Volume 2 - Part 1 - Standard Specifications

Project: DS 208/1
‫ربط مشاريع المطورين العاجلة على نظام الصرف الصحي التابع‬

‫ منطقة بر دبي‬- ‫لبلدية دبي‬
Interconnecting Urgent Development to DM
Sewerage System
Bur Dubai Area
Tender Documents
Volume 2 Part 1
Standard Specifications
December 2022
Employer:
Sewerage and Recycled water Projects Department
P.O. Box 67, Dubai, UAE
Tel: 04-8815555
Fax: 04-2246666.
Consultant
ITALCONSULT ⚫ P.O. Box 23461 ⚫ Dubai ⚫ Tel: 04-3330605 ⚫ Fax: 04-2952020
DS-208/1 Volume 2 Part-1
DUBAI MUNICIPALITY
SEWERAGE AND RECYCLED WATER PROJECTS DEPARTMENT
PROJECT: DS 208/1
INTERCONNECTING URGENT DEVELOPMENTS TO DM SEWERAGE SYSTEM
BUR DUBAI AREA
TENDER DOCUMENTS
GENERAL INDEX
VOLUME 1 : TENDER AND CONTRACT CONDITIONS
VOLUME 2 : PROJECT SPECIFICATIONS
PART 1: STANDARD SPECIFICATIONS
PART 2: PARTICULAR SPECIFICATION
VOLUME 3 : BILL OF QUANTITIES
VOLUME 4 : DRAWINGS
PART 1: STANDARD DRAWINGS
PART 2: PROJECT DRAWINGS
VOLUME 5: INFORMATION TO TENDERER
December 2022 Page 1 of 1

General Specifications for Civil Works
Dubai Municipality
Sewerage and Recycle Water Projects Department

DUBAI MUNCIPALITY
DRAINAGE AND IRRIGATION DEPARTMENT

General Specifications
PART 1
Table of Contents
Section 1 General
Section 2 Site Clearance and Earthworks
Section 3 Concrete
Section 4 Pipe, Pipework, Manholes and Chambers
Section 5 Brickwork and Blockwork
Section 6 Inspection and Testing of Pipelines and Structures
Section 7 Corrosion protection and Surface Coatings
Section 8 Buildings Specifications
Section 9 Metals and Plastic Materials
Section 10 Safety Procedures
Section 11 Pipeline Renovation , Replacement and Abandonment
Section 12 Manhole Renovation and Abandonment and Pumping

Station and Rising Main Abandonment
Section 13 Piles and Piling
Section 14 Microtunnelling and Pipejacking
Section 15 Geotechnical Instrumentation and Monitoring
Section 16 Protection of Existing Structures and Services
OPEN DATA / ‫ﺑﻳﺎﻧﺎﺕ ﻣﻔﺗﻭﺣﺔ‬

DUBAI MUNICIPALITY
SEWERAGE AND RECYCLE WATER PROJECTS
DEPARTMENT
GENERAL SPECIFICATIONS
SECTION 1
GENERAL
DM/SRPD Section 1 General Rev 00 June

2016
OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

Dubai Municipality
DOCUMENT CONTROL SHEET
Revision No. Date Revision Description
DM/SRPD Section 1 General Rev 00 June Page i of iii
2016

Dubai Municipality
SECTION 1
GENERAL
CONTENTS
1 GENERAL........................................................................................................................... 1
1.1 GENERAL INFORMATION ................................................................................................ 1
1.1.1 Preamble .............................................................................................................. 1

1.1.2 Abbreviations and Standards ................................................................................ 1
1.1.3 Datum ................................................................................................................... 7
1.1.4 Right of Way ......................................................................................................... 7
1.1.5 Borehole Data ....................................................................................................... 8
1.1.6 Interpretation of Drawings ..................................................................................... 8
1.1.7 Responsibility of Contractor .................................................................................. 8
1.1.8 Governing Standards ............................................................................................ 8
1.1.9 Groundwater Levels in Dubai ............................................................................... 9
1.1.10 Pollution of Khor Dubai and the Arabian Gulf ....................................................... 9
1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE ................................................... 10
1.2.1 General ............................................................................................................... 10

1.2.2 Specific Requirements ........................................................................................ 16
1.2.3 Location of Contract Offices and Other Contract Facilities ................................. 17
1.2.4 Service Authorities .............................................................................................. 17
1.3 GENERAL REQUIREMENTS .......................................................................................... 18
1.3.1 Materials and Manufactured Items ..................................................................... 18

1.3.2 Submittals ........................................................................................................... 23
1.3.3 Setting Out the Work .......................................................................................... 37
1.3.4 Notice of Operations ........................................................................................... 38
1.3.5 Traffic Safety and Control ................................................................................... 38
1.3.6 Access to Private Land ....................................................................................... 39
1.3.7 Roads and Site to be Kept Clean ....................................................................... 39
1.3.8 Compensation for Damage to Property .............................................................. 39
1.3.9 Existing Services ................................................................................................ 40
1.3.10 Continuous Working ........................................................................................... 41
1.3.11 Temporary Staging for Structures ....................................................................... 41
1.3.12 Water Supply ...................................................................................................... 41
1.3.13 Filling in Holes and Trenches ............................................................................. 42
1.3.14 Protection of Works from Weather ...................................................................... 42
1.3.15 Keeping the Works Free from Water .................................................................. 42
DM/SRPD Section 1 General Rev 00 June Page ii of iii
2016

Dubai Municipality
1.3.16 Sign Boards ........................................................................................................ 42

1.3.17 Templates ........................................................................................................... 43
1.3.18 Assistance to the Engineer ................................................................................. 43
1.3.19 Surveying Equipment .......................................................................................... 45
1.3.20 Laboratory ........................................................................................................... 47
1.3.21 Minimum Test Requirements .............................................................................. 48
1.3.22 Sources of Materials ........................................................................................... 55
1.3.23 Programming the Progress of the Works ............................................................ 55
1.3.24 Progress Reports ................................................................................................ 55
1.3.25 Progress Photographs ........................................................................................ 56
1.3.26 Suppression of Noise .......................................................................................... 56
1.3.27 Closing of Roads ................................................................................................ 56
1.3.28 NOC from Relevant Authorities .......................................................................... 57
1.4 TOPOGRAPHICAL SURVEY........................................................................................... 57
1.4.1 GENERAL REQUIREMENTS ............................................................................. 57

1.4.2 SURVEY CONTROL POINTS ............................................................................ 58
1.4.3 SURVEY WORK ................................................................................................. 58
1.4.4 NON COMPLIANCE ........................................................................................... 59
1.5 SPECIFIC OBLIGATIONS ............................................................................................... 59
1.5.1 Sequence of Construction .................................................................................. 59

1.5.2 Safety Requirements .......................................................................................... 60
1.5.3 Setting Out .......................................................................................................... 61
1.5.4 Progress Reports, Photographs and Site Records ............................................. 61
1.5.5 As-built Records ................................................................................................. 63
1.5.6 Contract Correspondence ................................................................................... 63
1.5.7 Corrosion Control ................................................................................................ 63
1.5.8 Provision and Final Removal of Temporary Site Roads ..................................... 64
1.5.9 Use of Highway ................................................................................................... 64
1.5.10 Access to Private Land ....................................................................................... 65
1.5.11 Return of Materials to Store ................................................................................ 65
1.5.12 Flows in Pipelines and at Pumping Stations ....................................................... 66
1.5.13 Issue of Taking - Over Certificate ....................................................................... 66
1.6 VENDOR LIST FOR CIVIL ITEMS.................................................................................... 67
DM/SRPD Section 1 General Rev 00 June Page iii of iii
2016

Dubai Municipality
1 GENERAL
1.1 GENERAL INFORMATION
1.1.1 Preamble
These Specifications shall be read in conjunction with the other documents of the
Tender and Contract Documents and Drawings. The Contractor shall comply with all
the provisions contained within these Documents. The Contractor shall take note of
the Appendices contained in these Specifications. Where items of the Specifications
are also covered in the Appendices the requirements of the Appendices shall take
precedence.
The provisions contained in the specification shall prevail over the provisions
contained in the referenced standards in each section of the specification.
Any clause in these Specifications which relates to work or materials not required by
the Contract shall be deemed not to apply.
In order to avoid needless repetition of such phrases as "to the Engineer" and "by the
Engineer" or "the Engineer's Representative" throughout these Specifications it shall
be understood that when an order, instruction, decision, exercise of judgment or other
similar act is indicated, such order, instruction, decision, exercise of judgment or other
similar action will be issued, given, made or referred to the Engineer or the Engineer's
Representative.
1.1.2 Abbreviations and Standards
The following abbreviations are used in the Specifications:
cm Centimetre
d Day
dia Diameter
ha Hectare
h Hour
kg Kilogram
kN Kilo Newton
kW Kilowatt
l Litre
MDD Maximum Dry Density
m Metre
DM/SRPD Section 1 General Rev 00 June Page 1 of 74

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Dubai Municipality
m², sq m Square Metre

m³, cu m Cubic Metre
mg Milligram
mm Millimetre
months Months
MPa Mega Pascal
Nr, No Number
Pa Pascal
Sec Second
Set Set
T Tonne
Reference to a technical society, institution, association or governmental authority is
made in the Specifications in accordance with the following abbreviations as well as
these indicated on the Drawings.
AA Aluminium Association
AABC Associated Air Balance Council
AAN American Association of Nurserymen
AAMA Architectural Aluminium Manufacturers Association
AASHTO American Association of State Highway and Transportation Officials
ACI American Concrete Institute
ADC Air Diffuser Council
AFI Air Filter Institute
AGCA Association General Contractors of America
AIA American Institute of Architects
AIMA Acoustical & Insulating Materials Association
AIEE American Institute of Electrical Engineering

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Dubai Municipality
AISC American Institute of Steel Construction
AISI American Iron & Steel Institute
AITC American Institute of Timber Construction
ALS American Lumber Standards
AMCA Air Moving & Conditioning Association
ANSI American National Standards Institute
AOAC Association of Official Agricultural Chemists
APA American Plywood Association
ASA American Standard Association
ARI Air Conditioning & Refrigeration Institute
ASAHC American Society of Architectural Hardware Engineers
ASHRAE American Society of Heating, Refrigerating and Air conditioning

Engineers
ASSE American Society of Sanitary Engineers
ASTM American Society for Testing and Materials
AWI Architectural Woodwork Institute
AWPA American Wood Preservers Association
AWPI American Wood Preservers Institute
AWS American Welding Society
AWWA American Water Works Association
BHMA Builders Hardware Manufacturers Association
BIA Brick Institute of America
BRI Building Research Institute

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Dubai Municipality
BS British Standard
BSCP British Standard Code of Practice
BS EN European Standards
BSI British Standards Institution
CDA Copper Development Association
CEE International Commission on Rules for Approval of Electrical

Equipment (Europe)
CIRIA Construction Industry Research and Information Association
CRSI Concrete Reinforcing Steel Institute
CS Commercial Standard, US Department of Commerce
CSI Construction Specifications Institute
CTI Cooling Tower Institute
DEWA Dubai Electricity and Water Authority
DM Dubai Municipality
DIN Deutsche Institute for Norming, Germany
ETISALAT Emirates Telecommunications Corporation
FGMA Flat Glass Marketing Association
FPL Forest Products Laboratory
FS Federal Specification
FSIWA Federation of Sewage and Industrial Waste Association
FTI Facing Tile Institute
GA Gypsum Association
GTA Glass Tempering Association

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Dubai Municipality
HPMA Hardwood Plywood Manufacturers Association
IEC International Electro-technical Commission
IEE Institute of Electrical Engineers of London
IEEE Institute of Electrical & Electronics Engineers
IES Illuminating Engineering Society
ISA Instrument Society of America
ISO International Organisation for Standardisation, Switzerland
MIA Marble Institute of America
MLMA Metal Lath Manufacturers Association
MSSVFI Manufacturers Standardization Society of the Valves and Fittings

Industries
NAAMM National Association of Architectural Metal Manufacturers
NAFM National Association of Fan Manufacturers
NAPF National Association of Plastic Manufacturers
NBGQA National Building Granite Quarries Association
NBHA National Builders Hardware Association
NBS National Bureau of Standards
NCMA National Concrete Masonry Association
NEC National Electrical Code (NFPA No.70)
NEMA National Electrical Manufacturers Association
NEMI National Elevator Manufacturing Industry Inc.
NFC National Fire Code
NFPA National Fire Protection Association

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Dubai Municipality
NFPA National Forest Products Association
NHLA National Hardwood Lumber Association
NHPMA National Hardwood & Pine Manufacturers Association
NPA National Particleboard Association
NRMCA National Ready Mixed Concrete Association
NSC National Safety Council
NSF National Sanitation Foundation
NTMA National Terrazzo & Mosaic Association
NWC National Water Council, UK
NWMA National Woodwork Manufacturers Association
OSHA Occupational Safety & Health Administration
PCA Portland Cement Association
PCI Prestressed Concrete Institute
PDI Plumbing & Drainage Institute, USA
PEI Porcelain Enamel Institute
PS Product Standard, US Dept of Commerce
ROS Redwood Inspection Service
RTI Resilient Tile Institute
SCMA Southern Cypress Manufacturers Association
SDI Steel Door Institute
SIGMA Sealed Insulating Glass Manufacturers Association
SJI Steel Joint Institute
SMACNA Sheet Metal & Air Conditioning Contractors National Association

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SMFMA Sprayed Mineral Fibre Manufacturers Association Inc
SPIB Southern Pine Inspection Bureau
SPR Simplified Practice Recommendation, US Dept of Commerce
SSPC Steel Structure Paining Council
SWFPA Structural Wood Fibre Products Association
TCA Tile Council of America
TEMA Tubular Exchange Manufacturing Association
TIMA Thermal Insulation Manufacturing Association
TPI Truss Plate Institute
UL Underwriters Laboratories Inc
UPC Uniform Plumbing Code
USCGS US Coast & Geodetic Survey
WCLB West Coast Lumber Inspection Bureau
WRI Wire Reinforcement Institute
WPA Western Wood Products Association
1.1.3 Datum
The levels shown on the Drawings are referred to Dubai Municipality datum. The
location and details of benchmarks to be established by the contractor shall be
obtained / transferred by him from Dubai Municipality datum Level / Survey
Department. The Contractor shall make his own arrangements to ensure that the
Works are constructed to the levels shown on the Drawings or as amended by the
Engineer, and if it is found necessary to cover or destroy any of such bench-marks
the Contractor shall transfer the level of such bench-marks to other approved fixed
points, which shall then be surveyed and marked on the Drawings. The survey station
details obtained by the Contractor from the Dubai Municipality Survey Section shall
be at Contractor’s cost.
1.1.4 Right of Way

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Dubai Municipality
The Contractor shall make all the necessary arrangements for any land required for
working areas outside the right of way, including payment when necessary, and the
Employer does not accept any liability in connection with such land. This includes
land for compounds, temporary working shafts and roads, detours, diversions and
stock piling materials.
1.1.5 Borehole Data
Any soils and materials test results and information provided for the Contractor with
the Contract Documents at Tender stage is for his information only. The Contractor
shall be deemed to have studied this information during the preparation of his Tender
and to have carried out any further tests as he may consider necessary. No claims for
additional payment will be considered from the Contractor on the grounds that the
information is insufficient, incorrect, or misleading. The Contractor shall submit copies
of all geotechnical tests performed for review by DM/Dubai Central Laboratory.
1.1.6 Interpretation of Drawings
The Employer and the Engineer accept no responsibility for any omissions from or for
correctness of the representation of existing features on the Drawings.
1.1.7 Responsibility of Contractor
Where the approval of the Engineer is required under these Specifications such
approval shall not relieve the Contractor of his duties, responsibilities or liabilities
under the Contract.
1.1.8 Governing Standards
Wherever in the Specifications tests on materials, tests on completed work and

construction control tests are called for or implied, they shall be carried out
accordingly to, and the materials shall comply with, the requirements of the
Specifications (latest edition) with the priority of latest edition of standard shall be as
follows:
(a) National standards such as UAE & DM Standards

(b) International standard such as ISO
(c) Secondary international standard such as BSI & DIN
(d) Others as stated in this Specification such as ASTM, etc.
The Contractor shall provide for the exclusive use of the Engineer copies of each and
any codes of practice, international standard, test methods, etc. relevant to the works,
properly indexed and maintained in good order and readily available to the Engineer
at all times. Upon completion of the works the said codes, standards, etc., shall be
handed over to the Engineer.

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Dubai Municipality
In addition the Contractor shall retain on site for the use of the Engineer all
manufacturers’ literature relating to all the products to be used in the works, current
BSI Handbook No. 3 and the manufacturers’ installations instructions for all relevant
products, materials components and installations.
The Contractor shall comply with all codes, regulations and standards referred to
throughout the specification.
All references to codes, regulations and standards referred to in the specification

shall, unless otherwise stated, mean the latest edition, amendment or revision of such
reference in effect as of the date of the specification.
For all materials where no governing standard is quoted in the Specification then a
suitable national / International standard approved by the Engineer (BS, BS EN,
AASHTO, DIN or ANSI/ASTM) shall be used.
Present an affidavit from the manufacturer certifying that the product complies with
the applicable section of the specification. Where requested or specified, submit
supporting test data to substantiate compliance with the applicable section of the
specification.
Where a standard referred to in the specification is in the form of a recommendation

or suggestion, such recommendation or suggestion shall be deemed to be mandatory
unless conflicting with any particular specification.
Neither the contractual relationship duties nor responsibilities of the parties in contract
nor those of the Engineer shall be altered by mention or inference otherwise in the
Specification
1.1.9 Groundwater Levels in Dubai
The Contractor will be deemed to have carried out his own investigations at the time
of Tender to ascertain for himself the nature of the soil conditions and in particular the
groundwater levels that will be encountered.
Method statements for dealing with groundwater shall be submitted within three
weeks of the signing of the Contract.
1.1.10 Pollution of Khor Dubai and the Arabian Gulf
The Contractor shall ensure that no extraneous matter, rubbish or polluting liquid is
deposited or discharged to the Khor Dubai (Creek) or to the foreshore or sea of the
Arabian Gulf.

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Dubai Municipality
1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE
1.2.1 General
a) The Contractor shall provide, maintain and keep clean temporary site offices with
all associated equipment and services for the exclusive use of the Engineer's
Representative and his staff, from commencement until completion of the whole
of the Works.
b) The temporary site offices shall be as-new prefabricated portable unit/s or

alternatively of some other form of weatherproof design and construction to the
approval of the Engineer. The building shall be erected on suitable solid
foundation.
c) The offices shall have full partitions and room sizes shall be as shown in the
Schedule of Offices. All rooms shall have individual entrance doors.
d) Corridor and entrance areas shall be additional to the office sizes.
e) The offices shall be air-conditioned with the exception of the Toilet, Shower and
Kitchen areas.
f) All rooms shall have glazed windows complete with fly screens and Venetian sun
blinds.
g) Adequate fitted hardware, electrical switches, sockets, lighting, plumbing fittings,

sanitary ware and fittings and fixtures, etc., shall be provided as necessary for the
different areas.
h) The electrical installation shall provide for simultaneous use of all electrical
appliances.
i) The electrical supply shall be 220-250 volts, 50 Hz. The Contractor may either
arrange for a temporary power supply to the offices or alternatively provide and
maintain adequate diesel generator sets. All electricity bills throughout the
contract period until completion of construction and defects liability period shall be
paid by the Contractor.
j) The Contractor may either arrange for a temporary mains water supply or
alternatively provide tankered water supply. All water bills shall be paid by the
Contractor throughout the contract period until completion of construction and
defects liability period.
k) A minimum of two telephone lines with extensions shall be provided for the offices
along with a third line for an independent telefax facility and a fourth ISDN line as
shown in the Schedule of Fittings and the Contractor shall pay all installation and

2016

Dubai Municipality
rental charges, and call charges, if any, for UAE calls only, throughout the
contract period until completion of construction and defects liability period.
l) Covered car parking areas of approved construction for ten (10) cars shall be
provided adjacent to the offices. The final requirements shall be based on
Engineer’s approval.
m) The Contractor shall submit any necessary drawings and calculations for the
construction of the offices for the Engineer's approval before commencing
construction and shall be responsible for ensuring that the offices are structurally
sound. The Engineer may request alterations at this stage. The drawings shall be
approved in writing by the Engineer before installation/construction shall
commence.
n) The offices shall be completed and all the equipment provided by the end of the
Mobilisation Period.
o) Throughout the duration of the Contract (including defects liability period), the
Contractor shall ensure an uninterrupted supply of gas, water and electricity to the
offices.
p) The Contractor shall provide all items listed in the following Schedule of Offices
and Schedule of Fittings. The Contractor shall obtain the Engineer’s approval for
all furniture and equipment proposed.
Table1.1 SCHEDULE OF OFFICES
Room No of Room
Description Number Remarks
No. Staff Size
1 Resident Engineer 1 (6 x 4) m 1 Toilet

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Dubai Municipality
Room No of Room
Description Number Remarks
No. Staff Size
attached
2 Conference Room - (10 x 4) m 1 - do -
3 Asst. Resident Engineer 1 (4 x 4) m 1

(Civil)
4 Mechanical / Electrical 2 (8 x 4) m 1
Engineer
5 Quantity Surveyor 1 (4x 4) m 1
6 Material Engineer 1 (4 x 4) m 1
7 Inspectors 2 (8 x 4) m 1
8 Surveyor & Draughtsman 2 (8 x 4) m 1
9 Typist/ Clerk 1 (4 x 4) m 1
10 Record Room (8 x 4) m 1
11 Toilet with Ablution facility (2 x 2) m 2
12 Shower room (4 x 3) m 1
13 Kitchen (4 x 4) m 1
14 Dubai Muncipality Liaison (4 x 4) m 1 Toilet

Officer attached
15 Ladies Toilet (4 x 2) m 1
16 Sample and Material (3 x 3) m 1

Storage
17 Covered Parking Area 10
Table 1.2 SCHEDULES OF FURNISHINGS & FITTINGS

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Dubai Municipality
The fittings required under this contract for the rooms within the Engineer’s site
offices indicated in the schedule of offices, shall be as per the Engineer’s approval
and are as follows:
Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 Executive desk with nr 1 - 1 - - - - - - - - - - 1 - - -

two locking drawers
and swivel chair
2 Conference table for nr - 1 - - - - - - - - - - - - - - -

14 person meeting
3 Desk with two locking nr - - - 2 1 1 - - - - - - - - - - -

drawers and swivel
chair
4 Desk with two nr. nr - - - - - - 2 2 - - - - - - - - -

locking drawers and
chair
5 Chair, cloth fabric nr 3 14 2 4 2 2 2 2 2 - - - - 2 - - -

covered, padded steel
frame
6 Typist Desk and chair nr - - - - - - - - 1 - - - - - - - -
8 Inclined plan table for nr 1 - 1 1 1 1 1 1 - - - - - 1 - - -

drawings
9 Six drawer plan chest nr 1 - 1 1 - - - 1 - - - - - - - - -
10 Samples cupboard nr 1 - 1 1 1 1 1 - - - - - - - - - -
11 Four drawers steel nr 1 - 1 1 1 1 - - 1 - - - - 1 - - -

filing cabinet
12 Shelving & pin boards nr As required on Site
13 In / out tray nr 1 - 1 2 1 1 2 2 1 - - - - - - - -
14 Lockable Filing cabinet nr 1 - 1 1 1 1 - - 1 - - - - - - - -
15 Waste paper basket nr 1 2 1 2 1 1 2 2 1 1 - - - 1 - - -
16 Telephone handset nr 1 1 1 2 1 1 2 2 1 - - - - 1 - - -
17 Mobile Phones nr 1 - - - - - - - - - - - - - - - -
18 Misc desk equipment, nr 1 - 1 2 1 1 2 2 1 - - - - 1 - - -

punch, stapler, pencil
sharpener, etc.

