be delivered to the site in the manufacturers original sealed containers
unopened and shall be used strictly in accordance with the manufacturers
instruction
Paints shall not be adulterated and any paint that has deteriorated shall not be used
and shall be removed from site forthwith.
The colours and tints of paints shall be selected by the S.O. and the priming,
undercoats and finishing coats shall be of differing tints as approved and shall be
obtained from the same manufacturer.
Painting work shall be done by skilled workmen approved by the manufacturer and
appropriate equipment or tools shall be used.
No painting shall be done under conditions which may jeopardize the quality of
finished paintwork.
During painting, care shall be taken to prevent stain or damage to other works.
Surfaces to be painted shall be dry, free from dirt, oil, grease, old loose paint and
other deleterious matter. All cracks shall be raked out and stopped and all holes and
dents shall be filled.
Unless otherwise specified in the manufacturers instructions, each coat of paint
applied on masonry or metal surfaces shall be allowed to dry and subsequently
rubbed down lightly with sand paper before the next coat is applied. Any dirt or
dust shall be removed from preceding coat immediately before proceeding with
application of the next coat.
All priming to shop fabricated components shall be done at the shop.
Finished surfaces shall be uniform in finish and colour and be free from brush marks
or other defects.
Sample areas showing all tints of paints to be used shall be prepared by the
Contractor as and when required by the S.O.
Q.1
2.0
TYPE OF PAINT
NO. OF
COATS
DRY FILM
THICKNESS
(MICRON)
Primer Coat
75
Intermediate Coat
100
Finishing Coat
Nippon Polyurethane
Recoatable Finish or
equivalent
150
325
3.0
TYPE OF PAINT
NO. OF
COATS
DRY FILM
THICKNESS
(MICRON)
Primer Coat
Copon EA 9 Finish Hb or
equivalent
50
Intermediate Coat
Copon EA 9 Finish Hb or
equivalent
50
Nippon Polyurethane
Recoatable Finish or
equivalent
50
150
Finishing Coat
Q.2
4.0
Q.3
R MISCELLANEOUS
1.0
R.1
metal, the termination of the fencing at the gate shall be by means of another mild
steel of angle post fixed to one side of the gate post and strengthened by struts as
described herein before. The chain mesh shall be strained by 3 strands of 0.71mm
(gauge) diameter galvanized steel straining wire threaded through the mesh and
fixed to the posts.
Where shown in the drawings, the bottom of link mesh shall be buried in
continuous concrete curbs of Grade 25 mix concrete. Unless detailed otherwise in
the drawings, the cross-sectional dimension of curb shall be 100mm wide x 230mm
high with 75mm protruding above the ground.
Gates shall be constructed as detailed in the Drawings.
All the posts, struts and gates shall be painted in accordance to Painting Work
Specification.
2.0
3.0
PRE-CAST CHAMBERS
Pre-cast valve chambers, unless otherwise specified, shall be as shown in the
Drawings and in accordance to Concrete Work Specification.
4.0
WASHOUT
Washout shall be constructed at locations specified in sub-clause 8.5 of section C or
as may be directed by the S.O. The washout branches shall be connected to the
pipeline by special washout tees and sluice valves. From the washout sluice valves,
MS pipe or uPVC pipes Class E shall be laid to the nearest drain or stream. The
discharge point shall be downstream.
R.2
5.0
INDICATOR POST
The Contractor shall provide and fix ABS indicator posts close to the centre line of
pipes, at valves, washout and other points as directed by the S.O. The details of
indicator posts are shown in the Drawings.
R.3