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Dubai Municipality
19 Portable dry powder nr - 1 - - - - - - - 1 - - 1 - - - 1

fire extinguisher (as per
EHS requirement)
20 Fire Blanket nr - - - - - - - - - - - - 1 - - - -
21 First Aid Kit (as per nr - - 1 1 - - - - 1 - - - - - - - -

EHS requirement)
22 Maximum – minimum nr - - - - - - - - - - - - 1 - - - 1
thermometer
23 Refrigerator 0.28 m³ nr 1 - - - - - - - - - - - 1 - - - -
24 Water filter nr - - - - - - - - - - - - 1 - - - -
25 Microwave nr - - - - - - - - - - - - 1 - - - -
26 Plastic 5 litre insulated nr - - - - - - - - - - - - 1 - - - -

cold water container
27 Oil Filled Room nr 1 2 1 1 1 1 1 1 1 - - - - 1 - - -

Heaters
28 Sink unit nr - - - - - - - - - - - - 1 - - - -
29 Electric kettle nr - - - - - - - - - - - - 1 - - - -
30 Plain paper heavy duty nr - - - - - - - - 1 - - - - - - - -

photocopier (A3/A4
format reduction/
enlargement facility,
cassette feeds, sorting
facility (LATEST
MODEL)
31 Desktop computer for nr - - - - - - - 2 - - - - - - - - -

Draughtsman as
specified (2) below
32 Desktop computer for nr - - - - - - - - 1 1 - - - - - - -

secretary as specified
(3) below
33 Desktop computer for nr 1 - 1 2 1 1 - - - - - - - 1 - - -

engineer as specified
(4) below
34 Heavy duty colour nr - - - - - - - - 1 - - - - - - - -

A4/A3 Laser Printer as
specified (5) below

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Dubai Municipality
35 Light duty A4 Laser nr 1 - 1 - 1 - - - - - - - - - - - -

Colour Printer as
specified (6) below
36 A3/A4 Scanner: nr - - - - - - - 1 1 - - - - - - - -
Flatbed Scanner as
specified (7) below
37 A0 Inkjet Plotter as nr - - - - - - - 1 - - - - - - - - -
below
38 Electronic calculators nr 1 - 1 2 1 1 2 2 1 - - - - - - - -
39 Digital Still Camera nr 1 - - - - - - - - - - - - - - - -
5MEGA Pixels or
Higher Resolution
12 x Optical zoom 2.5"

LCD Screen 32MB or
Higher Memory Card
40 Punch large nr - - - - - - - - 1 - - - - - - - -
41 Binding machine nr - - - - - - - - 1 - - - - - - - -
(adjustable for A4 size
to full scap size)
42 Stapler large nr - - - - - - - - 2 - - - - - - -
43 Filing racks nr As required on Site
44 Personnel Protection nr As required on Site

Equipment
45 Refreshments nr As required on Site
NOTES:
1. All consumables including Ink Cartridges, Photocopy papers, Plastic Binding Rings, films and developing etc. to
be at the Contractor’s cost.
2. Desktop Computer (Draughtsman)

Quad Core Xeon E3-1245 (3.30 GHz, 8M L3, 2GT, Turbo) .

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Dubai Municipality
Operating System: Genuine Windows® 7 Professional, Media, 64-bit

Memory: 8GB, 1333MHz, DDR3 SDRAM, ECC (2 DIMMS)
Graphics: 1.0GB NVIDIA® Quadro® 600, Dual MON, 1 DP & 1 DVI NVS600 1 [320-1896] 6
Boot Hard Drive: 500GB 7200rpm 3.5 Inch SATA Hard Drive with NCQ and 16MB Cache
DVD and Read-Write Devices: 16X DVD+/-RW SATA
3. Desktop Computer (Secretary)

Intel® Core™ i5 2400 Processor (3.1GHz, 6M)
Operating System(s): Genuine Windows® 7 Professional, 64-bit
Memory: 4GB DDR3,Non-ECC,1333MHz Dual Channel SDRAM,2x2GB
Boot Hard Drives: 250GB 3.5 6.0Gb/s SATA with 8MB DataBurst Cache
Removable Media Storage Device: 8X Slimline DVD+/-RW, Roxio Creator™ CyberlinkPowerDVD™ No
Video Cards: Integrated Video, Intel® HD Graphics 2000 (1DP & 1 VGA)
4. Desktop Computer for Engineers

Intel® Core™ i5 2400 Processor (3.1GHz, 6M)
Operating System(s): Genuine Windows® 7 Professional, 64-bit
Memory:4GB DDR3,Non-ECC,1333MHz Dual Channel SDRAM,2x2GB
Boot Hard Drives:250GB 3.5 6.0Gb/s SATA with 8MB DataBurst Cache
Removable Media Storage Device: 8X Slimline DVD+/-RW, Roxio Creator™ CyberlinkPowerDVD™ No
Video Cards:Integrated Video, Intel® HD Graphics 2000 (1DP & 1 VGA)
5. Heavy duty colour A4/A3 Laser Printer

25 to 30 PPM with Duplex facility, 1200x1200 dpi print quality, A3 and A4 separate trays, 1 GB Memory, maximum: 1 GB,
Hard disk: Standard 8 GB Built in Memory, Connectivity, standard: 1 Hi-Speed USB 2.0 ,1 Gigabit Ethernet 10/100/1000,
IPv6, BiDi.
6. Light duty A4 Laser Colour Printer

20 to 30 PPM with Duplex facility, 600x600 dpi print quality, A4 separate, 1 GB Memory or 512MB, Connectivity,
standard: 1 Hi-Speed USB 2.0 ,1 Gigabit Ethernet 10/100/1000, IPv6, BiDi.
7. Light duty A4 Laser Colour Printer

Flatbed Scanner, 4800x9600 dpi Resolution, Auto Document feeder, USB compatible.
8. Server with back up facility

Dell Power Edge T420 Server with internal tap drive.
9. Microsoft office latest version 2013 and Acrobat standard for all computers
10. Primavera –P6 one license ( for RE or QS)
1.2.2 Specific Requirements
a) The Contractor shall be responsible for making all arrangements and payments in
respects of any land required for the site of the building.
b) The Contractor shall be responsible for the security of the building and its
contents at all times and shall employ watchmen for this purpose.

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Dubai Municipality
c) The Contractor shall supply the Consultant's staff with all safety clothing and
equipment that shall be necessary for site working such as safety helmets,
reflective waistcoats, etc.
d) The building shall be well constructed, burglar proof, mosquito proof and weather
proof and shall have sufficient doors and glass covered windows for proper light
and ventilation. Floors shall be covered with suitable, approved flooring.
e) The Contractor shall retain on site for the exclusive use of the Engineer all codes
and standards referred to in the Specification.
f) The building and services shall be available, fully maintained, until 1 month after
the issue of the Taking Over Certificate for the whole of the Works.
g) Following the completion of the whole of the Works and the Defects Liability
period respectively, the Contractor shall remove the offices from the Site and
reinstate the area to natural condition or as directed by the Engineer.
h) The building and all equipment, materials, fittings, etc., supplied for the office,
shall become the property of the Contractor after the completion of the Works.
1.2.3 Location of Contract Offices and Other Contract Facilities
Within 14 days of the date of the Letter of Acceptance issued by the Employer the
Contractor shall submit a plan or plans showing his proposed locations for and details
of:
a) Offices for the Engineer and Engineer's Representatives.
b) The Contractor's Site Offices.
c) The Contractor's Stores, Plant and Maintenance Yard, Concrete Batching and
Materials Stockpiling Facilities.
d) Principal routes for heavy plant and lorries.
e) Areas for the temporary storage and permanent dumping of excavated material.
The Offices of the Contractor's Project Manager will normally be adjacent to or

close to those of the Engineer for ease of communication.
The plan(s) shall be submitted to the Engineer in six (6) copies for approval. Any
reasonable changes or modifications suggested by the Engineer shall be
incorporated. All locations shall be subject to the approval of the Employer.
Departures from the approved details shall not be permitted unless written
consent is obtained from the Engineer.
1.2.4 Service Authorities

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Arrangements for mains water supply, mains electricity supply and telephone
connections shall be made through:
a) Dubai Electricity and Water Authority -Water Division
b) Dubai Electricity and Water Authority -Electricity Division
c) Etisalat Emirates Telecommunications Corporation (Dubai)
The Service Authorities shall be deemed to also include Departments and/or Sections
of Dubai Municipality and any other public or private authority responsible for
services.
1.3 GENERAL REQUIREMENTS
1.3.1 Materials and Manufactured Items
a) Materials and manufactured items shall be suitable for the climate and
environmental conditions described in this specification.
b) The environmental conditions may be different in different parts of the Works and
materials shall be selected and manufactured items designed accordingly to
withstand the relevant corrosive elements. In particular all products or materials in
contact with sea water, sewage or a saline/ sewage environment shall be non-
biodegradable.
c) All local customs, laws and regulations laid down by the Employer or other
governing body relating to the supply or source of materials shall be complied
with.
d) All materials and equipment specified in the Contract Documents which are to be
incorporated in the Works must be obtained from or through a Dubai Emirate
supplier and /or manufacturer. The supplier or manufacturer must be registered
with Dubai Municipality. If such specified materials or equipment are not available
from the Dubai Emirate market, any other source would be acceptable.
e) The contractor shall be responsible for liaising with the suppliers; obtaining,
checking for accuracy and issuing all drawings and other documents and for co-
ordination of supply and installation.
f) Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a "Certificate of Guarantee" signed by the authorised
representative of the manufacturer, which will legally bind the manufacturer to the
product delivered.
g) Such Certification shall state that the materials specifications and test results are
in compliance with the specified requirement of the pertinent designations of the

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most recent edition of ASTM, BS or any other approved equivalent National

Standard unless otherwise directed.
h) Falsification of such Certificates, Materials, Specifications or Test Results shall be

just cause for the rejection of the materials.
1.3.1.1 Quality of Materials, Manufacture and Standards
a) All materials and manufactured items supplied for incorporation into the
permanent works shall be new, of high quality and of sound workmanship. They
shall be purchased only from approved suppliers who shall be capable of
demonstrating the suitability of their products by reference to similar works and
certified test results, and be suitable for the purpose for which they are intended
as stated in the Specification.
b) Materials and manufactured items shall normally be certified as complying with

relevant specifications of a recognised national or international standards (ISO)
organisation which shall be subject to the approval of the Engineer but in
dimensional respects they shall be compatible with ISO standards. Where pipes
and access covers are produced to British Standard (BS) they shall be kitemark-
certified or similarly approved.
c) All materials and manufactured items shall also have an approved national
certificate of conformance similar to BSI quality kite mark or national agreement
certificate such as BBA for non – standard products and systems which shall be
subject to approval by the Engineer and verification by Dubai Municipality – Dubai
Central Laboratory.
d) Materials not covered by a third party product certification scheme shall be

assessed by acceptable tests on each batch. Sampling and testing shall be
carried out by an organisation independent of the producer at the producer’s
works or in the stockholder’s yard.
e) The Contractor shall provide, for the sole use of the Engineer, original copies of
the latest editions of any national or international standards, in English, which
may be called for as being required in the execution of the Contract. These may
include alternative standards to those to which the materials are manufactured for
use as a comparative quality guide. The standards will become the property of the
Engineer and will not be returned to the Contractor at the end of the Contract. The
rates inserted in Volume 3 shall be deemed to cover provision of any standards
so provided.
1.3.1.2 Approval of Materials and Manufactured Items
The Contractor shall submit to the Engineer full information as detailed below, for all
proposed materials and manufactured items.

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a) Prior to the placing of any order for materials or manufactured items, the
Contractor shall submit, in triplicate, a Request for Approval. The information shall
be clearly and neatly presented in a standard format to be agreed with the
Engineer. No orders shall be placed until one copy of the Request for Approval
has been returned duly signed and dated. The information required is as follows:-
(i) Name and address of proposed supplier or manufacturer.
(ii) Reference numbers and titles of relevant specifications of a recognised

national or international standards organisation with which the materials or
manufactured items will comply together with relevant copies of the
specifications in English as indicated in Clause 1.3.1.1 above.
(iii) Samples of materials representing the quality of the bulk of such materials
the Contractor proposes to use.
(iv) Manufacturer’s literature and data sheets for articles and fabricated items.
(v) Sufficient information to demonstrate that the materials or manufactured
items are suitable and comply with Specification.
b) Following approval of an order for manufactured items designed for incorporation

in the Works the Contractor shall submit detailed drawings and installation
drawings for approval. Following approval three copies of such drawings shall be
submitted.
c) Prior to despatch to site or to a designated place of storage the Contractor shall

provide the following:-
(i) Facilities for inspection and testing at suppliers’ pits or quarries,

manufacturer’s works or approved independent testing centres as
appropriate. Inspection and or witness testing may be carried out by the
Engineer or other appointed Inspector.
(ii) Details of the supplier’s or the manufacturer’s quality control test procedures
and copies of test certificates.
(iii) Shipping and consignment identification details.
1.3.1.3 Approval of Construction and Testing Methods
For all elements of the Works the Contractor shall submit to the Engineer in duplicate,
fully detailed method statements describing his proposed construction and testing
techniques and programme for execution. These shall be supported, where
applicable, by calculations for temporary works for supporting excavated faces and
shuttering of concrete.
Written approval shall be obtained before any work is commenced.

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1.3.1.4 Contractor’s Staff
The final requirements for the contractor’s staff shall be based on the project requirement
and subjected to Engineers approval .
a) Project Manager
A qualified and experienced Project Manager who holds a bachelor’s degree in

engineering from a recognised university with minimum 20 years of experience
out of which a minimum 7 years of experience in similar role of
handling/managing the projects involving civil, mechanical, electrical &
instrumentation control works.
b) Construction Manager
A qualified and experienced Construction Manager who holds a bachelor’s

degree in engineering from a recognised university with minimum 15 years of
experience out of which a minimum 7 years of experience in similar role of
handling/managing the projects involving civil, mechanical, electrical &
instrumentation control works.
c) Senior Site Engineer
A qualified and experienced Senior Site Engineer who holds a bachelor’s degree
in civil engineering from a recognised university with minimum 10 years of
experience out of which a minimum 5 years of experience of site works in similar
role.
d) Mechanical Engineer
A qualified and experienced Mechanical Engineer who holds a bachelor’s degree

in mechanical engineering from a recognised university with minimum 10 years of
role of handling the mechanical works of the project.
e) Electrical Engineer
A qualified and experienced Electrical Engineer who holds a bachelor’s degree in

electrical engineering from a recognised university with minimum 10 years of
role of handling the Electrical, Instrumentation and control works of the project.
f) Tunnel/ Microtunnelling/ Pipe jacking Engineer
The Contractor shall appoint a fully qualified and experienced Pipe jacking
Engineer having Engineering Degree in appropriate discipline, At least 10 years’
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Dubai Municipality
experience out of which not less than 5 years should be related experience,
Possess direct experience of design and laying of pipes by pipe jacking and
microtunneling methods, Good knowledge of pipe design for NDM works . He will
be responsible for microtunneling / pipe jacking design and execution activities.
Details for the qualifications and experience of the proposed Pipe jacking
Engineer shall be given in the appropriate schedule of the Schedule of
Particulars.
g) Materials Engineer
The Contractor shall appoint a fully qualified and experienced Materials Engineer
to be in charge and responsible for the testing, investigation and quality control of
soils, aggregates, cement, concrete, building materials generally, and to be
responsible for the operation of the Contractor’s Materials laboratory. Details of
the qualifications and experience of the proposed Materials Engineer shall be
given in the appropriate schedule of the schedules of particulars.
h) Engineering Geologist
The Contractor shall appoint a fully qualified and experienced Engineering

Geologist to prepare the report on aggregate sources for concrete as required by
Specification. The Geologist shall be appointed at least for the period up to the
approval by the Engineer of the proposed aggregate sources, and shall be
available for short periods thereafter for consultancy purposes. Details for the
qualifications and experience of the proposed Engineering Geologist shall be
given in the appropriate schedule of the Schedule of Particulars.
i) Planning Engineer
A qualified and experienced Planning Engineer who holds a bachelor’s degree in

engineering from a recognised university with minimum 10 years of experience
out of which a minimum 5 years of experience in similar role. He should have
hands on experience in planning and monitoring of the project. Advanced
software skills are a must including MS project and Primavera.
j) Technical Office Engineer
A qualified and experienced Technical Office Engineer who holds a bachelor’s

degree in mechanical or in civil engineering from a recognised university with
minimum 10 years of experience and with minimum 3 years of experience in
similar role of handling the material data sheets submission and approvals.
k) Site Engineer
A qualified and experienced Site Engineer who holds a bachelor’s degree or

diploma in civil engineering from a recognised university/ institution with minimum
5 years of experience and with minimum 2 years of experience of site works.
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Dubai Municipality
l) Quantity Surveyor
A qualified and experienced Quantity Surveyor who holds a bachelor’s degree in

engineering or relevant Quantity Surveying degree from a recognised
university/institution with minimum 7 years of experience or diploma in
engineering with 10 years of experience and with minimum 5 years of experience
in similar role.
m) Safety Officer
The Contractor shall appoint an experienced Safety Officer, who shall be

responsible for the implementation of safe working practices throughout the
Contract.
The Safety Officer shall when required, deal directly with the Engineer’s
Representative on matters of safety, and shall submit Accident Reports as
required in the Conditions of Contract in a form to be agreed.
1.3.2 Submittals
1.3.2.1 Contents
This Section includes:
1. Submittal Procedures
2. Product Data
3. Shop Drawings
4. Samples
5. Initial List of Spares
6. Operation and Maintenance Manuals
7. Certificates and Affidavits
8. Project Documentary
9. Miscellaneous Submission

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1.3.2.2 Definitions
a) Product Data and Shop Drawings
(i) Includes drawings, diagrams, illustrations, brochures, schedules, bill of

materials, and other data prepared specifically for the Work.
(ii) Information may be prepared by Contractor, his subcontractors, suppliers or

distributors, equipment manufacturer, or fabricators.
(iii) Information must illustrate or describe manufacture, fabrication,

construction, and installation of the Work or a portion thereof.
b) Manufacturer’s Representative
(i) Person actively working at manufacturer’s factory with minimum 5 years

experience
(ii) Familiar with actual problems of manufacturing, installing, and operating the
product.
(iii) Sales representative or agents are not acceptable.
c) Working Drawings
(i) Contractor prepared plans for temporary structures and facilities.
(ii) Elements of work which may affect the safety of persons or property shall
be certified by a qualified engineer.
(iii) Calculations demonstrating adequacy of Contractor’s design shall be

submitted with the working drawings.
(iv) Follow submittal requirements for shop drawings.
d) Samples
(i) Physical examples illustrating materials, plant/equipment, or workmanship

for permanent Works.
(ii) Establish standards by which the Work will be judged.
e) Manuals
(i) Manufacturer’s written installation, start-up, operating, maintenance and

repair instructions.

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(ii) Include parts lists, pictures, sketches and diagrams specific to the
equipment supplied to document the manufacturer’s requirements.
1.3.2.3 Submittal Procedures
a) Contractor shall make submissions only to the Engineer. All submittals, requests
for action, notifications, etc. shall be through the Engineer.
b) All data and correspondence prepared by subcontractors and suppliers shall be

submitted through the Contractor as follows:
(i) All submittals shall be in English.
(ii) Make all corrections and changes to submittals as required by the Engineer
and resubmit until approved.
(iii) Review submittals returned by the Engineer.
c) The Contractor shall ensure the following:
(i) Determine if changes requested by the Engineer result in extra cost.
(ii) Notify Engineer in writing within 5 days of receiving submittal if contractor

believes extra costs are incurred.
(iii) Failure of the contractor to notify the Engineer of the extra costs or
Contractor’s proceeding with the work waives Contractor’s claim for
compensation.
d) The Contractor shall review and approve all shop drawings, product data,
samples and manuals required by the contract documents prior to submitting
them to the Engineer. Review and approval shall be for compliance with the
contract requirements and shall have the following significance:
(i) Approval indicates Contractor has verified all materials, field measurement,
field construction criteria and similar items.
(ii) Approval also indicates Contractor has co-ordinated information contained

in submittal with Work requirements of other trades and with the Contract
Documents.
e) The Contractor’s reviews and submissions to the Engineer shall be such as to not
delay the work. The Contractor shall prepare submittals in such a manner that no
more than one re-submittal is necessary to obtain the Engineer’s approval.
f) Submissions of manufacturer’s data, including data specified as “for information

only” shall be made prior to beginning any portion of the work using materials
contained in the submittals.

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g) Contractor shall submit shop drawings and product data in accordance with
approved submittal schedule and allow adequate time for the Engineer’s view,
approval and transmittal back to the Contractor.
h) Contractor shall detail items not completely described on the Contract Drawings
in accordance with standard engineering practice.
(i) Adjust dimensions shown on the Contract Drawings to reflect dimensions of

equipment provided.
(ii) Co-ordinate dimensions shown on the Contract Drawings as well as actual

equipment dimensions with measurements of existing, adjacent,
incorporated, and completed work to ensure all components fit into the
space available.
(iii) Verify all dimensions before beginning any work depending on such data.
i) The Contractor shall identify each and every deviation from the Contract
Documents to the Engineer either on the shop drawing or in the letter of
transmittal and:
(i) Explain reason for deviation.
(ii) Compare requested deviation with contract requirement.
(iii) Explain why deviation is equal to or better than contract requirement.
(iv) Contractor shall not be relieved of responsibility for executing work in

complete conformance with Contract Documents for submittals not
identifying deviations, even when such submittals may have been approved.
j) Contractor shall submit shop drawings and product data for related equipment
items and integrated system components at the same time.
k) Partial submissions may be returned to the Contractor without review.
l) Contractor shall co-ordinate shop drawings and products:
(i) Co-ordination shall include:
 Drawings and data previously submitted.
 Drawings and data being prepared.
 Drawings and data previously approved.

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(ii) Contractor’s approval and submission of shop drawings and data to the
Engineer indicates that such co-ordination has been performed and
completed.
m) Contractor shall direct Engineer’s attention either in writing or on the re-submitted

documents to each and every revision including those requested by the Engineer
on previous submittals and explain, in writing, the reasons for the revision. The
Contractor shall not deliver materials or equipment either to storage or at the
project site and not incorporate into the works until such items have been
approved or authorised in writing by the Engineer.
n) The Contractor shall not perform any work until shop drawings have been
submitted to and approved by the Engineer.
o) All submittals from the Contractor shall include a label or stamp which indicates
that the submittal has been reviewed and approved by the Contractor for
conformance to the contract requirements.
(i) The labels or stamp shall generally conform to the following:
SUBMITTAL NO. ________________
FOR CONTRACT NO. ________________
PROJECT NO. ___________________
CONTRACTOR: ___________________________
REVIEWED AND APPROVED for Conformance with the Contract

Documents
By: ______________________ DATE:_________________
___________________________
(Signature)
REFERENCE:
DRAWINGS NOS. _______________________
SPECIFICATION NOS. _______________________

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BoQ ITEM NOS. _______________________
(ii) A ten-character submittal identification and numbering system shall be

used. Submittals for Civil, Mechanical and Electrical items shall be
submitted separately.
i. The first character shall be either “D”, “S”, or “M”

representing shop or working drawing (D,) sample (S), and
operation/ maintenance manual (M).
ii. The next five digits shall be the applicable specification

Section number.
iii. The next three digits shall be the numbers 001 through
999 sequentially number each separate package
submitted under each specific Section number.
iv. The last character shall be the letter “A” through “Z”
indicating whether the submittal is the first submission (A)
or a re-submission (B through Z). The letter “B” indicates
the second submission (first re-submittal), “C” the third
submission (second re-submittal), etc.
v. An example of a submittal number is D-03300 – 008 – B

which indicates:
D - Shop Drawing
03300 - Specification for Concrete
008 - The eighth separate submittal under this
Section
B - The second submission (first re-submittal)
of that particular information.
p) Engineer’s Review
(i) Revised submittals will be returned to the Contractor with the Engineer’s
comments, if any.
(ii) Engineer’s review is for general conformance with the contract requirements
only.
1. All works are still subject to the detailed requirements of the

Contract Documents.

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2. Engineer’s review is to help the Contractor by discovering errors

and omissions.
(iii) The Engineer’s review does not relieve the Contractor of the obligation and
responsibility to co-ordinate and plan the details of the Work and fulfil the
intent and purpose of the Contract.
(iv) The Engineer’s review shall not relieve the Contractor of the responsibility
for accuracy, proper fit, or proper functioning and performance of the work.
(v) The Engineer reserves the right to require written confirmation from the
Contractor that the comments placed on submittals stamped “Approved as
Noted” will actually be implemented.
(vi) The Engineer will make every reasonable effort to process and return each
submittal within 30 calendar days after its receipt in the Engineer’s office.
i. Large or multiple submittals may require up to 45 calendar

days.
ii. Contractor may prioritize submittals and Engineer will review

and return them in the order of the highest priority.
iii. Individual drawings from large submittals with numerous

drawings may be returned as they are reviewed rather than
waiting for the entire review to be completed.
iv. The need for re-submissions or delays in obtaining the

Engineer’s review or approval shall not entitle the Contractor
to a time extension for contract completion.
(vii) Categories used by the Engineer to evaluate submittals are defined below:
i. Approved
No discrepancies have been identified.
ii. Approved As Noted
The submittal is acceptable subject to incorporation of the

comments listed.
iii. Disapproved
The submittal is unacceptable for the reasons cited.
iv. Incomplete
. The submittal is being returned without review.

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2. Insufficient information has been provided or the

submittal does not comply with the contract
requirements.
v. Noted
1. The submittal is not required by the contract

documents.
2. The Engineer will include it in the project files for
information only.
(viii) Incomplete submittals including those not correctly transmitted, incorrectly
titled and identified, or not bearing the Contractor's review and approval
stamp may be returned to the contractor without review. This may not be
used by the Contractor as a cause for delay.
(ix) Minimum Copies for Engineer's Review
i. Two (2) reproducible copies plus two photocopies or blue line

prints for each shop drawing.
ii. Four (4) copies of all product data and manuals.
iii. The Engineer will return one (1) reproducible and one copy or
print of each shop drawing and two (2) copies of product data or
manuals to the Contractor.
iv. The Engineer may require additional copies of all submittals (in
either electronic or hard copy format) by notifying the Contractor
in writing and such additional copies will be at no extra cost.
1.3.2.4 Product Data
a) Shall be explicit with regard to details of the actual products being furnished, and
shall provide sufficient information to the Engineer to determine that the products
submitted conform to the specification requirements.
b) The country of origin for all equipment and material to be used on project.
c) Affidavit from manufacturer of each equipment item that it has been installed and
is successfully operating in at least five facilities of a similar size and type as
specified.
d) Submittals with more than one style, size, capacity, etc. of a product on a page
shall clearly indicate which product type is being submitted for approval. Failure to
do this shall be cause for disapproval.
e) Present information on pages not larger than size A4.

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f) Include the name of the product manufacturer on all catalogue data.
1.3.2.5 Shop Drawings
a) Provide detailed drawings and written descriptions of both the assembly and all
components.
b) Drawings shall indicate proposed installation of Work as well as materials and

equipment being furnished.
c) Identify proposed deviations from the details or component arrangement as

specified or shown on the Drawings.
(i) Present reasons for the proposed deviations.
Explain why proposed deviation is "equal to" that specified.
d) Information shown on shop drawings shall be complete and sufficient for Engineer
to review for compliance with contract requirements, and shall include but not
necessarily be limited to the following:
(i) Layout dimensions and component sizes including bases, foundations,

anchors, and similar items.
(ii) Design criteria.
(iii) Materials of construction.
(iv) Component and assembly weights.
(v) Utility requirements (power, water, etc.).
(vi) Manufacturer's rating or performance curves.
(vii) Wiring diagrams and control schematics.
(viii) Recommended spare parts.
(ix) Special tools.
(x) Deviations from contract requirements.
(xi) Additional requirements contained in individual specification sections.
e) Copies of the Contract Drawings are not acceptable for submission as component
arrangement (layout) drawings.
f) Manufacturer's model numbers or catalogue numbers alone shall not be

acceptable for describing equipment or components.
1.3.2.6 Samples
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a) Furnish samples as required by the individual specification section.
b) Unless otherwise specified, samples shall be submitted as follows:
(i) Submitted to Engineer as specified.
Labelled and properly identified as follows:
i. Date.
ii. Project / Work Area for which offered.
iii. Specification section and applicable paragraph numbers.
iv. Contractor.
v. Supplier / Manufacturer.
vi. Product Identification (Trade Name).
c) Samples shall be accompanied by an approved transmittal form, specifications
and other pertinent data required for Engineer to determine that the material
conforms to the specification.
d) Three sets of samples shall be submitted unless otherwise specified.
(i) One set of approved samples and all disapproved samples will be returned
to the Contractor.
(ii) If requested in writing by the Contractor, samples of value will be returned to

the Contractor after completion of the Work.
(iii) Approved samples returned to the Contractor may be incorporated into the
work upon written approval of the Engineer.
1.3.2.7 Initial Spare List
a) Initial list of spares as recommended by the respective manufacturers shall be

submitted along with the material submittals.
1.3.2.8 Operation and Maintenance Manuals
The Contractor shall:

b) Submit manuals for all equipment and components specified.
c) Manuals shall be as specified.
d) Submit two copies for review.
(i) The Engineer will return one copy of the reviewed manual to the contractor
for correction.
The Engineer will retain one copy for project files.

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e) Submit six copies of approved manuals incorporating all of Engineer's comments

and corrections prior to beginning training.
1.3.2.9 Certificates and Affidavits
a) The Contractor shall provide the original and three copies of manufacturer's
certificates in accordance with the requirements specified in the Specification.
b) Definitions
(i) Certificate indicates test results, component manufacture, or installation

complies with specified standards.
(ii) Affidavit is a sworn statement by an officer of the company manufacturing

the product indicating that the information on the certificate is true and
accurate.
c) An affidavit shall accompany all certificates.
d) A statement from the contractor, sub-contractor, equipment supplier, or agent

indicating the product meets the requirements of the Contract Documents shall
not be considered as a certificate.
(i) Such submittals shall not be approved.
Corresponding equipment, products, or components shall not be accepted.
1.3.2.10 Project Documentary
The Contractor will be required to develop a professional documentary movie on the

project scheme covering each aspect of the project including startup, construction and
commissioning phases, The documentary movie should be oh high quality and the
content and duration of movie should be agreed with the Engineer at the start of the
project.
1.3.2.11 Construction Environmental Management Plan
The Contractor shall prepare and submit a construction environmental management

plan for the project as per Dubai Municipality guidelines given in the appendix.
1.3.2.12 Miscellaneous Submissions
a) Manufacturer's guarantees and warranties
(i) Submit 3 copies unless otherwise specified.
(ii) Submit prior to final acceptance.

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b) Work plans
(i) Submit 3 copies, unless otherwise specified, at least 30 days prior to

beginning work.
c) Submittal Schedule
(ii) Show the proposed date the contractor will deliver each required submittal
to the Engineer for review.
(iii) Submit within 10 calendar days of receiving notice to Commence.
d) Health, Safety and Fire Protection Plan
(ii) Refer to relevant Section for specific requirements.
e) Accident Reports
(ii) Refer to relevant Section for specific requirements.
f) Progress Reports
(i) Prepare and submit the Progress Reports described hereinafter in a form
provided by the Engineer.
(ii) Work activities and procurement reports should be referenced where

relevant to the approved Contractor's Construction Schedule.
(iii) Submit 3 copies unless otherwise specified.
(iv) Daily Construction Reports.
 Submit on a daily basis.
 Describe labour force and its allocation.
 Describe material and equipment utilised.
 Describe work progress during the day.
 Describe temperature and weather conditions.
 Describe any occurrence which may affect the progress of the Works.
(v) Procurement Status Reports

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 Submit on a weekly basis.
 Include a list of materials and items procured.
 Include list of items delivered to the site.
 Provide references to all correspondence and transmittals between the

Contractor and the Engineer regarding approval of such materials and
items.
(vi) Monthly Report
 Reflect monthly progress and status of the Work.
 Describe problem areas.
 Describe current or anticipated causes of delay along with their

estimated impact on progress and the corrective measures taken or
proposed.
 Include construction photographs.1
g) Inspection and Test Reports
h) Survey Data
(ii) Survey data is required to develop quantitative record of actual work

constructed, as part of damage and settlement surveys, surveys of adjacent
construction and similar efforts.
i) Close-out Submittals
(i) Refer to Section or specific requirements.
j) Record (As Built) Drawings
k) Schedule of Values
l) Letter of Authority
(i) Submit within 10 days after receipt of the Letter of Acceptance.
(ii) Identify the Project Manager and detail the extent of his authority and
responsibility.
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Dubai Municipality
 All work to be under direct supervision of Contractor's on-site

representative who shall be the Project Manager.
 Project Manager shall be present at the job site whenever Work is

underway.
 Project Manager shall have full authority to represent the Contractor.
 Communication given to or received from the Project Manager shall be

as binding as that given to or received from the Contractor.
m) Organisation Chart
(i) Submit for Engineer's approval not later than 14 days after receipt of the
Letter of Acceptance.
(ii) Show the executive, administrative, and construction supervision

organisation.
 Include all personnel from Project Manager through foreman level.
 Describe personnel duties.
 Amplify details provided after submission of Tender.
 Provide qualifications and experience of all personnel shown on the

Organisation Chart.
(iii) Update the Organisation Chart whenever key personnel are reassigned.
(iv) The Engineer may interview any of the Contractor's proposed staff prior to
approval.
(v) The Engineer may direct the Contractor to remove personnel from the site
who, in the Engineer's sole opinion,
 Exhibit inappropriate conduct.
 Who are incompetent or negligent in the performance of their duties.
 Who are otherwise considered undesirable.
n) Site Layout for Contractor’s Facilities
(i) Submit within 14 days after receipt of the Letter of Acceptance.
(ii) Site plan should include but not necessarily be limited to the following:
 Temporary facilities including accommodation.

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Dubai Municipality
 Storage areas including permanent dumping of excavated material and

all debris
 Crane positioning.
 Fences, gates and security lighting.
 Access for other Contractors, vendors, plant staff, visitors, etc.
o) Evidence of Insurance as required in Conditions of Contract.
p) Correspondence
(i) Provide one original and three photocopies of transmittals and letters
including attachments and enclosures.
(ii) Submit on A4 size whenever possible.
(iii) Clearly indicate the following on each document.
 Contract Number.
 Title of Project.
 Contractor's Name.
 Date.
 Correspondence Reference Number.
1.3.2.13 Spare Parts Recommended by the Manufacturer
The Contractor shall submit with the Operation and Maintenance Manuals a list of
spares as recommended by the respective manufacturers which would be required for
operating the equipment for a period of two (2) years on completion of the Defects
Liability Period.
Each item in the list shall be priced and the employer retains the option of purchasing a
part or all of the spares thus recommended by the Contractor.
1.3.3 Setting Out the Work
a) The Contractor shall set out the work as to lines and grade in accordance with the
Drawings and secure the approval of the Engineer's Representative before
constructing the work. The Engineer's Representative will, if he deems it necessary
revise the lines or grades and will require the Contractor to adjust and to stake-out
accordingly. The Contractor shall give the Engineer's Representative not less than 24
hours’ notice of his intention to set out or give levels for any parts of the Works, in
order that arrangements may be made for checking. The Contractor shall be
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Dubai Municipality
responsible for obtaining any setting-out data he may require from Dubai Municipality
Survey Section. The Contractor shall also be responsible for obtaining Dubai
Municipality Survey Section’s approval on right-of-way. Any costs incurred in this
shall be borne by the Contractor.
b) The Contractor shall, as a requirement of the Contract and without extra charge,
provide all necessary instruments, appliances, surveyor personnel and labour, and
any other material or staging, which the Engineer's Representative may require for
checking the setting out or for any relevant work to be done. Any marks made by the
Engineer's Representative or Contractor shall be carefully preserved and, if
destroyed, shall be replaced by the Contractor at his own expense and to the
approval of the Engineer. Work shall be suspended for the time necessary for
checking the lines and levels on any part of the work, and shall proceed only after
approval of measurements.
c) In the case of any variation from the approved works, the Contractor shall give the
Engineer three copies of cross-sections and profiles of the graphical record or notes
and computations of his stake-out as required by the Engineer. At his option he may
submit cross mark on one copy with his approval of the proposed lines of the work or
his revisions thereof and return it to the Contractor. The Contractor shall resubmit for
approval any cross-sections the Engineer may amend.
1.3.4 Notice of Operations
a) The Contractor shall, when required, supply in writing full information regarding
the localities in which the materials are being obtained and in which the work is
being prepared.
b) No permanent work shall be carried out without the consent in writing of the
Engineer's Representative. Full and complete notice, in writing, shall be given 24
hours in advance of the time of the operation in order to make such arrangements
as deemed necessary for inspection.
1.3.5 Traffic Safety and Control
a) The Contractor shall provide, erect and maintain such traffic signs, lamps barriers
and traffic control signals as may be necessitated by the construction of the
Works in accordance with Road and Transport Authority and Dubai Traffic Police
requirements. The Contractor shall submit proposals for dealing with such
situations to the Engineer, RTA and Dubai Traffic Police for consent. Compliance
with this Clause shall not relieve the Contractor of any of his other obligations and
liabilities under the Contract.
b) The Contractor shall, after consultation with any statutory or other authority
concerned, submit to the Engineer for his approval a programme based on such
consultation showing the scheme of traffic management he proposes for carrying
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Dubai Municipality
out the Works before commencing any work which affects the use of the public
highway rights of way or parking areas and thereafter furnish such further details
and information as necessitated by the Works or as the Engineer may require.
c) The Contractor shall not commence any work which affects the public highway
until all traffic safety measures necessitated by the work are fully operational.
d) The traffic diversion and signs, lamps, barriers and traffic control signals shall be
in accordance with the requirements of regulatory authorities.
e) Traffic signs shall comply with the requirements of RTA. The flashing rate for
flashing lamps shall be within the range 120-150 flashes per minute. The
minimum luminous intensity of the lamps shall be 0.5 candelas for steady lamps,
1.0 candela for ripple lamps at their peak, and 1.5 candelas for flashing lamps at
their peak.
f) The Contractor shall keep clean and legible at all times all traffic signs, lamps,
barriers and traffic control signals and he shall position, reposition, cover or
remove them as necessitated by the progress of the Works.
g) Where road diversions roads are approved these must be maintained at

frequencies to suit the traffic volume using them. A good running surface must be
maintained and must at all times be free from ruts and potholes.
1.3.6 Access to Private Land
The Contractor shall give three weeks’ notice to the owner/occupier before entering
private lands and the Contractor shall not enter on to those lands until given
permission by the Engineer.
1.3.7 Roads and Site to be Kept Clean
a) The Contractor shall take great care and all reasonable precautions to ensure that
roads and thoroughfares used by him either for the construction of the Works or
for the transport of plant, labour and materials are kept clean during such
construction or transport and in the event of their requiring cleaning in the opinion
of the Engineer the Contractor shall take all necessary and immediate steps to
clean them.
b) On completion of dewatering the Contractor shall immediately dismantle and

remove from the Site disused discharge pipes and dewatering points.
c) Each individual site of work must be clean during the work and must be
thoroughly cleaned up on completion.
1.3.8 Compensation for Damage to Property

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a) The Contractor shall reinstate all properties whether public or private affected by
the Works, Temporary Works, constructional plant, labour materials or transport
to a condition at least equal to that existing before his first entry on to them.
b) If in the opinion of the Engineer the Contractor shall have failed to take
reasonable and prompt action to discharge his obligations in the matter of site
clearance or reinstatements the Engineer will inform the Contractor in writing of
his opinion in which circumstances the Employer reserves the right to carry out
the reinstatement himself or to arrange for it to be carried out by others or to
make payments to the owners and occupiers in respect of such matters for which
the Contractor is responsible. All such costs incurred and payments made will be
deducted from any monies due or which shall become due from the Employer to
the Contractor.
1.3.9 Existing Services
Drains, pipes, cables and similar existing services encountered in the course of the
Works shall be protected from injury or damage by the Contractor at his own cost so
that they may continue to function uninterruptedly to the satisfaction of the owners
thereof and the Contractor shall not store materials or otherwise occupy any part of
the site in any manner likely to hinder the operations of such owners.
a) The Contractor shall protect and support, during the progress of the Works, all
pipe mains, cable wires and other apparatus which might be endangered by his
operations. The approximate positions and alignments of known services are
indicated on the Drawings, but no guarantee of exact location can be given, and
the Contractor must communicate with the authorities and/or proprietors
concerned to locate them exactly, and he shall then prepare shop drawings 1/500
scale for each Utility as directed by the Engineer. When approaching each
indicated position, the Contractor shall search, by safe methods which will not
endanger the service, to determine its precise position.
b) The Contractor shall make his own arrangement with the owners of the services
and with other persons interested, for any diversions, temporary stoppages and
reinstatements, and he shall allow in his programme for all such arrangements.
c) If any underground service is encountered unexpectedly, excavation shall cease,

and the Engineer's Representative shall be notified immediately. Emergency
work, as necessary, should be put in hand without delay and without prejudice to
the indemnity of the Employer.
d) The Contractor shall give notice, in writing, to the Engineer and to the appropriate
service company of all damages to existing services caused by him or by any
Subcontractor in the course of the Works. He shall be held responsible for any
such damage and shall immediately have such damage made good at his own

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expense and shall relieve the Employer of all claims in respect of any loss or
interruption involved.
e) If in the opinion of the Engineer, it is necessary or expedient that any pipe, drain,
ditch, cable or overhead wire (including supports) should be broken out, stopped
up, diverted, taken down, or altered, the cost of doing so shall be the
responsibility of the Contractor. Such work shall be executed only on the written
instruction of the Engineer.
f) All existing sewers, culverts, water courses and drains of every kind and condition
that have been altered, extended or otherwise interfered with either directly or
indirectly by the work, or that may by leakage, silting, stopping of free flow or
otherwise interfere with or delay the execution of the work, shall be made good,
cleaned, placed in working order, supported, maintained, and protected and the
Contractor shall provide everything necessary for efficiently dealing with,
protecting, pumping or removing, as the case may be, all water, sewage, or spoil
there from.
1.3.10 Continuous Working
If in the opinion of the Engineer it is necessary for the safety of the Works or for any
other reason, the Contractor shall, when so ordered, carry out the Works, or any
portion thereof continuously by day and night. The Contractor will be reimbursed the
agreed extra costs, provided the necessity for the order is not a result of the
Contractor's negligence.
1.3.11 Temporary Staging for Structures
Temporary staging shall be provided by the Contractor to enable the construction

operations to be performed in the required sequence. The staging shall be properly
designed and constructed for the loads which it will be required to support, and
complete details of the arrangements proposed shall be submitted to the Engineer for
approval.
Such approval, however, will not relieve the Contractor of his responsibility for the
adequacy of the staging. The cost of such staging is to be included in the tendered
rates and prices entered in the Bills of Quantities.
1.3.12 Water Supply
The Contractor shall carry out an investigation prior to submitting his Tender as to the
availability of water for the purpose of the Works and shall consult and arrange with
the appropriate authorities and consider all legal aspects. The Contractor shall be
entirely responsible for the supply of sufficient water of the specified quality at all
times throughout the Contract, and the costs shall be deemed to be covered in the
Contract rates and prices.

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1.3.13 Filling in Holes and Trenches
The Contractor, immediately on completion of any part of the work, shall, at his own
expense, fill up all holes and trenches which have been made or dug by him and are
not part of the Works. Holes, cavities, trenches or depressions shall be backfilled with
suitable materials and compacted to the grade required or as directed by the
Engineer. The Contractor shall clear away all rubbish and materials that is no longer
required for the execution of the work, whether his own or any other party to the
satisfaction of the Engineer.
1.3.14 Protection of Works from Weather
The Contractor, at his own expense, shall protect all works and materials from
damage by weather. All damage caused by adverse weather conditions, whether by
flooding or intense heat or any other weather conditions shall be rectified by the
Contractor at his own expense. Abnormal weather conditions shall not be considered
any reason for a claim by the Contractor for compensation for damage.
1.3.15 Keeping the Works Free from Water
The Contractor shall at his own expense keep the works at all times well drained and
excavations whether above or below the normal water level of the water table free
from storm or percolating water which may accumulate on the Site and which may
interfere with progress of construction or has or is likely to have deleterious effect on
the work in progress or the use thereof, by provision of temporary open drains and
sub-soil drains, diversion of ditches and other surface water channel or by pumping or
other means as required.
1.3.16 Sign Boards
a) The Contractor shall provide and erect signboards as detailed in the BoQ, at the
Site and at the Offices of the Engineer and the Contractor. Normally signboards
will be required on all major road approaches to the Site.
b) The layout and lettering size and location of all signboards and their siting shall be
subject to the approval of Dubai Municipality.
c) The signboards shall give, in English and Arabic, the name of the Project and the
names, Post Office Box numbers and contact telephone numbers of the
Employer, the Engineer and the Contractor. The boards shall be of dimensions
as shown on the drawings and shall be of durable construction capable of
withstanding the effects of the climate for at least the period of the construction
and the Defects Liability Period. The boards shall be mounted on substantial
frames.
d) The signboards shall be periodically cleaned, remain legible and be maintained in

a structurally safe condition throughout the period of construction and Defects
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Dubai Municipality
Liability Period. Upon issue of the Defects Liability Certificate they shall be
removed from the Site within two weeks.
1.3.17 Templates
a) When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of certain
work. The templates will be in accordance with the Specifications and Drawings
where such are provided.
b) All templates must be approved and shall be maintained in good order to provide
the section required for the entire works. Templates may be checked from time to
time and any deficiencies noted shall be rectified immediately.
c) The Contractor shall also supply straight edges and lines when required to control
the work.
1.3.18 Assistance to the Engineer
a) The Contractor shall provide and maintain for the use of the Engineer such
surveying and engineering instruments as the Engineer may require for his duties
as detailed in (Clause 1.3.19). The Contractor shall provide the Engineer with all
necessary assistance in checking the setting out of the Works and interpreting
any information used by the Contractor for this purpose including the sole use of a
minimum of three (3) chainmen.
b) The Contractor shall provide the Engineer with all assistance, equipment and
material required to document and record progress of the Works.
c) The Contractor shall provide all assistance, equipment and material required by
the Engineer for all the measurement of the Works for monthly valuation and for
the final certificate payment.
d) The Contractor shall be responsible for all follow up and co-ordination with all the
service departments. (Electricity, Water, Drainage, Street Lighting, Telephone,
Horticultural, etc.).
e) The Contractor shall provide all unskilled labour and necessary tools as directed
by the Engineer.
f) If at any time before the commencement or during the progress of the work it
appears to the Contractor that for the proper execution of a specified part of the
Works, shop drawings are necessary, these drawings shall be established by the
Contractor and submitted to the Engineers' Representative for approval. The
Engineer's Representative shall have authority to order at any time and the
Contractor shall agree to provide any number of shop drawings which, in the
opinion of the Engineer's Representative are necessary for the proper execution
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Dubai Municipality
of a specified work. The Contractor shall not proceed with the above mentioned
work until these shop drawings are approved by the Engineer's Representative.
The Contractor shall not be entitled to any extra compensation or extension of
time for the preparation of the above mentioned drawings.
(i) These details shall be dimensioned in the metric system and shall describe
accurately the method of fabrication, applied finish and sizes of all members
and fixings and shall indicate methods of marking of components for site
erection.
(ii) The Engineer shall furnish the Contractor with paper print and digital
contract drawings, to be updated as the Works proceed. The Contractor
shall provide full details of revisions to these drawings, both digitally and
hard copies, in accordance with Dubai Municipality Drainage and Irrigation
Department requirements. Required information shall include the following:
Main Drawings:
 1 set of paper prints on hangers.
 1 set of paper prints bound.
 1 set of digital drawings on CD.
The information should be sufficiently detailed to include, but not be limited

to the following:
 Offsets from permanent references such as road edge, road centerline,

kerb line, building line, etc., at suitable intervals as directed by the
Engineer, for all services encountered during the Works and during trial
trenches including description of offsets.
 Level profiles for all sewerage, drainage, rising mains.
 House connection layout and details to be completed as separate

drawings and included on main sewer layout drawings.
 Modifications to any standard details for specific constructions.
 Service Details determined from trial excavations and at crossing points.
 Mechanical and Electrical details
The Contractor shall at the commencement of works, provide the Engineer's

Representative for his full and exclusive use sufficient number of water, soil, concrete,
asphalt, and room thermometers as required by the Engineer.

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1.3.19 Surveying Equipment
1.3.19.1 General
The contractor shall provide and maintain in good condition at all times, the following
new survey equipment and materials during the continuance of the Contract for the
exclusive use of the Engineer and his staff:
Table 1.3 Schedule of Equipment
Item Description No. Required
1. Rolling Straight Edge As required
2. Electronic total station (TC 1800 or equivalent) with data 1

recording and transfer facilities to computer including
data logger etc.
3. Target reflectors with 2 km range 2
4. Tripod for reflector 2
5. Automatic level, tripod and staff (NAK 2 or equivalent) 3
6. Staff Levelling Plate 3
7. 3 metre ranging poles (folding or detachable type) 10
8. 50 metre steel tape ( Non-corrosive) 8
10. Fibre tape, 30 m length with case 3
12. 3 metre steel pocket tape graduated in mm 2
13. Conical Plummet 2
14. Steel straight edge , 1 m length 1
15. Spirit Level , 1 m Length Aluminium spirit level 1 metre 1

long with four plumbs and two level tubes

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Dubai Municipality
16. Spirit Level , 4 m Length 1
17. Mason string line , 100 m length 6
18. Portable concrete thermometer, ELE Model EL 34 – 112 6

or approved equal
19. Shovel 3
20. Flask, with thermal insulation, 1 litre capacity 3
21. Water containers, 5 litre capacity 3
22. Thermometers, wet and dry bulbs, graduated in degrees 3

C and F
23. Crack detection pocket microscope, latest model or 1

approved equal
24. Pocket penetrometer ELE latest model or approved 3

equal
25. Optical Square 1
26. Manhole lifting keys for : heavy duty covers 6

medium duty covers 6
light duty covers 6
27. Weatherproof, rubber-cased torches 6
28. Survey arrows, wooden pegs, hilti nails etc As required
29. Safety helmets As required
30. Marking chalk, paint As required
31. Copy of all standards referred to in the Specification 1
32. Digital camera 6 mega pixel or better 1

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33. Hammer 1 kg 2
34. Hammer 3 kg 2
35. Level books, field books, surveying umbrellas As required
36. Silica gel bags As required
37. Universal straight edge 3 metre with edge gauge 1
1.3.19.2 Expendable Materials
The Contractor shall provide adequate supplies of expendable materials such as

stationary, pencils, inks, drawing paper, pens, pegs, brushes, paint and other similar
items required for the satisfactory completion of survey and as required by the
Engineer's Representative.
1.3.20 Laboratory
See Appendix for Laboratory Testing.
1.3.20.1 General
Testing of all materials and completed work shall be carried out in accordance with
DM Administrative Decision No. 160 for 2000.
a) For testing of materials, etc., the Contractor shall use either:
(i) the services of an accredited independent laboratory.
(ii) The services of Dubai Municipality Dubai Central Laboratory (DM-DCL)
b) All transportation of personnel and materials together with the provision of all
assistance to laboratory testing shall be borne by the Contractor. For this purpose
one (1) approved long wheel base 4WD vehicle shall be maintained for this
specific use by the Contractor to be at the sole and full time disposal of the
Engineer. The role of this vehicle will include the delivery and uplifting of all
material for the laboratory including test results. Contractor's technician shall not
participate in the testing. Notice of tests shall be given to the Dubai Municipality at
least one day prior to the proposed testing.

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c) Dubai Municipality shall charge the Contractor for all testing and re-testing. Also
Dubai Municipality shall, at the discretion of the Engineer, have the right to charge
for additional material testing where this additional testing is, in the view of the
Engineer, caused by negligence or insufficient testing prior to submission of
materials on the part of the Contractor. All charges for testing and/or re-testing will
be at Dubai Municipality standard rates current at the time of testing/re-testing.
d) The testing of the Works by the Dubai Municipality does not absolve the
Contractor of his responsibility for the quality control of workmanship and
materials.
e) The Engineer and the Contractor's authorised representative shall be permitted to

witness any testing carried out by the Dubai Municipality Dubai Central
Laboratory (DM-DCL)
f) Dubai Municipality Dubai Central Laboratory (DM-DCL) will not be held liable for
the interpretation and correctness of test data. This will also be the responsibility
of the Engineer and the Contractor, respectively.
g) All sampling for such tests shall be carried out by the Consultant's Inspectors and
labelled as per the relevant standard sampling requirements (as listed in Clause
1.3.21).
h) Copies of the tests carried out by independent laboratories shall be forwarded to

the Dubai Municipality Dubai Central Laboratory (DM-DCL) for information if they
so require.
i) Wherever there is a reference to Dubai Municipality Construction Quality Control

and Research Section (DM CQC & RS) it shall be read as Dubai Municipality
Dubai Central Laboratory (DM-DCL).
1.3.21 Minimum Test Requirements
The following is the schedule of minimum requirements governing tests of materials

which shall be carried out during the execution of the Works. Should the Engineer's
Representative deem it necessary to increase or reduce the number of the following
mentioned tests, he shall issue his written instructions to the Contractor as and when
required, following due consultation with the Employer.
Table 1.4. Minimum Test Requirements of Materials
Materials Frequency Relevant Standard and test methods
Water for concrete One test for each source and as BS 3148 or BS EN 1008
directed by the Engineer
thereafter the minimum ASTM D512, ASTM D513, ASTM

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frequency test as specified in Cl. D516, ASTM D1293 BS 1377
3.2.2.2.
Part 3
Portland Cement One bag of cement for Quality BS 12 (BS EN 197) – O.P.C.&
testing shall be taken from each MSRPC/ASTM C150 Type II
200 tonnes or fraction thereof
for each source or BS 4027 – SRPC or ASTM C150
manufacturer. Frequency test as Type 5
specified in Clause 3.2.2.2. Test Method : BS EN 196 & BS
4550 :P3 Section 3.8:1978
Coarse Aggregate One sample for quality testing BS EN 12620 :2002 – Latest Edition.
for Concrete shall be taken from each
designated source. After BS 812 – Parts 103, 105, 111, 112, ,
approval frequency test shall be BS EN 933.1:2012, BS EN 933-
carried out as specified in Table 7:1998, BS EN 1744-1:2009 , BS EN
3.4. 1367-4:2008, BSEN 932 & 1097,
ASTM-C88, C131/C535
C123, C142, C117, C127/C128,

C289, C295, C586, C227 and P214
Fine Aggregate for As for Coarse Aggregate above. BS EN 12620:2002+A1:2008

Concrete
As for Coarse Aggregate above.
ASTM C40, C128
Bitumen Binder for As specified in Clause 3/47.1, As specified in Clause 3/26.3 of

Bituminous mixers Section 3 of Roads Specification Section 3 of Roads Specification
(Refer Appendix). (Refer Appendix).
Coarse Aggregates As specified in Clause 3/47.2, As specified in Clause 3/22.4, Section

for Bituminous Section 3 of Roads Specification 3 of Roads Specification (Refer
Mixtures (Refer Appendix). Appendix).
Fine Aggregate for As for Coarse Aggregate above. As specified in Clause 3/23.4, Section
Bituminous mixtures To be followed as specified in 3 of Roads Specification (Refer
Clause 3/47.2 of Section 3 of Appendix).
Roads Specification (Refer
Appendix).

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Bituminous Mixtures As specified in Clause 3/47.3, To be followed as specified in Clause

3/47.4 and 3/47.5 of Section 3 of 3/47.3, 47.4 & 47.5 Section 3 of
Roads Specification (Refer Roads Specification (Refer Appendix).
Appendix).
Suitable fill materials As specified in Clause 2.18. To be followed as specified in Clause

for Earthworks & 2/12.
Embankment
Materials for As specified in Clause 2.22.7. To be followed as specified in Clause

Structural Fill 2/12 & 3/8 of Section 3 Pavement
Construction (Refer Appendix).
Natural rounded One sample at the start of the Grading : BS EN 933.1:2012

coarse aggregate for project. After approval, samples
pipe bedding and of each nominal sizes of Compaction fraction : BSEN 752
surround specified aggregate for every Sulphate Content as SO3 : BS EN
1000 m3. 1744-1:2009
Improved Subgrade As specified in Clause 2/18. To be followed as specified in Clause

Material 2/12.
Soil classification, soil chemical

tests and soil strength tests.
Soil compaction tests:
i. MDD/OMC test as specified. To be followed as specified in Clause

2/17
As specified in Clause 2/18.

Insitu density test.

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If directed by the Engineer the
following tests may also be
carried out on the material as
laid on site.
iii. Field C.B.R. with a speedy BS 1377: Part 9: Test 4.3

estimate for moisture content
and dry unit weight.
Sub-bases, i. As specified in Section 3 of To be followed as specified in Section

Aggregate Road Road Specification Clauses 3 of Road Specification Clauses 3/6.2,
base and Wet mix 3/6.5, 3/13.1, 3/20.1 and 3.20.2 3/6.3, 3/6.4, 3/6.5, 3/8.2, 3/8.3, 3/10,
( Refer Appendix). 3/15.1, 3/15.3 and 3/18.1 ( Refer
Appendix) .
After laying and compaction the

following testing procedure shall
be followed as specified in
Clause 3/6.5, 3/13, 3/20 of
Section 3 - Pavement
Construction ( Refer
Appendix)..
BS 1377: Part 9: Test 2.2

Field density (3 no.)
Reinforcing Steel Reinforcement steel shall be BS 4449 of Latest Edition

supplied to site with
(uncoated) manufacturer’s mill certificate
and third party compliance
certificate for each load for all
diameters. When directed by the
Engineer:
a) at the start of the project all

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Dubai Municipality

specified test on reinforcement
shall be performed for the
following types:
i. Steel fabric reinforcement.
ii. Mild steel and high yield
(hot rolled) bars.
iii. Cold worked steel bars.
) Frequency test for the

reinforcement not covered by
third party certification scheme
shall be tested for every 100
tons as directed by the
Engineer.
Fusion bonded Epoxy coated reinforcement ASTM A775 / A775 M

epoxy coating on shall be supplied on site with
steel reinforcement coating applicators compliance
for concrete certificate for each load. When
directed by the Engineer all
specified tests shall be
performed:
at the start of the project on

each diameter of reinforcement
frequency tests on every 100

tons of reinforcement
Concrete Shall be obtained from each BS 8500 – 1&2 : 2006

mixer for each individual pour.
AMD: BS EN 206-1: 2002
a) Slump tests and compaction ) Sampling of fresh concrete

factor tests shall be carried-out
at the site of the actual placing BS EN: 12350-1: 2009
of concrete as directed by the ) Method & determination of slump BS
Engineer. EN 12350-2:2009

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) Method of determination of
compacting factor BSEN 12350-3:
2009.
)
Preparation of concrete ) Sampling of fresh concrete
specimens & curing of
specimens. BS EN: 12350: 2009 Part 1
) Method of making concrete cubes

from fresh concrete BS EN 12390-2
) Method of curing test cubes BS EN

12390-2
) Method of making test cylinders

ASTM C496:1996.
b) Frequency test as specified in ) Sampling of fresh concrete

Table 3.18.
BS EN: 12350:2009 Part 1
Precast Concrete a) Flexural / transverse strength BS 7263-1:2001 , BS 7263-3:2001

and water absorption for each
supplier of precast kerbs and
slabs (3 no. samples).
Subsequently, on approval of a
source or supplier, 3 samples Sampling in accordance with BS 7263
will be tested every 1000 unit for P1: 2001
kerbs and 1000 units for slab
tiles.
b) At the start of the project, BS 5911-P3:2010

crushing strength of concrete
encased GRP microtunnelling
pipe on 1% of total length.
Concrete mix design One trial mix for each class of

concrete shall be verified by
DCL prior to approval by the
Engineer. For every mix design
the following test shall be

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Dubai Municipality

included
Fresh Concrete One test for each class of RCC

concrete
ASTM C232:1999
i. Bleeding test
ii. Air content in air-entrained

concrete BS EN 12350 P7:2009/ASTM C173
iii. Free water cement ratio BS 1881
iv. Workability BS EN 1250-2:2000
v. Wet Density BS EN 12350-6
vi. Drying shrinkage BS EN 12390-7-2000/ BS EN 772-

2:1998 , BS EN 771-3:2003
vii. Total sulphate and chloride
content in the mix As specified in Table 3.10
viii. Durability test as specified in Table 3.13
Hardened Concrete i. Density and compressive BS EN 12390-7, BS EN 12390-3

strength of concrete
ii. Depth of water penetration

BS EN 12390 P8:2009
iii. Initial surface absorption
ISAT-BS 1881:P208:1996
iv. Flexural Strength of
Concrete Prism BS EN 12390-5
v. Tensile Strength of Con.

Cylinder ASTM C496 or BSEN 12390-2
vi. Chloride permeability
vii. Water absorption ASTM C 1202: 1999

viii. Durability test As specified in BS1881: P122
As specified in Table 3.13

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Dubai Municipality
1.3.22 Sources of Materials
The Contractor shall be responsible for obtaining the Approval of the local Authorities
for the sources of materials and he shall have no right to claim for any compensation
if he is to pay for the material at its source.
1.3.23 Programming the Progress of the Works
a) A detailed computer-based programme using critical path methods shall be

produced by the Contractor as set out in the Conditions of Contract. This shall
include full details of resources and rates of progress. The Engineer may require
the Contractor to modify the programme on occasions during the course of the
Contract. The Contractor shall work to the latest approved programme at all
times.
b) In planning his programme the Contractor shall allow reasonable time for the
Engineer to confirm setting out details as the Works proceed in accordance with
the programme.
c) The Contractor shall indicate on his programme whether the work is to be carried
out during normal site hours or whether overtime or a shift system is necessary to
execute the Works.
d) The Contractor shall present a weekly summary to the Engineer detailing

personnel, plant materials and equipment orders and shipping movements of
same.
e) Before the close of Site on each working day the Contractor shall submit a brief
programme for the following working day stating in which area of the site work will
be carried out and the location of plant and labour. The format of the programme
shall be agreed with the Engineer. The Contractor shall also submit for the
Engineer’s approval a daily record of manpower and plant resources.
1.3.24 Progress Reports
The Contractor shall be required to submit to the Engineer weekly and monthly
progress reports on the first day of the week following and the first day of the month
following respectively.
a) Weekly Report
The report shall include: the meteorological data; Contractor's plant and labour
returns; a brief summary of work completed.
b) Monthly Report
The report shall include: a description of the month's work; details of any
problems relating to the Works; quantities; records of test results; charts
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Dubai Municipality
illustrating progress in terms of work done against programmed work and the
financial status of the Contract including value of works completed, certified and
monies received; progress photographs.
1.3.25 Progress Photographs
a) The Contractor shall arrange to take monthly record photographs of the Works in
progress. These photographs shall cover such extent of the Works as the
Engineer shall direct. The days upon which the photographs are to be taken shall
be decided by the Engineer.
b) The Contractor shall provide the Engineer on the last day of each month one set
of progress photographs, with dates imprinted on it, which shall comprise the
following:
(i) One colour negative of each photograph for an anticipated maximum of fifty
exposures per month.
Ten colour prints (294 x 210 mm) of each of a maximum of twenty of the
negatives as selected by the Engineer.
Soft copy of Photograph on a memory card
c) The prints are to be processed by an approved professional and shall be in colour

on heavy weight paper with matt finish. The photographs shall have computer
produced descriptions incorporated thereon. Each photograph shall be provided
with an approved clear plastic cover for binding.
d) The copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of exposure.
1.3.26 Suppression of Noise
The Contractor shall make every reasonable endeavour both by means of temporary
works and by the use of appropriate plant or silencing devices to ensure that the level
of noise resulting from the execution of the Works does not constitute a nuisance.
1.3.27 Closing of Roads
a) The Contractor shall give four weeks’ notice in writing to the Engineer of his
intention to commence work on any public road (which shall include un-made
rights-of-way).

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Dubai Municipality
b) The closure of public roads will not be permitted without the written permission of
the Roads & Transport Authority, the Dubai Traffic Police and the Engineer. The
Contractor shall submit five (5) copies of his proposals for diverting traffic
indicating positions of all signs, cones, lights and anything else which may be
necessary. The Contractor shall comply with any Specification for traffic
diversion, including surfacing requirements, safety and control laid down by the
Authorities in Dubai and shall be responsible for continuous maintenance.
c) A period of up to 30 days may be required by the authorities to process permits

authorising the cutting of existing carriageways.
d) In the event of such permission being refused the Contractor shall have no claim
for any additional payment.
e) No work will be permitted on a public road verge, central reservation or garden

without the SIGNED approval of the respective Authorities copies of which must
be submitted to the Engineer before work commences.
f) The Contractor’s work shall be so arranged that use of the roads affected by the
work shall be restored to the public with the minimum of delay. 24 hour
construction work, subject to fulfilling the regulatory requirements, is expected in
ROW area to restore the road at the earliest. Laying of the pipelines, backfilling,
testing of the pipeline, temporary reinstatement and clearance of the Site shall
follow closely behind excavation and the Engineer may limit the length of
excavation when necessary.
1.3.28 NOC from Relevant Authorities
Notwithstanding the requirements of clause 48 of "Conditions of Contract for Works of

Civil Engineering Construction, (Part 1 - General Conditions)" it shall be the
Contractor's responsibility to obtain all required No Objection Certificates (NOC) from
the relevant Authorities and submit them to the Engineer prior to the Engineer issuing
a Taking Over Certificate.
1.4 TOPOGRAPHICAL SURVEY
1.4.1 GENERAL REQUIREMENTS
a) The Contractor shall maintain in good working order at all times the instruments
provided by him for the setting out of the works, and shall make such instruments
available to the Engineer as required for checking out or taking measurements.
All equipment must be calibrated by an independent agency.
b) The Contractor shall employ a surveyor acceptable to the Engineer to perform

survey work.
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Dubai Municipality
1.4.2 SURVEY CONTROL POINTS
a) Site bench marks shall be accurately and safely established, maintained and
cleared away upon completion of the works all to the satisfaction of the Engineer.
Such bench marks shall be related to the nearest permanent Municipality bench
mark. Record locations, with horizontal and vertical data, on project record
documents.
b) Prepare a plan detailing the location of the bench marks and keep up to date
throughout the period of the contract. Reproducible copies of the plan so
prepared shall be supplied to the Engineer as and when he may require.
c) Protect survey control points prior to starting site work and preserve during
construction.
d) Promptly report to Engineer the loss or destruction of any control point or

relocation required because of changes in grades or other reasons.
e) Replace dislocated survey control points based on original survey control. Make
no changes without prior written notice to Engineer.
1.4.3 SURVEY WORK
a) Verify locations of survey control points prior to starting work and check
periodically and whenever required.
b) Before the works or any part thereof are commenced, the Contractor and the
Engineer shall together make a complete survey and take levels of the site and
agree all particulars upon which setting out of the works shall be based, including
existing plant, buildings and services.
c) Such levels shall be related to the temporary bench marks and plotted by the
Contractor and after agreement of the drawings, shall be signed by the Engineer
and the Contractor and shall form the basis of setting out of the works. Three
copies of the drawings shall be submitted to the Engineer.
d) Failing such surveys and agreements being prepared and/or signed by the
Contractor, the surveys of the Engineer shall be final and binding upon both
parties.
e) Confirm elevations and locations of the work are in conformance with the
drawings.
f) Promptly notify Engineer of any discrepancies discovered in control points,

elevations and locations of the work.

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Dubai Municipality
g) Accurately set out the positions, levels and dimensions of all parts of the works in
relation to reference data given on the drawings. Any delay or loss resulting from
errors in the setting out of the works shall not be accepted.
h) Provide all assistance which the Engineer may require for checking setting out
and for taking measurements of the works, including labour, equipment and
transportation.
i) Setting out shall be approved by the Engineer before commencing the works, but
such approval shall in no way relieve the Contractor of his responsibility for the
correct execution of the work.
j) The Engineer reserves the right to order levels to be taken at any time considered
necessary for the full and proper supervision and measurement of the works.
k) On request the Contractor shall submit documentation verifying accuracy of

survey work.
1.4.4 NON COMPLIANCE
a) Work which fails to meet the specified levels of accuracy must not be rectified
without approval.
b) Propose rectification measures for parts of the works which do not meet the
specified levels of accuracy to the Engineer for approval. Rectification measures
necessitating removal and replacement of sub- standard work may not be
approved. Pay all costs and losses associated with rectification of sub-standard
work.
1.5 SPECIFIC OBLIGATIONS
1.5.1 Sequence of Construction
a) The Contract Programme to be submitted in accordance with Clause 14 of the

Conditions of Contract shall propose in comprehensive detail a sequence of
construction. The programme shall be accompanied by histograms showing the
Contractors expected regular interim work valuations and the proposed variation
in manpower necessary throughout the Contract Period to meet the Contract
Programme.
b) The Contract Programme shall take account of all safety requirements and liaise
with other Contractors working within or next to the area in order to minimise
interference with the other Contracts and to keep disruption of public access
within the area to a minimum.
c) The works are to be left in a safe and tidy condition to the complete satisfaction of
the Engineer. Any road closures or traffic diversions must be arranged between

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Dubai Municipality
the Contractor and the Roads Department and all costs involving any road
closures or traffic diversions are deemed to be included in the Contractors rates.
d) The programme shall also make due allowance for the maintenance of access to
all residential and commercial properties and for a sequence of work satisfactory
to the Emergency Service Authorities in maintaining facilities for their operations
should the need arise, and for the general safety of the public.
e) Particular attention is drawn to the problems, which may arise with the disposal of
flows from dewatering operations. Careful consideration must be given to the
minimisation of surface disruption and obstruction and to the likelihood that
permission for dewatering or other stabilisation operations from or through the
surface of paved areas is unlikely to be granted.
f) Disruption of the existing service networks in the area must be avoided,

particularly to the existing water, sewerage, drainage and irrigation systems, and
overhead/ underground electricity cables. Due consideration for maintaining the
existing systems shall be allowed for when preparing the Contract Programme.
g) The Contractor shall take all necessary precautions and responsibility while
crossing or carrying out works close to the vicinity of high voltage transmission
towers and overhead transmission lines. No claim for damages or additional work
arising from such damages will be considered by the Employer.
h) The Contractor shall pay particular attention to the problems of vehicular access
in the areas of work. Vehicular access shall be maintained along roads affected
by the works so far as possible. Should it become necessary to close a road then
the Contractor shall obtain the necessary permits and arrange an alternative
detour for the duration of the road closure. The details of road closures for traffic
diversion should be submitted to the authorities for approval at least 14 days in
advance of commencement of the works.
i) The Contractor shall restrict his hours of work to daylight hours only unless
specific approval has been obtained from the authorities to carry out work during
night time hours.
1.5.2 Safety Requirements
a) The Contractor's attention is directed to the requirements of Section 10 of this

Specification and to improve safety during the execution of the Contract the
following information is specifically required to be submitted as part of the
Contract Programme. No approval to the programme will be given until the
Engineer is satisfied that adequate safety procedures exist.
(i) Entry procedures and instructions to staff working in confined spaces.

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It should be noted that there is NO confined space which may be considered

safe and EVERY entry or re-entry into chambers, drains etc. should be treated
with as much respect as entry into an obviously dangerous atmosphere such
as a live sewer. There is ALWAYS the risk of accidental spillages/discharges
upstream, which may cause contamination of an otherwise safe environment.
These can occur at any time and without notice.
(ii) Details of training provided to staff together with dates of original training
and dates of subsequent refresher courses.
(iii) Procedures to be followed in case of an incident, accident or emergency

including liaison with the Emergency Service Authorities.
(iv) Details of special safety equipment held and names of personnel certified
for its use.
(v) Chart detailing both the Company and the contract management chains of
command together with clearly defined areas of responsibility.
(vi) All procedures must be in writing with clearly defined areas of responsibility.
Where appropriate they should conform to accepted practices and
procedures.
b) Copies of certain relevant publications are held by the Resident Engineer, in a

bound volume entitled, ‘Entry into confined spaces: Hazards and Precautions’, to
which reference may be made.
c) Particular problems of health and safety may arise with respect to non-disruptive
methods of trenchless construction employed for new pipeline construction or for
pipeline replacement or manhole renovation and the Contractor must ensure that
adequate precautions and satisfactory working practices are adopted in the
execution of such works to protect the health and safety of all personnel engaged
in executing the works and in their supervision.
1.5.3 Setting Out
The Contractor shall note that the alignment of pipelines and the location of chambers
and other structures as indicated on the drawings are for guidance only. The specific
setting out details, alignment and location, will be confirmed on site following the
review of actual site conditions, trial trenches and existing and proposed services.
1.5.4 Progress Reports, Photographs and Site Records
1.5.4.1 General

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Dubai Municipality
The Contractor will be required to submit to the Engineer, in an A4 format unless

otherwise indicated, weekly and monthly progress reports as detailed below. Reports
shall be neatly presented and shall be submitted in triplicate
1.5.4.2 Weekly Reports
Weekly Reports shall be submitted on the first working day of the following week, and
shall include but not be limited to the following:
a) Average, maximum and minimum daily ambient temperatures and humidity; all
readings to be taken at one time.
b) Rainfall data, if appropriate, and general weather report.
c) Contractors labour and plant returns in an A4 format to be agreed with the

Engineer.
d) Brief summary of work completed.
1.5.4.3 Monthly Reports
Monthly Reports, including mounted selected photographs shall be submitted by the

twenty-eighth day of the month concerned, and shall include but not be limited to the
following:
a) Description of the extent and nature of the month’s work.
b) Details of any problems relating to the Works with substantiating documentation if

relevant.
c) Cumulative summaries of excavation and concrete quantities and lengths of

pipeline laid and tested.
d) Records of materials, equipment and plant tested with copies of test results where
relevant.
e) Charts illustrating progress achieved compared to the Contract Programme in an

A4 or A3 format to be agreed with the Engineer.
f) Charts illustrating the financial status of the Contract including value of works
completed, certified and monies received in an A4 or A3 format to be agreed with
the Engineer.
g) Copies of site instructions and variations issued by the Engineer.
h) Progress Photographs as detailed below.

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Dubai Municipality
i) A detailed programme of work to be carried out in the following month in chart

form to an A3 or A4 format to be agreed with the Engineer and a general
summary of work for the coming three months.
j) Copies of the agreed weekly labour and plant returns.
k) Coloured progress photographs to be taken, illustrating progress and work

completed on each section of the Works. Photographs shall be taken under the
direction of the Engineer by a professional or other approved photographer and
shall be automatically stamped with the date on which the photographs are taken.
Seven prints of each photograph, at least 150 mm by 100 mm, shall be submitted.
Six prints of each photograph shall be separately mounted, with typewritten titles, on
headed sheets in an A4 format to be agreed with the Engineer.
1.5.4.4 Monthly Reports
The Contractor will supply three sets of finalised and approved record drawings to the
Engineer upon completion of the works in the latest Microsoft format on CD. The
record drawings will use the DLTM coordinate system unless otherwise specified by
the Engineer.
1.5.5 As-built Records
a) Complete and As-Built Record Drawings will be prepared by the Engineer for
submission to the Employer.
b) The Contractor shall assist the Engineer to ensure that information regarding as-
built structures, pipelines and the final materials testing report in accordance with
Dubai Municipality Central Laboratory requirements is presented in a concise and
clear manner. For this purpose, the Contractor shall supply marked up dye-line
prints of the Contract drawings.
c) The Contractor will supply three sets of finalised and approved record upon
completion of the works in the latest Micro station format on CD. The record
drawings will use the DLTM coordinate system unless otherwise specified by the
Engineer.
1.5.6 Contract Correspondence
Unless the Contractor wishes to correspond directly with the Engineer on specific
subjects all correspondence will be addressed to the Engineer's Representative and
be submitted in duplicate.
1.5.7 Corrosion Control

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Dubai Municipality
a) The Contractor shall be deemed to have apprised himself of the particular

problems of corrosion of materials in Dubai by study of this Specification and
visiting the site. The sea water contains high amount of salinity and chlorides.
b) Attention is drawn to the corrosive nature of hydrogen sulphide gas in the

presence of moisture on Cementitious and some metallic materials.
c) In addition windblown chlorides are present in the atmosphere and the

groundwater contains sulphates and chlorides.
d) All materials must be appropriate to withstand the corrosive effects of their

environments.
1.5.8 Provision and Final Removal of Temporary Site Roads
Suitable subkha roads will be provided by the Contractor to allow access to all
sections of the works at all times. Suitable precautions will be taken to prevent
misuse of site roads by the general public. The Contractor shall be responsible for
reinstating these areas to their original condition after completion of the work.
1.5.9 Use of Highway
a) The Contractor shall give 4 weeks’ notice in writing to the Engineer of his intention
to commence work on a public highway.
b) The closure of public highways will not be permitted without the written
permission of the Dubai Municipality, Road Transport Authority, the Dubai Traffic
Police and the Engineer. The Contractor shall submit 5 no. copies of his
proposals for diverting traffic, indicating positions of all signs, cones, lights and
anything else which may be necessary. The Contractor shall comply with any
specifications for traffic diversion, including surfacing requirements, safety and
control laid down by the Authorities in Dubai and shall be responsible for
continuous maintenance.
c) Where a temporary diversion of the public highway is approved which will be

utilised by public traffic then the route shall have an asphalt surface. A subkha
only track will not be acceptable.
d) No work will be permitted on a public highway verge, central reservation or

garden without the SIGNED approval of the respective Authorities copies of which
must be handed to the Engineer before work commences.
e) The Contractor's work shall be so arranged that use of the highways affected by
the Works shall be restored to the public with the minimum of delay. Laying of the
pipelines, backfilling, testing of the pipelines, temporary reinstatement and
clearance of the Site shall follow closely behind excavation and, unless written

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Dubai Municipality
permission is obtained, the Contractor shall not occupy more than a 100 meters
length of highway at any one location at any time.
f) The work shall be carried out in such a manner as to cause minimum interference
with the public use of highways, footpaths and other thoroughfares, and only such
plant, materials, tools, etc., as shall from time to time be required for immediate
use shall be deposited thereon. Storage depots, offices, etc., shall be sited
elsewhere.
g) The Contractor shall comply in all respects with current Local Orders issued by
regulatory authorities with respect to excavation and reinstatement in public roads
corridors.
h) The Contractor shall maintain a clean, safe and adequate passageway for
pedestrians along highways and to each adjoining property. Unless he shall
obtain the written consent of the Statutory Authority to close the road, he shall
also maintain a satisfactory passageway for vehicular traffic.
i) The Contractor shall maintain those parts of the highway, etc., not temporarily
occupied by the Works in a clean, passable and safe state.
1.5.10 Access to Private Land
The Contractor shall give 3 weeks’ notice to the owner / occupier before entering
private land.
1.5.11 Return of Materials to Store
If acceptable to Dubai Municipality and with their prior approval, any materials ordered
and intended for incorporation in the permanent works such as pipes and fittings, DI
covers etc., which are certified by the Engineer to be in excess of requirements at the
end of the contract, due to design changes or the cancellation of works subsequent to
the placing of the order, payment for materials returned to the Dubai Municipality
Stores will be made at the values shown on manufacturers’ quotations current at the
time of Tender as obtained by the Contractor at the time of Tender plus an
appropriate percentage addition and no additional payment will be made for the cost
fluctuations.
The Contractor is responsible for transporting and stacking these materials to the
Storekeeper's satisfaction. The associated transportation and stacking charges will be
paid for at the rates determined under the Contract.
The inventory of returned surplus materials shall clearly indicate the source from
which the Contractor originally purchased / collected the materials together with the
purchase price.

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Dubai Municipality
1.5.12 Flows in Pipelines and at Pumping Stations
The Contractor must also maintain normal flow conditions in any other existing
irrigation pipelines affected by the construction of the pipe line. Any diversion works,
under-pressure tapping, over pumping or temporary pipelines required to comply with
this requirement are deemed to be included in the Contractor’s rates for the
completion of the connection of the works.
No claim for delay, damage or additional work arising from this requirement will be
considered by the Employer.
During the execution of the Works the Contractor shall maintain flows in pipelines and
at pumping stations or alternatively provide adequate means of diverting the flows or
over pumping of the flows to the satisfaction of the Engineer.
The Contractor should note that the Employer may decide to carry out over pumping
utilising his own plant and resources and the Contractor shall make due allowance for
the necessary coordination with the Employer with respect to the Contract
programme. Such arrangements will not relieve the Contractor of his obligations for
the maintenance of flows and the safety of the Works, personnel and the general
public.
No claim for delay or additional work arising from this requirement will be considered
by the Employer.
1.5.13 Issue of Taking - Over Certificate
Notwithstanding the requirements of Clause 48 of "Conditions of Contract for of Civil

Engineering Construction, (Part 1 - General Conditions)" it shall be the responsibility
to obtain all required "No Objection Certificates (NOC) from the relevant Authorities
and submit them to the Engineer prior to the Engineering issuing a Taking Over
Certificate.
The Contractor shall note that it is a Dubai Municipality requirement that No Objection
Certificates must be obtained from all Service Authorities in compliance with Dubai
Municipality Administrative Order No. 123/98 regarding satisfactory completion of the
Works. Dubai Municipality will not approve the issue of the Taking Over Certificates
by the Engineer until all such certificates have been obtained.

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Dubai Municipality
In connection with the obtaining of final No Objection Certificates, the current

Standard Procedure for obtaining Dubai Municipality No Objection Certificate for
project completion (Taking-Over) is applicable. The Contractor must ensure that the
latest requirements of Dubai Municipality are compiled with prior to making the
application for final.
No Objection Certificate to Roads Department ( RTA). The Contractor's attention is

drawn for Technical circular 28/94 for Final Material Test Report and Technical
Circular No. 5/2001 for NOC from General Maintenance Department. The Contractor
is obliged to comply with various local orders, circulars, letters issued from time to
time for the purpose of Taking Over Certificate.
The Contractor's attention is also directed regarding the provision of Approved

Operation and Maintenance Instruction Books prior to issue of the Taking Over
Certificate.
1.6 VENDOR LIST FOR CIVIL ITEMS

Tenderer to select the civil items from the list of recommended vendor list given in
Table 1 below and they shall select only one manufacturer or supplier from the list
below and mention in the tender proposal.
It is Tenderer’s responsibility to ensure that the offered make / supplier fully comply
with the tender specifications & functional aspects, delivery, construction requirement
as required by specifications, drawings.
Tenderer may propose for any civil item(s) where vendor name are not specified or
not included in the recommended vendor list in the table below. Such proposal will
be subject to Engineer clarifications during tender clarifications and tender evaluation.
All the necessary information required by Engineer will be requested and it shall be
submitted by Tenderer immediately to the Engineer for tender assessment.
Table 1 Vendor List
Sr. Item Manufacturer Supplier
1 Readymix Concrete M/s. Conmix Ltd.Sharjah - M/s. Conmix Ltd.Sharjah

U.A.E / M/s. Emirates - U.A.E / M/s. Emirates
Beton Readymix L.L.C.Dubai Beton Readymix
- U.A.E / M/s. Technical L.L.C.Dubai - U.A.E /
Readymix Concrete Co. M/s. Technical Readymix
L.L.C.,Dubai - U.A.E / Concrete Co.
Austrian Arabian Ready Mix L.L.C.,Dubai - U.A.E /
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Dubai Municipality
Concrete LLC, Dubai-UAE / Austrian Arabian Ready

Unibeton Ready Mix LLC Mix Concrete LLC,
,Dubai- UAE Dubai-UAE / Unibeton
Ready Mix LLC ,Dubai-
UAE
2 Manholes Cover M/s. Veralco, Cyprus / M/s. M/s. Mac Al Gurg,Dubai,

and Frames Ducast Factroy L.L.C,Dubai - U.A.E / M/s. Ducast
U.A.E / M/s. Carnation Factroy L.L.C,Dubai -
Industries Ltd.,West Bangal U.A.E / M/s. Dutco
– India / M/s. Plasma Alloys Tennant LLC, Dubai -
Pvt. Ltd, Gujarat – India / U.A.E / Ducast Factory,
M/s. Majid Bukatara Building Dubai- UAE
Materials Trading LLC,
Dubai - U.A.E / Elkington
Gatic-UK / Ducast Factory,
Dubai- UAE
3 Double Triangular Ducast Factory, Dubai- UAE Ducast Factory, Dubai-

DI cover & frame UAE
4 GRP Sealing Plate M/s. Mechanical Engineering M/s. Mac Al Gurg,Dubai,

Services Est.,Dubai - U.A.E / U.A.E / Mechanical
Scott Bader, Dubai-UAE Engineering Services
Est.,Dubai - U.A.E
5 GRP Manhole Liner Gulf Eternit Ind Co. Ltd, Gulf Eternit Ind Co. Ltd,
Dubai-UAE / Dubai Pipes Dubai-UAE / Dubai Pipes
Factory, Dubai-UAE Factory, Dubai-UAE
6 GRP In-situ Al Nahar Fibre Glass Al Nahar Fibre Glass

lamination, GRP- Products LLC, Dubai-UAE / Products LLC, Dubai-
Performed M/s. Dubai Pipes Factory UAE / M/s. Dubai Pipes
Benching, GRP-Flat Co. L.L.C, Dubai - U.A.E / Factory Co. L.L.C,Dubai
Sheet, GRP M/s.Extraco Sharjah, U.A.E / - U.A.E / M/s.Extraco
Circular sheet Notredame Fibre Glass & Sharjah, U.A.E /
Ind. Marble Est., Sharjah – Notredame Fibre Glass &
UAE / Arabtec Engg. Ind. Marble Est., Sharjah
Services (GRP section) LLC, – UAE / Arabtec Engg.
Dubai-UAE / Union Fibre Services (GRP section)
Glass Factory LLC, Dubai- LLC, Dubai-UAE / Union

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Dubai Municipality
UAE Fibre Glass Factory LLC,

Dubai- UAE
7 Epoxy coating for M/s. Hempel Paints M/s. Mechanical

Manhole Cover & (Emirates) , Sharjah-UAE Engineering Services
frame Est.,Dubai - U.A.E
8 Detectable Warning M/s. Kangaroo Plastics M/s. Dutco Tennant LLC,

Tapes Middle East LLC, Dubai - Dubai - U.A.E / M/s. Al
U.A.E / M/s. Al Samir Plastic Samir Plastic Factory
Factory (L.L.C),Sharjah - (L.L.C),Sharjah - U.A.E
U.A.E
9 Reinforcement M/s. Emirates Steel, Abu M/s. Ghantoot Building

Steel (Epoxy Dhabi - U.A.E / Cicon Epoxy Materials Trading L.L.C,
Coated) & steel cutting Plant LLC, Dubai - U.A.E /Cicon
Abu Dhabi- UAE / Habas Epoxy & steel cutting
Fuatpsa Sokak No. 26 Plant LLC, Abu Dhabi-
34880 Soganlik / Istanbul- UAE / RAK Middle East
Turkey Traders LLC, RAK-UAE /
Al Jaber Protective
Coating LLC, Abu Dhabi-
UAE
10 Polyethylene sheets M/s Dubai Plastic Factory M/s Dubai Plastic

LLC, Ajman- UAE Factory LLC, Ajman-
UAE
11 Geotextile Filter M/s. Terram Limited, U.K. / M/s. Geco Chemical Co.
Membrane M/s. Dupont, Luxembourg / Ltd., Sharjah - U.A.E /
Dupon DE Nemours M/s.Chabros nternational
International Luxembourg Group FZCO, Dubai -
U.A.E / Cloisall Co LLC
Dubai-UAE
12 Independent M/s. Geoscience Testing

Testing Laboratory , Laboratory,Dubai - U.A.E
Geotechnical / M/s. Material Lab,
Investigation Dubai - U.A.E / M/s Arab
Centre for Engineering
Studies, Dubai-UAE

2016

Dubai Municipality
13 Concrete Repair M/s. Corrotech Construction M/s. Corrotech

Mortar Chemicals,Dubai - U.A.E Construction Chemicals,
Dubai - U.A.E
14 Pipe Bedding and M/s. Al Amara Crushers, M/s. Flagstone

Surround Hattah, Dubai / M/s. Emaar L.L.C,Dubai - U.A.E /
Mahdha Company M/s. Alma Mechanical
Crusher,Oman / Wadi Al Cont., Sharjah - U.A.E /
Rawda / Emmar Mahdha Co. Dubai Al Ahlia Transport
Crusher-Oman Est., Dubai-UAE / Al
Akhilaa General Trading
LLC, Dubai - UAE
15 Annulus Grout M/s. Emirates Beton M/s. Emirates Beton

Readymix L.L.C, Dubai - Readymix L.L.C, Dubai -
U.A.E / Austrian Arabian U.A.E / Austrian Arabian
Ready Mix Concrete LLC, Ready Mix Concrete
Dubai-UAE LLC, Dubai-UAE
16 Aggregate Road M/s. Al Amara Crushers, M/s. Flagstone L.L.C,

Base Hattah, Dubai / M/s. Ajman Dubai - U.A.E / M/s.
Land Crusher,Ajman - U.A.E Flagstone L.L.C, Dubai -
/ Golden Swan Crusher & U.A.E / Dubai Al Ahlia
Transport LLC, Dubai- UAE Quick Transport LLC,
Dubai-UAE
17 Water Proofing M/s. Henkel Polybit M/s. Henkel Polybit

Membrane Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E / Duproof Trading (L.L.C), Dubai -
LLC, Dubai-UAE / Alyaf U.A.E / SAG Roofing,
Industrial co. Ltd., KSA Dubai- UAE
18 Controlled M/s Fibretex A/S, Specilised Industries

Permeability Svendborgvej 2, Box 8029, LLC, Dubai- UAE
Formwork (CPF) DK-9220 Aalborg, Denmark
Liner
19 PVC Water Stop M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E / M/s. Trading (L.L.C), Dubai -
Corrotech Construction U.A.E / M/s. Corrotech

2016

Dubai Municipality
Chemicals, Dubai - U.A.E / Construction

Greenstreak, 3400 Tree Chemicals,Dubai - U.A.E
Court Industrial Boulevard / Peninsula Int’l General
St. Louse, Missouri Trading LLC, Dubai-
UAE
20 Hydrophilic Polymer M/s. Henkel Polybit M/s. Henkel Polybit

Based Water Stop Industries Ltd., Umm Al Industries Ltd., Umm Al
Quwain - U.A.E / M/s. Quwain - U.A.E / M/s.
Corrotech Construction Corrotech Construction
Chemicals,Dubai - U.A.E Chemicals,Dubai - U.A.E
21 Epoxy Coating M/s. Corrotech Construction M/s.Corrotech

Chemicals,Dubai - U.A.E / Construction
M/s. Henkel Polybit Chemicals,Dubai - U.A.E
Industries Ltd., Umm Al / M/s. Henkel Polybit
Quwain - U.A.E Industries Ltd., Umm Al
Quwain - U.A.E
22 Ductile Iron M/s. ACO, Australia M/s. Al Mostaqbal

Concrete Infill Type Building Materials
Covers & Frames Trading L.L.C,Dubai -
U.A.E
23 Joint Sealant M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E Trading (L.L.C), Dubai -
U.A.E
24 Concrete Curing M/s. Henkel Polybit M/s. Henkel Polybit

Compound Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Quwain - U.A.E Quwain - U.A.E
25 Interlocking Tiles, M/s. Phoenix Concrete Block M/s. Phoenix Concrete

Kerbs & Concrete Factory L.L.C,Dubai - U.A.E Block Factory L.L.C,
Blocks / National Tiles & Block Co. Dubai - U.A.E / National
Ltd , RAK Tiles & Block Co. Ltd ,
RAK
26 Safety Chain, M/s. Dutco Tennant LLC, M/s. Dutco Tennant LLC,
Eyebolt and D- Dubai - U.A.E Dubai - U.A.E

2016

Dubai Municipality
Shackle
27 SS Grab Bar ( Hand M/s. Dutco Tennant LLC, M/s. Dutco Tennant LLC,
Hold) Dubai - U.A.E Dubai - U.A.E
28 SS Material Standard Fabrication & Engg Standard Fabrication &

(Platform, ladder, Works, Dubai-UAE Engg Works, Dubai-UAE
safety cage,
handrail, spindle,
support bracket
etc.)
29 Neoprene Rubber International Rubber Corrotech Construction

Sheet Company, Dubai UAE Chemicals, Dubai-UAE
30 Polycrete M/s. Henkel Polybit M/s. Henkel Polybit

(Cementitious Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Repair mortar Quwain - U.A.E Quwain - U.A.E
/Cementitious
fairing coat)
31 Hydroseal P M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Quwain - U.A.E Quwain - U.A.E
32 Polycoat M/s. Henkel Polybit M/s. Henkel Polybit

Rubberized Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Bitumen Emulsion Quwain - U.A.E Quwain - U.A.E
33 Polygrout Non M/s. Henkel Polybit M/s. Henkel Polybit

Shrink Free Flow Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Cementitious Grout Quwain - U.A.E Quwain - U.A.E
34 Polyprime solvent M/s. Henkel Polybit M/s. Henkel Polybit

based bitumen Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Primer Quwain - U.A.E Quwain - U.A.E
35 Polyquick ( Quick M/s. Henkel Polybit M/s. Henkel Polybit

Setting Repair Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Mortar) Quwain - U.A.E Quwain - U.A.E

2016

Dubai Municipality
36 Renderoc for Al Gurg Fosroc LLC, Dubai- Al Gurg Fosroc LLC,

concrete repairing UAE Dubai-UAE
37 Damp Proof Course Ruberoid Building Emirates Specialities Co.

Products,UK LLC, Dubai- UAE
38 Epoxy resin patch Al Gurg Fosroc LLC, Dubai- Al Gurg Fosroc LLC,
mortar for use in UAE Dubai-UAE
damaged concrete
joint edges
39 Mortar for sealing BASF Construction chemical BASF Construction

crack LLC, Dubai-UAE chemical LLC, Dubai-
UAE
40 GRP Vent Cowl Gulf Pipe Industries LLC, Gulf Pipe Industries LLC,
Dubai-UAE Dubai-UAE
41 GRP Grated Covers Union Fibre Glass Factory Union Fibre Glass
with Chequered LLC, Dubai- UAE Factory LLC, Dubai- UAE
Finish
42 Hollow Blocks Phoenix Concrete Products, Phoenix Concrete

Dubai-UAE Products, Dubai-UAE
43 Concrete Tiles for Terrazzo Dubai Co. LLC, Terrazzo Dubai Co. LLC,
roofing Dubai- UAE Dubai- UAE
44 Block work and Ancon Wall Ties, UK / Emirates Specialities Co.

Plaster Accessories Expamet, UK / Xpa wall LLC, Dubai-UAE
Ties, UAE
45 Premixed Mortars SODAMCO Holding Tyar SODAMCO Holding Tyar

and Plasters ( Center, Abu Dhabi-UAE Center, Abu Dhabi-UAE
Premix SRC-2,
SRC-S & SP-1)
46 Aluminium Windows M/s Al Ghurair / Gulf Blossom Aluminium &

Extrosions Co. / GGI (UAE) Glass Ind. LLC, Ajman-
/Domus Greece, Ajman-UAE UAE

2016

Dubai Municipality
47 Fire Rated Roller Duodex Engg & trading Bin Dasmal Doors Est.,
Shutter SDN.BHD, Malaysia Dubai-UAE
48 External paint Caparol Farben Lacke Caparol LLC, Dubai-

Bautenschutz GmbH, UAE.
Germany
49 Steel Doors ( Fire Qatar Metal Const. Ind. LLC, Qatar Metal Const. Ind.
rated) Sharjah-UAE LLC, Sharjah-UAE
50 Aluminium Gates Link Middle East Ltd., Dubai- Link Middle East Ltd.,
UAE Dubai- UAE
51 Chain Link fence Link Middle East Ltd., Dubai- Link Middle East Ltd.,
UAE Dubai- UAE
52 Asphaltic Concrete Al Futtaim Tarmac Nablus Road Contracting

Wearing Course LLC, Dubai-UAE

2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 2
SITE CLEARANCE AND EARTHWORKS
DM/SRPD Section 2 Site Clearance and Earthworks Rev 00 June
2016

Dubai Municipality
DM/SRPD Section 2 Site Clearance and Earthworks Rev 00 June Page i of iv

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Dubai Municipality
SECTION 2
SITE CLEARANCE AND EARTHWORKS
CONTENTS
2 SITE CLEARANCE AND EARTHWORKS ........................................................................ 1
2.1 SITE CLEARANCE – DESCRIPTION................................................................................ 1

2.2 SURVEY BEFORE COMMENCEMENT ............................................................................ 1
2.3 DEMOLITION REQUIREMENTS ....................................................................................... 1
2.4 GENERAL SITE CLEARANCE.......................................................................................... 2
2.5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS ............... 2
2.6 ROAD SIGNS ..................................................................................................................... 2
2.7 DISPOSAL OF MATERIAL ................................................................................................ 3
2.7.1 Disposal of Surplus Material ................................................................................. 3

2.7.2 Disposal of Historical Artifacts .............................................................................. 3
2.8 EARTHWORKS AND SITE PREPARATION ..................................................................... 3
2.8.1 General ................................................................................................................. 3

2.8.2 Earthwork .............................................................................................................. 4
2.8.3 Site Earthwork ...................................................................................................... 4
2.8.4 Levels to be recorded ........................................................................................... 6
2.8.5 Bracing and Shoring ............................................................................................. 6
2.8.6 Inspection by Engineer ......................................................................................... 7
2.8.7 Existing Services .................................................................................................. 7
2.8.8 Control of Water .................................................................................................... 7
2.8.9 Excess Excavation to be Made Good ................................................................. 11
2.8.10 Foundation Preparation ...................................................................................... 11
2.9 CLASSIFICATION OF EXCAVATION AND BACKFILL ................................................. 12
2.9.1 General Classification ......................................................................................... 12

2.9.2 Excavation Materials ........................................................................................... 12
2.9.3 Identification of Common and Rock Excavation ................................................. 12
2.10 EXCAVATION REQUIREMENTS .................................................................................... 13

2.11 BORROW PIT SITE WITHIN PROJECT WORK AREA .................................................. 15
2.12 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS
MATERIALS .............................................................................................................................. 15
2.12.1 Top Soil............................................................................................................... 15

2.12.2 Suitable Material ................................................................................................. 16
2.12.3 Unsuitable Material ............................................................................................. 16
2.12.4 Material for Improved Subgrade Layer ............................................................... 17
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Dubai Municipality
2.13 MAIN PLANT AND EQUIPMENT FOR EARTHWORKS CONSTRUCTION ................... 18
2.13.1 General ............................................................................................................... 18

2.13.2 Compacting Equipment ...................................................................................... 18
2.13.3 Hauling and Weighing Equipment ...................................................................... 20
2.14 EMBANKMENT CONSTRUCTION .................................................................................. 22
2.14.1 General ............................................................................................................... 22

2.14.2 Embankment Foundation and the Designated Filling Area ................................ 23
2.14.3 Suitability Testing on Materials ........................................................................... 25
2.15 PLACING AND COMPACTION REQUIREMENTS ......................................................... 25

2.16 MOISTURE CONTROL REQUIREMENTS ...................................................................... 26
2.17 STANDARD EARTH WORKS COMPACTION PROCEDURE ........................................ 27
2.17.1 General ............................................................................................................... 27

2.17.2 Compaction Tests ............................................................................................... 27
2.17.3 Testing ................................................................................................................ 27
2.18 MINIMUM TEST REQUIREMENTS ................................................................................. 27
2.18.1 Embankment and Filling Works .......................................................................... 27

2.18.2 Improved Subgrade ............................................................................................ 28
2.18.3 Rock Fill and Rock Soil Mixtures ........................................................................ 28
2.19 STABILISING CRUSHED MATERIAL............................................................................. 29

2.20 EXCAVATING AND FILLING FOR STRUCTURES ........................................................ 31
2.21 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS ......................................... 36
2.21.1 Activities prior to excavation starting .................................................................. 36

2.21.2 Setting out........................................................................................................... 36
2.21.3 Topsoil and Surfacing Materials ......................................................................... 36
2.21.4 Land Drains ........................................................................................................ 36
2.21.5 Hand Excavation ................................................................................................. 37
2.21.6 Support to Excavations ....................................................................................... 37
2.21.7 Dewatering .......................................................................................................... 38
2.21.8 Formation ............................................................................................................ 41
2.21.9 Excavation at or near roads ................................................................................ 41
2.21.10 Surface condition of excavated area .................................................................. 43
2.22 PIPELINE TRENCH AND THE RELATED STRUCTURES EXCAVATION .................... 44
2.22.1 Excavation for Pipelines ..................................................................................... 44

2.22.2 Excavation for Cables/Ducts ............................................................................... 44
2.22.3 Excavated Material for Pipe Trench .................................................................... 44
2.22.4 Replacement of Unsuitable Material ................................................................... 45
2.22.5 Disposal of Material ............................................................................................ 45
2.22.6 Cofferdams ......................................................................................................... 45
DM/SRPD Section 2 Site Clearance and Earthworks Rev 00 June Page iii of iv
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Dubai Municipality
2.22.7 Backfilling Pipe Trench Excavations and the Related Structures ....................... 46
2.22.8 Filter Material ...................................................................................................... 49
2.22.9 Backfilling of Trenches for Cables/Ducts ............................................................ 49
2.22.10 Reference Standards .......................................................................................... 50
2.23 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT ............................... 51
2.23.1 General ............................................................................................................... 51

2.23.2 Reinstatement of Unpaved Land ........................................................................ 51
2.23.3 Reinstatement within Road Corridors ................................................................. 52
2.23.4 Reinstatement of Other Surfaced Areas ............................................................. 52
2.23.5 Excavation and Reinstatement in Developed Reservations ............................... 53
2.24 PROTECTION TO EMBANKMENT SLOPE .................................................................... 53

2.25 CEMENT-STABILISED AGGREGATE CAPPING LAYER ............................................. 53
2.26 BACKFILLING AROUND STRUCTURES ....................................................................... 53
2.26.1 Definition ............................................................................................................. 53

2.26.2 Backfill ................................................................................................................ 53
2.26.3 Backfill Materials ................................................................................................. 53
2.26.4 Control of Water .................................................................................................. 54
2.26.5 Inspection by Engineer ....................................................................................... 54
2.26.6 Backfilling - Placement ....................................................................................... 54
2.26.7 Backfilling - Compaction ..................................................................................... 54
DM/SRPD Section 2 Site Clearance and Earthworks Rev 00 June Page iv of iv

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Dubai Municipality
2 SITE CLEARANCE AND EARTHWORKS

2.1 SITE CLEARANCE – DESCRIPTION
This work shall consist of the removal, wholly or in part, and satisfactory disposal of
all fences, structures, abandoned pipelines, contaminated soil, logs, hedges, shrubs,
brush, grass, weeds, other vegetation, stumps of diameter less than 150 mm
including wet or dried sludge, concrete slabs and any other obstruction which are not
designated or permitted to remain. It shall also include the salvaging of designated
materials and backfilling the resulting trenches, holes and pits.
Clearing shall be performed wherever necessary in preparation of the performance of

works such as excavation, fill or embankment or any other construction where shown
on the plans as specified or directed by the Engineer.
Grubbing shall follow the operation of clearing where ordered by the Engineer or as
shown on the plans and shall consist of removing all stumps, roots and objects of
similar nature. Grubbing shall be carried out in such a manner that roots and stumps
will not grow again or otherwise cause any damage.
2.2 SURVEY BEFORE COMMENCEMENT
Prior to starting the site clearance, the Contractor shall carry out a thorough survey of
structures, fences, trees, etc. that are to be removed. The Engineer shall be fully
informed of the results of this survey and the amount and extent of the demolition and
site clearance shall then be agreed with the Engineer.
2.3 DEMOLITION REQUIREMENTS
a) The Contractor shall in a careful manner, raze, remove and dispose of all
foundation structures, fences and other obstructions or any portions of which are
within the right-of-way, except utilities and those for which other provisions have
been made for removal. All designated salvageable material shall be removed,
without unnecessary damage, in sections or pieces which may be readily
transported, and shall be stored by the Contractor at specified places within the
project limits or at designated storage areas as directed by the Engineer. All such
salvageable material shall be deemed the property of the Employer.
b) Where directed by the Engineer, the Contractor shall excavate in trench and
break out redundant pipe ducts and surrounds. Where pipes are to be removed
and either salvaged or re-laid they shall be carefully removed and every
precaution taken to avoid breaking or damaging the pipe. The pipes shall be
stored when necessary so that there will be no loss or damage before relaying.
The Contractor will be required to replace sections lost from storage or damage
by negligence or by the use of improper methods in their removal.
DM/SRPD Section 2 Site Clearance and Earthworks Rev 00 June Page 1 of 54

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Dubai Municipality
c) Trenches and pits resulting from demolition and site clearance below ground level
shall be properly cleaned out (including pumping) and filled with suitable material
and compacted in accordance with the relevant Specifications up to sub-grade
level or as otherwise directed by the Engineer.
d) Where required, the Contractor shall be responsible, prior to demolition, for the
disconnection of all services and clearance from the Dubai Municipality and all
other Service Authorities.
2.4 GENERAL SITE CLEARANCE
a) Before commencing any excavation or fill, the area shall be cleared of all trees,
stumps, roots, bushes, vegetation, debris, materials or other obstructions.
b) Before removal of any trees or shrubs the Contractor shall obtain written consent
from Dubai Municipality Horticultural Section at least two weeks in advance of the
planned removal.
c) The Engineer's approval of any removal of trees and undergrowth must be

obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of in tips
off site (Sub section 2/7). Holes left by stumps or roots shall, within one week, be
filled with suitable material, and compacted to the Engineer's satisfaction in
accordance with Specification Clause 2/17.
2.5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS
a) Attention is directed to the Contractor's obligations under law and under this
Contract with regard to damage, particularly with regard to protection of property,
plants and landscape and to responsibility for damage claims.
b) Existing highways, improvements, facilities, adjacent property, services, and trees

and plants designated for preservation shall be protected from injury or damage
which could result from the Contractor's operations.
c) The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.
2.6 ROAD SIGNS
a) All existing road signs, street name plates and the like affected by the works are
to be carefully taken down and stored.
b) Signs to be re-erected shall be cleaned, provided with new fixings where

necessary and the posts re painted in accordance with the Specifications.
c) Redundant signs shall be transported to the stores or depots of relevant

Authorities.

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Dubai Municipality
d) Any sign, street name plate or the like damaged by the Contractor during his
operation shall be repaired or replaced at the Contractor's cost.
2.7 DISPOSAL OF MATERIAL
2.7.1 Disposal of Surplus Material
All materials arising from site clearance which are surplus to or unsuitable (as defined
in Section 2/12) for use in the Works shall become the property of the Contractor and
shall be disposed of by him either off the Site to an approved tip (Al Warqaa, Al
Bayadia / Al Lussaily on Al Ain road etc.) or if directed or otherwise agreed by the
Engineer on the Site in an approved manner.
2.7.2 Disposal of Historical Artifacts
a) Where specified, certain materials arising from the site clearance and excavation
shall remain the property of the Employer.
b) All fossils, antiquities and other objects of interest or value which may be found or
uncovered on the site shall remain or become the property of the Employer and
upon discovery of such an object the Contractor shall forthwith:
c) Use his best endeavours not to disturb or damage the object;
d) Cease work which would endanger the object or prevent or impede its removal;
e) Inform the Engineer of the discovery and precise location of the object;
f) The Engineer will issue instructions on the procedure to be adopted which may
include conditions to permit the examination, excavation or removal of the object
by a third party.
2.8 EARTHWORKS AND SITE PREPARATION
2.8.1 General
a) Principal work in this Section includes general requirements for earth including
site preparation.
b) The entire area within the limits of earthwork as indicated shall be constructed to
the lines, grades, elevations, slopes, and cross sections indicated on the
Drawings with added allowance for the thickness of any pavement, blinding
concrete, lining and riprap if required.
c) Slopes shall present a neat uniform appearance upon completion of the work and
shall be approved by the Engineer.
d) Excavated materials meeting the requirement of fill materials shall be conserved

for subsequent use or placed as earth fill immediately after excavation upon
approval of the Engineer. If not immediately re-used, excavated materials shall

2016

Dubai Municipality
be stockpiled within or adjacent to the project work area approved by the

Engineer.
e) Suitability of all excavation materials for specific purposes shall be determined by

the Engineer.
f) Contractor shall not waste or otherwise dispose of suitable excavated materials.

All excavation shall be performed under the limitations and requirements set out
in the sections of this specification pertaining to control of water.
2.8.2 Earthwork
a) Earthwork shall include all site preparation to the lines and grades indicated on
the drawings including, but not limited to the following:
(i) Excavation of all materials of whatever nature encountered
(ii) Handling, hauling and compaction of required fill materials
(iii) Disposal of all excess excavated material
(iv) Shoring and protection work
(v) Preparation of subgrade
(vi) Dewatering as necessary
(vii) Protection of adjacent property
(viii) Backfill
(ix) Surface reinstatement
(x) Forming embankment
(xi) Construction temporary cofferdam / bund for construction works.
2.8.3 Site Earthwork
2.8.3.1 Borehole Data
Borehole data is provided in the Volume-5 of tender document.
a) This data is for information only and without any warranty as to the correctness of
the information contained therein.
b) Availability of this data to the Contractor does not relieve him of his:
(i) Obligation to thoroughly investigate for himself the nature of the site and the
sub-soil conditions therein;

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Dubai Municipality
(ii) Obligations and responsibilities under the terms and conditions of the
Contract.
2.8.3.2 Contractor’s Responsibilities
a) The Contractor shall be deemed to have visited the site prior to submitting his
tender and made all necessary inspections and investigations and allowed for the
following in his tender:
(i) Means of access and working space
(ii) Nature of the ground and sub-soils
(iii) Presence of existing foundations or other hidden obstructions
(iv) Level of the water table
(v) Extent of rock
(vi) Support to neighbouring properties and structures
(vii) All factors affecting the work
b) Any information made available to the Contractor, either in these documents or by

any other source, will not relieve the Contractor of his responsibility to decide for
himself the nature and extent of the work nor will it guarantee that similar
conditions will apply on other parts of the site.
c) The Contractor shall be deemed to have contacted the relevant statutory bodies
to establish the existence of any existing, live or redundant services adjacent to or
passing through the works and shall be deemed to have allowed in his tender for
their location, diversion, demolition or removal.
d) Boring logs and related information depict subsurface conditions only at the
specific locations and at the particular time designated on the logs.
(i) Soil conditions at other locations may differ from conditions occurring at the
boring locations.
(ii) Passage of time may result in a change of the sub-surface conditions or

water levels at the boring locations.
(iii) Employer does not guarantee any statements, opinions, or conclusions

contained in the report.
(iv) Contractor shall assume all responsibility for:
 Deductions and conclusions made by him regarding the nature of the

materials to be excavated.
 Difficulties involved
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Dubai Municipality
 Dewatering
 Maintaining the required excavations
 Carrying out the work affected by the subsurface conditions at the site of
the works.
 Carrying out his own investigation to satisfy himself the validity of the
above data.
e) Neither the Employer not the Engineer shall be liable for any loss sustained,
indicated by or deducted from said borings, samples, tests, and / or reports, and
the actual conditions encountered during progress of the work.
2.8.4 Levels to be recorded
a) Bench marks and setting out baselines are to be agreed with Engineer.
b) Before the surface of any part of the site is disturbed or the works thereon are
begun, the Contractor shall take and record levels on 10m grids of such part, in
the manner specified or as agreed with the Engineer.
c) Two (2) working days’ notice is to be given to the Engineer so that the recording
of levels can be performed in the presence of the Engineer.
2.8.5 Bracing and Shoring
a) Excavated surfaces shall be supported as necessary to safeguard:
(i) Work and workmen
(ii) To prevent sliding or settling of the adjacent ground
(iii) To avoid interruptions in existing services
(iv) Damage to existing improvements and utilities infrastructure
b) Width of the excavation shall be increased if necessary to provide for sheeting,

bracing, shoring, and other supporting installations.
c) Contractor shall also obtain the permission of the relevant authorities for the
surface width of the excavation required.
d) Contractor shall furnish, place and subsequently remove such supporting

installations unless ordered otherwise by the Engineer.
e) Contractor shall furnish before commencement of excavation for any structure,

three copies of drawings showing details of the bracing he proposes to use,
together with all relevant calculations, demonstrating the sufficiency of the
proposals.

2016

Dubai Municipality
f) No excavation work shall commence until the Engineer’s consent has been
obtained. Such consent shall in no way relieve the Contractor from any of his
contractual obligations and responsibilities.
2.8.6 Inspection by Engineer
a) When the specified levels of trench or structure excavation are reached, the
Engineer shall inspect the ground exposed.
b) If he considers that any part of the ground is by its nature unsuitable, he may
direct the Contractor to excavate further and to refill the further excavation with
such materials as he may direct.
c) If the bottom of any trench or structure excavation, while acceptable to the

Engineer at the time of his inspection, may subsequently become unacceptable
due to exposure to weather conditions, equipment traffic, due to flooding or
become puddled, soft or loose during the progress of the works, the Contractor
shall remove such damaged, softened or loosened material and excavated further
by hand.
d) In this case the cost of the extra excavation and of the additional foundation
materials required will be the Contractor’s responsibility if necessitated by his
negligence.
2.8.7 Existing Services
a) The Contractor shall check with the relevant authorities to determine what existing
underground services are present in the site area and locate and effectively seal
off drain ends.
b) When necessary, the Contractor shall divert services still in use and provide all
temporary works necessary to maintain such services in full functional order. He
shall also reinstate such services to the approval of the relevant authorities at the
earliest opportunity in compliance to the regulations and obtain necessary permits
and NOCs.
c) Bench marks and other permanent structures in the site area are protected from
damage or displacement.
2.8.8 Control of Water
2.8.8.1 General
a) The Contractor shall furnish, install and operate all necessary machinery,
appliances, and equipment to keep excavations free from water during
construction and shall remove all water so as not to cause damage to private
property, or to cause a nuisance or menace to the public all as specified herein.

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b) Berms shall be provided to prevent surface water from draining into structural
excavations. Earth banks shall be suitably protected from damage by erosion
during construction. The Contractor shall ensure that at all times during
construction:
(i) No groundwater shall come into contact with any concrete surface or
reinforcement
(ii) Any structure shall be capable of withstanding any hydrostatic pressure to

which it may be subjected during construction and until completed.
2.8.8.2 Drainage Provisions
a) Drainage ditches, diversions, and temporary pipes shall be constructed as

required to maintain drainage of the work areas.
b) Shall be constructed with cross-sectional area and gradient at least equal to that
of the intercepted watercourses, as approved by the Engineer.
2.8.8.3 Dewatering
a) Contractor shall perform dewatering as required so that all work under the
Contract is installed on dry areas and excavations, including without limitation the
construction of all structures and underground piping.
b) Contractor shall ensure that dewatering is carried out only to a depth sufficient for
the required excavation.
2.8.8.4 Qualified Personnel
Contractor shall, where extensive dewatering is required:
a) Be fully qualified to perform the dewatering operations or
b) Shall furnish the services of an experienced, qualified and equipped dewatering

subcontractor to design and operate the dewatering and groundwater recharging
systems required for the work, all subject to the Engineer's approval.
2.8.8.5 Monitoring
a) Where required to do so by the Engineer, the Contractor shall establish a

specified number of groundwater level monitoring stations at each site which will
be observed during the work. These shall be located as directed by the Engineer
and consist of acceptable open tube piezometers.
b) Settlement gages shall be provided to the approval of and as designated by the

Engineer at each site, times and locations to monitor settlement of new and
existing facilities as directed.

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2.8.8.6 Submittal
a) Where deemed necessary by the Engineer, shop drawings and data shall be
submitted for record purposes only, but not for review or approval showing the
intended plan for dewatering and recharging operations.
b) Details of locations and capacities of dewatering wells, well points, pumps,

sumps, collection and discharge lines, standby units, water recharge system,
water disposal methods, monitoring and settlement measuring equipment, data
collection and dissemination shall be included. These shall be submitted not less
than 30 days before start of dewatering operations.
2.8.8.7 Operation
a) Contractor shall furnish, install and operate all necessary pumping, well-point
dewatering appliances and equipment to keep excavations free from water during
construction.
b) The Contractor shall dewater and dispose of water so as not to cause injury to the
public or private property or to cause a nuisance or a menace to the public.
c) Contractor shall at all times have on hand sufficient pumping equipment and
machinery in good working condition for all ordinary emergencies including power
outage.
d) Contractor shall have available at all times competent workmen for the operation
of the pumping equipment.
e) Excavations shall be kept free of water during:
(i) Excavation, construction of chambers, etc.
(ii) Installation of pipelines.
(iii) Placing of structural and trench backfill.
(iv) Placing and setting of concrete.
f) Contractor shall control surface runoff so as to prevent entry or collection of water

in excavations.
g) Static water level shall be drawn down a minimum of 300 mm below the bottom of
the excavation to:
(i) Maintain the undisturbed state of the foundation soils.
(ii) Allow the placement of any fill or backfill to the required density.
h) Dewatering system shall be installed and operated so that the groundwater level
outside the excavation is not reduced to the extent that would damage or
endanger adjacent structures or property.
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2.8.8.8 Maintenance of Existing Water Table Level
a) All required operations shall continuously maintain the level of the water table
outside the dewatered areas to prevent damage to structure, pipelines, etc.,
adjacent to the excavations.
b) A water injection recharging system shall be maintained to replenish the

groundwater supply as required to maintain the water table including pumps,
piping, well points, standby units, other required equipment and a source of water
sufficient to meet the recharge requirements should supply of water from
dewatering operations be interrupted or become inadequate.
2.8.8.9 Protection of Existing Facilities
a) Where any sloped excavation infringes on, or potentially endangers any existing
facilities or structures.
(i) Shoring, sheeting, and bracing shall be provided according to plans and
calculations made by a qualified Engineer.
(ii) A copy of such plans and calculations shall be given to the Engineer for
record purposes.
b) At his expense, the Contractor shall repair and make good:
(i) all damage or resettlement to foundations or other portion of any existing

facilities or structures
(ii) damage to existing works caused by permanent or temporary failure of

excavation protection, operation of the dewatering or recharging systems or
failure to maintain the existing groundwater level outside the dewatered
areas.
2.8.8.10 Disposal of Water
Water not injected back into the ground shall be disposed of lawfully without damage
to new and existing facilities or adjoining properties.
2.8.8.11 Removal
a) Release of groundwater to its static level shall be performed to:
(i) Maintain the undisturbed state of the natural foundation soils.
(ii) Prevent disturbance of compacted fill or backfill.
(iii) Prevent flotation or movement of structures, pipelines and sewers.
b) Equipment shall be removed when no longer required, but monitoring and

settlement measurement systems shall be maintained in operation until removal
is approved by the Engineer.
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c) To the extent approved by the Engineer, well points and such items may be
abandoned in place.
2.8.9 Excess Excavation to be Made Good
The Contractor at his own expense shall remove from the site all materials resulting
from excess excavations below that required for the foundation, lining or bedding and
shall make good the same with Grade 25 concrete or suitable fill materials as
instructed by the Engineer.
2.8.10 Foundation Preparation
2.8.10.1 General
a) Foundations for earth fill shall be stripped to remove all obstructions, vegetation,
debris, or other unsuitable materials.
b) Except as otherwise specified:
(i) Foundation surfaces shall be graded to remove surface irregularities
(ii) Shall be scarified and loosened to a minimum depth of 100 mm.
c) Moisture content shall be controlled as specified for engineered fill. Surface

materials of the foundation shall be compacted and bonded with the first layer of
earth fill as specified for subsequent layers of earth fill.
2.8.10.2 Rock Foundations
a) All rock foundation and abutment surfaces shall be cleared of all loose materials
by hand or other effective means and shall be free of standing water when fill is
placed.
b) Previous rock foundations shall be excavated to 150 mm below finished grade

shown on the drawings and a lining shall be placed as specified herein.
c) Fill placed immediately adjacent to such rock foundations or where not accessible
with large compaction equipment shall be compacted to the specified density by
means of hand tamping or manually directed power tampers or plate vibrators.
2.8.10.3 Benching
a) Where slope of existing soils to receive fill exceeds 1:4 horizontal benches shall
be cut to key the new fill material to the existing soils.
b) At least 600 mm of existing soil normal to the original slope shall be removed and
recompacted as the new fill is brought up in layers.

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2.9 CLASSIFICATION OF EXCAVATION AND BACKFILL
2.9.1 General Classification
Excavated material shall be classified as:
a) Road Excavation
b) Borrow excavation
c) Structural excavation
d) Trench excavation
2.9.2 Excavation Materials
a) Excavations include all materials of whatsoever nature, suitable or unsuitable,

excavated to the required profile within the project work site and excavated within
the limits of the Right of Way for the preparation up to the formation levels of each
structure.
b) All such materials after deduction for material declared unsuitable by the Engineer
shall be considered to be available for use at locations requiring fill.
c) All excavations shall be sub-classified as Common Excavation and Rock

Excavation.
2.9.3 Identification of Common and Rock Excavation
Authority to identify and define the physical characteristics which determine the
classification as "Common Excavation" and "Rock Excavation" in accordance with the
intent of the following provisions shall be vested by the Engineer.
2.9.3.1 Common Excavation
a) Shall consist of the excavation and satisfactory disposal of all soils, rock soil
mixtures of sand stone features and silty sand, certain strata and rock boulders
less than one (1) cubic metre in volume.
b) Strata which are altered and weathered and are in place, but which are not firm
enough, or in the opinion of the Engineer are not rigid enough to have all the
characteristics of rock excavation shall be classified as common excavation.
2.9.3.2 Rock Excavation
a) Shall consist of the excavation and satisfactory disposal of all unaltered and un-
weathered firm and rigid igneous, metamorphic and sedimentary solid rock that in
the opinion of the Engineer is impracticable to remove by heavy mechanical
excavating equipment (e.g. Cat.D8) or by heavy duty hydraulic ripper, or by
approved pneumatic tools.

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b) These types of rocks would normally be removed by blasting with explosives, or

by heavy duty hydraulic breakers or by drilling and broaching with wedges and
sledge hammers if removed by hand.
c) Also individual boulders or detached pieces of rock exceeding one cubic meter in
size in trenches or excavations necessitating blasting or breaking as above are
considered as rock.
d) Cemented granular materials requiring the use of pneumatic tools or rippers will
not be defined as rock.
2.9.3.3 Borrow Excavation
a) If the demand for fill material exceeds the quantity of suitable material obtained
from the project work structures, trench excavations and the roadway excavation
then suitable material shall be imported to the worksite from the approved borrow
pit within project work area.
b) The excavation, haulage and discharge of material in its final place from a borrow
pit shall be classified as Borrow Excavation.
2.10 EXCAVATION REQUIREMENTS
a) All materials removed from the area of structural excavation and borrow pit shall
be reused in the designated backfill area around the structures, trench backfill
and in the formation of the embankment, shoulders and at such other places as
directed, unless it is declared unsuitable and ordered to be sent to tip by the
Engineer. No excavated material shall be wasted without written permission from
the Engineer, and when such material is to be wasted, it shall be hauled to the
approved tip or as otherwise directed by the Engineer.
b) Material suitable for top soil, base material, mineral aggregate or other specified
purpose, encountered in excavation, shall be reserved, if so directed, until it can
be placed in its proper position in the roadway. When specified or designated,
top soil shall be used as cover on embankment slopes to aid the regrowth of
vegetation or other purposes.
c) Excavated materials wasted by the Contractor without written permission of the

Engineer shall be replaced by the Contractor at his own expense.
d) During the construction of the roadway, the prepared formation shall be

maintained in such condition that it will be well drained at all times.
e) Rock, shale and other unsuitable material encountered in cuts shall be excavated
to the lateral limits and depth indicated on the plans or as otherwise directed. Any
over breakage below the depth shown on the plans or as otherwise directed will
not be paid for. Backfill of the over breakage shall be approved suitable material
and shall have the same density requirements as specified by the Contract and
shall be at the expense of the Contractor. If the backfill of the over breakage area
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designated by the Engineer is to be a crushed aggregate concrete or other

special aggregate the entire cost of the backfill of the over breakage shall be at
the expense of the Contractor. Un-drained pockets shall not be left in the surface
of the rock, but they shall be treated as directed by the Engineer.
f) All slopes, except in solid rock or other material which, in the judgement of the
Engineer, require a modified slope, shall be trimmed accurately to the slopes
shown on the cross-section drawings, and care must be exercised that no
material shall be loosened beyond the required slopes. Side ditches if required
shall be excavated in conformity to line, grade, and cross-section as shown on the
Drawings or as directed by the Engineer.
g) In cut areas, excavation shall be for the full construction width down to
'earthworks formation level' as shown in the approved drawing. For a further
depth of 15 cm the existing material shall be scarified, watered as necessary,
mixed and compacted to not less than 95% of maximum dry density as
determined by BS 1377 Part 4 : 1990 (Method 3.5 or 3.6). Field density shall be
determined by BS 1377 Part 9: 1990 (Method 2.1 or 2.2).
h) The 'improved subgrade layer', using specified imported material, shall then be
placed and compacted to not less than 95% maximum dry density as determined
by BS 1377 Part 4: 1990 (Method 3.5 or 3.6) to bring the embankment level up to
'top of improved subgrade level'. Field density shall be determined by BS 1377
Part 9 : 990 : (Method 2.1 or 2.2).
i) For cuttings 1.5 metres or more in depth the technical requirements, of the
Specification for "Excavation for Structures" (Sub-Section 2/20) shall be complied
with.
j) Where excavation to the finished graded section, that is 'earthworks formation

level', results in a formation or slopes of unsuitable soil, the Engineer may require
the Contractor to remove the unsuitable material to a depth directed and backfill
to the finished graded section with approved material compacted in accordance
with specified requirements for embankment construction. The Contractor shall
conduct his operations in such a way that the necessary cross-sectional
measurements can be taken and agreed with the Engineer before the backfill is
placed.
k) When the Contractor is required or directed to excavate unsuitable material in fill

areas, following general clearance of the area (see Specification Sub-Section
2/14.1 "Embankment Foundation"), the depth to which these unsuitable materials
are to be removed will be determined by the Engineer. The Contractor shall so
schedule the work so that authorised cross-sections can be taken before and
after the material has been removed.
l) All slopes, lines and grades shall be true, correct, and accurate and according to
those on the drawings or otherwise directed and approved by the Engineer. The

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'earthworks formation level' in cuts shall be accurate to the authorised profile

grade to plus or minus two (2) centimetres and, for 'top of improved subgrade'
level, plus or minus one (1) centimetre. Where discrepancies are found in the
Work the Contractor shall make necessary corrections.
m) The Engineer will check all or any part of the Work, as he deems necessary, to
determine conformance to the lines, grades, elevations and cross-sections.
2.11 BORROW PIT SITE WITHIN PROJECT WORK AREA
a) The Contractor shall obtain approval from the Employer for the location of the
borrow pit site. The Contractor shall be responsible to determine the quantities
and quality of the available material in the approved borrow site to meet the
requirements of the Contract. When required the borrow area shall be cleared
and grubbed in accordance with the requirements of Section 2/1.
b) The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such notice
from the Employer, the Contractor shall immediately cease removing material
from said borrow site. In the event the Employer revokes approval of the borrow
site, the Contractor shall locate a new borrow pit site as specified above.
c) The Contractor shall not claim any additional payment for any costs by reason of
the necessity of changing borrow site locations due either to the shortage of the
supply of borrow material available from the borrow pit site approved by the
Employer, or due to the Employer's decision to revoke approval of the borrow site
where the Contractor is obtaining borrow material for the Works.
d) The Contractor shall leave borrow pits in a condition acceptable to the Employer
and to the Engineer.
e) The Contractor will be solely responsible for ascertaining the location of such
approved borrow areas during the tender preparation stage. Locations, distances
to the work site and haulage from such approved borrow areas shall be taken into
consideration when preparing the unit tender price for Borrow Excavation.
2.12 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS

MATERIALS
2.12.1 Top Soil
a) Top soil shall be fertile, friable soil obtained from well drained arable land and
shall be free draining, non-toxic and capable of sustaining healthy plant growth.
b) The organic matter content of the topsoil material shall be 2% max.(BS 1377: Part
3: 1990: Method 3) with the minimum out of tolerances of individual tests by +
0.5% and have pH value between 7.0 and 9.0 (BS 1377: Part 3: 1990: Method 9).

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2.12.2 Suitable Material
a) Suitable material shall comprise all well graded sandy soil from coarse to fine
material that is acceptable in accordance with the Contract for use in the Works.
b) Suitable material for earthworks shall be approved soil with a plasticity index not
exceeding 6 when tested according to BS 1377 Part 2 1990 Clause 5.4 (liquid
limit shall not exceed 40% when tested according to BS 1377: Part 2: 1990:
Clause 4.5) obtained from excavations within the works or from borrow pits
approved by the Engineer.
c) Suitable material It shall not contain excess of 425 micron passing material 50%
when tested in accordance BS1377:P2: 1990 Cl.9.2 and of fines (not more than
20% passing Sieve Size 0.075mm determined by BS 1377: Part 2: 1990 Clause
9.2 "Determination of particle size distribution by wet sieving") and in excess of
2% organic matter content (BS 1377 Part 3:1990).
d) Suitable material for earthworks shall have a soaked CBR value at 95% of
maximum dry density not less than 10% when tested according to BS 1377 Part
4: 1990 (Method 7). The maximum particle size shall not exceed 63 mm.
e) Soluble salt content must be less than 5% by weight of dry soil tested to BS 1377
Part 3: 1990 (Method 7 & 5 for water soluble Chloride & Sulphate respectively).
f) The material shall possess satisfactory binding characteristic to enable it to be

compacted to give a well-knit surface as judged by the Engineer. The maximum
dry density of the soil shall not be lower than 1.75gm/cu.cm.
2.12.3 Unsuitable Material
Unsuitable material shall comprise of:
a) Rock particles exceeding 63 mm in size.
b) Organic matter (BS1377 Part 3 : 1990 method 3) containing greater than 2%

(stumps and other perishable material).
c) Material susceptible to spontaneous combustion.
d) Alluvial clay and silts, gypsum which contain high concentration of water soluble
sulphate greater than 5% and pyritic shale.
e) Soils of liquid limit exceeding 40% (BS 1377 Part 2 1990 Clause 4.5) and or
plasticity index exceeding 6 (BS 1377 Part 2 1990 Clause 5.4).
f) Material containing more than 5% of water soluble salts by weight of dry soil. BS
1377 Part 3: 1990 (Method 7.2 and 5.5 AMD 9028-1996) for water soluble
chloride and sulphate respectively.
g) Materials having CBR value less than 10%.

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h) Any other material which the Engineer may deem to be unsuitable for earthworks.
i) Soil groups A-6, A-7 (silt-clay materials more than 35% passing 75 micron sieve)
as specified in ASTMD 3282.
2.12.4 Material for Improved Subgrade Layer
Material for Improved Subgrade Layer shall meet the following requirements:
a) Not more than 20% by weight passing Sieve Size 0.075mm determined by BS
1377: Part 2: 1990 Clause 9.2 "Determination of particle size distribution by wet
sieving".
b) Soaked CBR value at 95% maximum dry density (soaked) BS 1377 Part 4 : 1990
(Method 3.5 or 3.6) not less than 30% when tested according to BS 1377 Part 4 :
1990 (method 7).
c) A chemical analysis of the proposed material shall be carried out to satisfy the
following requirements:
(i) The material shall be shown to have an acid soluble sulphate content of 2%
or less and a chloride content in the form of acid soluble chloride of 2% or
less by dry weight. The applicable
(ii) Test methods should be in accordance with BS1377 Part 3: 1990 (Method
5) and BS 1377 Part 3 : 1990 (Method 7) respectively.
d) When approved by the Engineer a sulphate content greater than that specified
may be acceptable when the carbonate content is in the region of 30 40% (BS
1377 Part 3: 1990 Method 6.3 AMD 9028-1996).
e) Higher chloride contents may be tolerated provided that the ratio of (carbonate +
sulphate) to chloride contents is maintained at approximately 15:1.
f) The moisture content of the material before compaction shall not vary by more
than +/- 3% of the optimum moisture content when tested in accordance with BS
1377: Part 2 : 1990 Test 3.2.
g) The material for improved subgrade shall be approved soil with a plasticity index
not exceedingly 6 (BS 1377 Part 2 1990 Clause 5.4) and liquid limit shall not
exceed 40% when tested according to (BS 1377: Part 2: 1990 Clause 4.5).
h) The material shall possess satisfactory binding characteristics to enable it to be

compacted to give a smooth well-knit surface as judged by the Engineer.
i) No excavated suitable material shall be removed from the Site without the
Engineer's written permission. Should the Contractor be permitted to remove
suitable material from the site to suit his operational requirements, then he shall
make good any consequent deficit or filling arising there from at his own expense.

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2.13 MAIN PLANT AND EQUIPMENT FOR EARTHWORKS CONSTRUCTION
2.13.1 General
a) The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in situ state or during handling and placing
or in its final compacted state. Unsuitable or faulty plant shall be removed from
the work site and borrow pits at the order of the Engineer.
b) The plant and equipment used for earthworks construction shall be maintained in
good working condition for the duration of the works. The Contractor shall apply
adequate quantities of plant and equipment necessary for the proper execution of
the works in an expeditious manner.
c) Main plant and equipment shall meet the requirements specified below:
(i) Equipment shall mean, where mentioned in these Specifications, all

machines, tools, equipment and all necessary parts for its operation and
maintenance. Also, the laboratory tools and instruments and/or equipment
necessary for the proper construction of the road and the proper completion
of all the works.
(ii) The Contractor shall submit, as stipulated in the "Instructions to Tenderer" a

detailed list of plant equipment which he shall undertake to bring to the site
to carry out the work. The list shall include for each piece of equipment, the
type, size, quantity, manufacturer, model, identification number and year of
manufacture.
(iii) The Contractor shall supply all plant and equipment necessary for the
construction of each phase of the work and it must be on the site, inspected
and approved by the Engineer prior to the commencement of the particular
phase of work. Any plant or equipment of portion thereof, which becomes
worn or defective shall be immediately repaired or replaced to the
2.13.2 Compacting Equipment
The compaction equipment for earthwork may be towed or self-propelled and shall
include a suitable combination of tamping rollers, grid rollers, segmented pad rollers,
vibrating rollers, pneumatic rollers and other compaction equipment that can
satisfactorily and uniformly obtain the required compaction.
2.13.2.1 Tamping or Sheep foot Rollers
a) Tamping or sheep foot rollers shall consist of metal rollers, drums, or shells
surmounted by metal studs with tamping feet projecting not less than sixteen and
one-half (16.5) centimetres from the surface of the roller, drum or shell.

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b) Tamping feet shall be spaced not less than fifteen (15) centimetres or more than
thirty (30) centimetres measured diagonally centre to centre and the cross section
area of each tamper foot, measured perpendicularly to the axis of the stud, shall
be not less than twenty-five and eight-tenths (25.8) square centimetres.
c) The weight of tamping rollers shall be such that when fully loaded, the load on
each tamper foot will be determined by dividing the total weight of the roller
(loaded) by the number of tamper feet in one (1) row parallel to the axis of the
roller.
2.13.2.2 Pull-type Steel Rollers
Pull-type steel rollers shall have not less than one and two-tenths (1.2) metre
effective width of roller and shall be designed and constructed so that the weight per
linear centimetre of roller can be varied from thirty five and seven-tenths (35.7)
kilograms to at least fifty-three and six-tenths (53.6) kilograms.
2.13.2.3 Self-Propelled Steel Rollers
a) The power mechanism shall be capable of propelling the roller smoothly and
without jerking when starting, stopping, or reversing directions free from backlash,
loose link motion, faulty steering mechanism and worn king bolts.
b) The steering mechanism shall have no lost motion, shall operate readily and
permit the roller to be directed on the alignment desired. The faces of all rollers
shall be smooth and free from defects which mark the finished road surface.
Rollers shall be equipped with water tanks and sprinkling devices which shall be
used for wetting the roller to prevent adherence of the placed material.
c) Two-axle tandem steel rollers shall weigh not less than eight (8) tonnes or more
than twelve (12) tonnes and shall have a weight per centimetre width of roll
between 35kg and 70kg.
d) Three axle tandem steel rollers shall weigh not less than eleven (11) tons. Three
axle tandem roller shall be so constructed that the roller, when locked in position
for all treads to be in one plane, are held with a rigidity which will satisfy the
following test under full load: with the weight of the roller supported on the central
roller, the tread of the central roller shall not be more than three (3) millimetres
above the plane tangent to the tread of the end roller. With the weight of the roller
supported on the end rollers, the tread of the central roller shall not be more than
six (6) millimetres below the plane tangent to the treads of the end roller.
2.13.2.4 Trench Rollers
The trench roller shall be of an approved type and shall weigh not less than fifty-three
and six tenths (53.6) kilograms per centimetre of width and shall be equipped with
water and sprinkling device that shall be used for wetting the roller to prevent
adherence of the placed material.

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2.13.2.5 Pneumatic Tic-Tyre Rollers
a) The tyres on the front and rear axles shall have wide smooth treads and shall be
staggered to provide complete coverage of the entire area which the roller travels.
The tyres shall be inflated to a pressure that has been approved by the Engineer
and the pressure shall be reasonably uniform in all tyres. The Contractor shall
provide a suitable gauge for determining air pressure in each tyre.
b) Light self-propelled pneumatic-tyre rollers shall be so constructed so that they

may be loaded to provide a gross weight of at least forty (40) kilograms per
centimetre of width of tyre tread.
c) Heavy self-propelled pneumatic-tyre rollers shall be constructed so that they can

be loaded to provide a gross weight of not less than twenty five (25) tonnes and
they shall have tyre pressures of 6-6.3 kg/cm2.
2.13.2.6 Vibration Compactors
a) Equipment using principle of vibration as a tamping force shall be in good

mechanical condition and shall be capable of transmitting forceful vibrations or
impacts to the various materials placed in construction.
b) The equipment may be the roller or pad type or a combination of roller and pad
type. Vibrating compactors shall be of the type and force approved by the
Engineer.
2.13.3 Hauling and Weighing Equipment
2.13.3.1 Hauling Equipment
a) Hauling equipment for aggregate shall consist of vehicles having dump bodies
suitable for dumping materials in a windrow or in spreader boxes. The bodies
shall be so constructed that their volume measurement can be accurately
determined. They shall be so constructed and maintained to prevent loss of
materials during hauling operations.
b) The equipment shall be provided with dump controls that can be operated from
the driver's seat. The bodies of hauling equipment using public roads shall be
fitted with tarpaulins to prevent the nuisance of spillage.
2.13.3.2 Weighing Equipment
a) Weighing equipment for truck -hauled material shall consist of accurate and
reliable platform scales and they shall be accurate to one per cent throughout the
range of use.
b) The scale shall have a platform of adequate length to weigh the longest truck or
truck-trailer combination which is in use on the Project, in one operation.

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c) Scales shall be inspected and sealed or certified by an approved scale company,

as often as the Engineer deems necessary to ensure their accuracy.
d) The seal or certification shall show the date of the inspection. Where no approved
scale company exists or at the option of the Engineer, the Contractor shall check
and adjust the scale in the presence of the Engineer in the method recommended
by the manufacturer and/or approved by the Engineer.
e) It is the Contractor's responsibility to have sufficient standard test weights for

each scale on the Site.
f) The Engineer, as often as he deems it necessary, shall direct the Contractor to

check and adjust any scale on site to ensure its accuracy.
g) The Contractor, shall when directed by the Engineer, make weight comparisons
with other permanently located scales that meet with the approval of the
Engineer. These weight comparisons shall be for the purpose of providing
information on the performance of the Contractor's scale and will not be used as a
basis for adjusting the scale.
h) The approaches to the scale platform shall be maintained by the Contractor to the
i) The Contractor shall furnish a suitable weather tight building to enclose the
indicating mechanism and shall have adequate lighting for the scale operator's
use.
j) The Contractor shall have on hand not less than ten (10) twenty-five (25) kilogram
weights for testing the scale.
2.13.3.3 Controlled Water Distribution Equipment
a) Equipment for distribution of water shall consist of distributors or tanks equipped

with spray bars, and when required, pumps to operate under pressure.
b) The pumps shall be of sufficient capacity to provide uniform and adequate

distribution. They shall be mounted on pneumatic-tyre trailers pulled by
pneumatic-tyre equipment.
c) The minimum capacity of any tank shall be four (4) cubic metres (m³) where
applicable.
d) The distributor equipment shall be constructed to permit accurate and uniform

distribution of the desired quantities of water per unit of surface area.
e) The control valves shall be constructed to permit full closing and to prevent
leakage.

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f) The water control valves shall be constructed to operate from the driver's seat or
provisions made for an additional operator to operate the control valves while the
equipment is travelling at the proper speed for distribution.
2.14 EMBANKMENT CONSTRUCTION
2.14.1 General
a) The work of embankment construction shall consist of cutting and filling the
designated fill areas as shown in the drawing and constructing roadway
embankment with suitable material, including the preparation of the areas upon
which they are to be placed and the placing and compacting of approved material
within roadway areas where unsuitable material has been removed.
b) All operations for embankment construction shall be performed in accordance

with the Specifications and in conformity with the lines, grades, and thickness and
typical cross-sections shown on the drawings or as estimated by the Engineer.
c) Compaction equipment shall conform to the number and type outlined in the
Contractor's detailed programme of work as approved by the Engineer and
satisfactory performance shall be the basis for such approval.
d) All materials derived from excavation shall be used in the general filling including
trench backfill, backfill around structures for embankment unless otherwise
declared unsuitable by the Engineer. When suitable materials of widely divergent
characteristics are drawn from different sources such materials may, if approved,
shall be mixed to meet filling requirements.
e) Prior to the commencement of embankment the Contractor shall construct trial

compaction lengths as directed by the Engineer. The soils used in the trials shall
be those encountered along the line of the road and project work area as
approved by the Engineer and/or those originating item the approved borrow pit.
The object of the trials is to determine the field compatibility of the material with
the plant and compaction equipment available with the Contractor. The Engineer
may order additional compaction trials when he deems them necessary.
f) During the construction of road /embankments the Contractor shall control and
direct construction traffic uniformly over the full width of the embankment?
Damage to compacted layers by construction traffic shall be made good by the
Contractor at his own expense.
g) The Contractor shall be responsible for the stability of all embankments and shall
replace all sections which, in the opinion of the Engineer, have been damaged or
displaced due to carelessness or neglect on the part of the Contractor, or due to
natural causes, such as storms, and not attributable to the unavoidable
movement of the natural ground upon which the embankment is made.

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h) During construction, the roadway shall be kept shaped and drained at all times.
When unsuitable material has been placed in the embankment, its removal shall
be at the expense of the Contractor.
i) Throughout the duration of the Contract all damage to completed earthworks

attributable to rain and rainfall run-off or to any other cause shall be made good
by the Contractor without delay and whenever possible within 24 hours of such
damage occurring.
2.14.2 Embankment Foundation and the Designated Filling Area
a) All debris, unsuitable material and vegetable matter shall be removed from the
surface upon which the embankment and the filling area is to be placed and the
cleared surface shall be completely broken up by ploughing, scarifying or
stripping to a minimum depth of twenty centimetres (20 cm).
b) The foundation material shall be adjusted to a moisture content within the

moisture range of ±3% of the optimum moisture content and compacted to not
less than ninety five per cent (95%) of the Maximum Dry Density as determined
by BS 1377 Part 4: 1990 (method 3.5 or 3.6).
c) Rock-soil mixtures of sandstone fractures and silty sand deposits obtained from
the excavation shall also be used at the lower part for the construction of the
embankment provided such materials fully comply with the following properties.
Table 2.14-1: Rock soil mixture suitable for embankments

Sr. Properties Standard Specs
1. Size 25% larger than 30 cm –
2. Size 50% larger than 7.5 cm –
3. Bulk Specific Gravity not less than 2.25 –
4. Water Absorption not more than 6% –
5. Testing by plate bearing test –
6. Filling material shall not be A-6, A-7 Type soil AASHTO M-145
d) If the original surface upon which the embankment is to be placed is an old

roadbed, the surface shall be ploughed scarified or broken up, regardless of the
height of the embankment to be placed and compacted to a density as
determined by the Engineer.

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Dubai Municipality
e) Where the embankment and the filling is to be placed on appreciably sloping

ground, this surface shall be benched in steps or trenched to key-in the new
construction in accordance with the Engineer's instructions, including if necessary
any under-draining of the affected part of the site.
f) In circumstances where backfill has to be deposited below standing water, the

Contractor shall use only an approved granular material of maximum size not
greater than 37.5 mm and which on analysis by sieving (BS 812: Part 103:
Section 103.1:85 c1.7.2 or 7.3, or BS 1377: Part 2: 1990: 9.2 or 9.3 latest edition)
complies with the requirements of Table below. Such material shall have a "ten
percent fines" value of not less than 5 tonnes when tested in accordance with
B.S. 812 : 1990 : P111 and may be deposited below water without the associated
use of compaction plant.
Table 2.14-2: Free draining material

BS Sieve Size % by Weight Passing
10 mm Up to 100
5 mm Not more than 85
0.600 mm Not more than 45
g) In circumstances where filling has to be deposited in a soft area, methods of soft

area treatment which may be directed by the Engineer shall be:
(i) Non-friable boulders of sizes between 150-300 mm shall be end dumped

over the soft area and rolled until the area is stabilised to the satisfaction of
the Engineer. Further stones of 10-70 mm size shall be rolled into the area
until all the areas are levelled and well blinded.
(ii) Crushed rock material shall be free from dirt, organic matter, shale and any
other deleterious material. The acceptance criteria shall be as follows:
Table 2.14-3: Crushed rock material acceptance criteria

Parameter Limit value
1. Grading (BS EN 933-1:2012 and BS 1377

Part 2 method 9.2 or 9.3: 1990)
Sieve (mm) Passing (%)
150 100

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200 80-100
37.5 -
25 20-50
19 -
9.5 0-15
2. Bulk specific gravity (ASTM C127 & C128) Not less than 2.65
3. Absorption (ASTM C127 & C128) Not more than 2%
4. Loss of Abrasion (ASTM C131 or C535) Not less than 30%
5. Loss of magnesium sulphate soundness 10% maximum

(ASTM C88 5 cycles)
h) The following field tests are to be carried out to confirm the load bearing nature of
the soft area prior to start stabilizing work:
(i) Field density test in accordance with BS 1377: P9:C2:1990
(ii) Plate bearing tests shall be carried out in accordance with ASTM
D1194/D1196. Frequency and unit shall be as directed by the Engineer.
(iii) CPT test in accordance with BS 5930: 1999.
2.14.3 Suitability Testing on Materials
a) During excavation, care should be taken to avoid indiscriminate mixing of soils of

widely differing classification and characteristics.
b) Excavated materials obtained from the cutting and borrow pit shall be stockpiled
within the respective areas and shall be used (after suitability test) for filling and
embankment construction.
c) Alternatively sufficient numbers of trial pit excavation from various locations and
depths shall be carried out to test the material to confirm its suitability
requirements specified in Clause 2/12.
d) All such trial excavations or stockpiling shall be carried out without extra charges.
2.15 PLACING AND COMPACTION REQUIREMENTS
a) Only approved materials shall be used in the construction of road embankments.

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b) In the formation of the embankment it is strictly forbidden to push the excavated

materials from the side of the road to the embankment by means of bull dozers.
c) The fill material shall be delivered and spread in layers not exceeding 25 cm
compacted thickness. The layers of fill shall be graded, levelled, pulverised and
mixed, with water added as necessary, to ensure homogeneous conditions
through the full depth of the un-compacted layer. For field density testing refer to
specification sub-section 2/18.
d) The compacted density of the fill shall be equal to or greater than as required
under Clause 2/18 as determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6).
e) The material to be imported for the "improved sub-grade layer" to be constructed

above "earthworks formation level" up to "top of improved sub-grade" level as
shown on the drawings shall conform to the Specification Sub-Section 2/12.
2.16 MOISTURE CONTROL REQUIREMENTS
a) When the moisture content of the embankment soil does not fall within 3% of the
optimum moisture content, water shall be added and thoroughly mixed into the
soil, by approved methods or the material shall be aerated, whichever is needed
to adjust the soil to the proper moisture content.
b) The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide moisture content in the soil
within the required range plus a reasonable amount to compensate for
evaporation and other unavoidable losses.
c) Water added in excess of this amount shall be considered as excess water and
must be removed by aeration or other suitable means as directed by the
Engineer.
d) Satisfactory methods and sufficient equipment shall be used for furnishing and
handling of the water so that there will be no undue loss due to evaporation or
waste. If water is added to cut areas or borrow pits, the surface of the areas or
pits shall be maintained in such a manner that will prevent undue loss of moisture
and segregation.
e) Use of saline water for earthworks will only be permitted if the percentage of
water soluble salts in the compacted fill does not exceed 3% by weight of dry soil
when tested in accordance with BS 1377 Part 3 : 1990 tests 5 & 7.
f) For subgrade material moisture range refers to sub-clause 2/12.

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2.17 STANDARD EARTH WORKS COMPACTION PROCEDURE
2.17.1 General
a) A dry density moisture content relationship test in accordance with BS 1377 Part
4: 1990 (method 3.5 or 3.6) will be made for each type of soil to be used in the
construction of the work to determine the Maximum Dry Density, the Optimum
Moisture Content and the Moisture Range required of the soil for satisfactory
compaction.
b) This method will be used to determine the maximum dry density of each type of
soil used in compacted fills, backfills, embankments and to measure the relative
compaction at optimum moisture content of compacted fills, backfills,
embankments and subgrades.
2.17.2 Compaction Tests
During the course of the work, tests shall be carried out under supervision of the
Engineer to:
a) Identify materials
b) Determine compaction characteristics
c) Determine moisture content
d) Determine density of fill in place
2.17.3 Testing
a) Regular testing shall be performed as detailed in 2/18 of the Specification.
b) Contractor shall adjust his operations so as to permit time to make tests and shall
excavate and fill such holes as may be required for sampling and testing.
c) Compaction tests shall be made prior to removal of dewatering systems.
d) A subsequent layer cannot be placed until the compaction density of the

proceeding layer has been approved by the Engineer.
2.18 MINIMUM TEST REQUIREMENTS
For the Contractor’s general guidance, the following tests will be required prior to use,
and during the construction of filling area, the embankment and of the sub-grade.
2.18.1 Embankment and Filling Works
a) Soil samples for Soil classification according to BS 1377: Part 1 and Part 2: 1990
latest edition, laboratory moisture/density relationship tests and California Bearing
Ratio shall be taken prior to use, from any proposed source of material.

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b) Each sample shall represent not more than 5,000 m³ or part of as directed by the
Engineer. Sampling shall be in accordance with ASTM D75: 2003, BS 1377 Part
1: 1990 and BS 5930:1999.
c) For every completed layer of fill at least:
(i) Three field density tests shall be performed for every unit of carriageway.
(One unit being 2250 sq.m) or as directed by the Engineer in accordance
with BS 1337 :P9 : 1990
(ii) Every compacted layer shall not be less than 95% of MDD. One test per
backfill layer for each structure or one test per 500 m2.
d) The Contractor shall carry out any additional compaction tests as ordered by the
Engineer at no additional cost.
2.18.2 Improved Subgrade
a) Samples for soil classification, laboratory moisture density relationship tests and
CBR tests shall be taken prior to use, from any proposed source of material. Each
sample shall represent not more than 3,000 m³ or as part of as directed by the
Engineer.
b) For every completed layer of subgrade, three field density tests shall be
performed on each unit of carriageway (one unit being 1500 m²) or as directed by
the Engineer.
c) The frequency of field compaction tests on the shoulders shall be three every unit
constructed or as directed by the Engineer (one unit being 1500 m²).
2.18.3 Rock Fill and Rock Soil Mixtures
a) Where embankments to be compacted are formed of material consisting

predominantly of sand stone or rock fragments of such size that the material
cannot be placed in layers of the thickness prescribed without crushing,
pulverising or further breaking down the pieces resulting from normal excavation
methods, the material may be placed in the embankment in layers not exceeding
a thickness twice the average size of the larger rocks, except that no layer shall
exceed 600 mm of loose measurement.
b) Materials shall be carefully placed so that all large stones will be well distributed
and the voids completely filled with smaller earth, sand or gravel to form a solid
embankment.
c) Each layer shall be bladed or levelled with motor grader, bull dozer or similar
equipment capable of shifting and forming the layer into a neat and orderly
condition.

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d) No rocks larger than eighty (80) mm in any dimension shall be placed in the top
one hundred and fifty (150) mm of the embankment unless otherwise noted on
the drawings.
e) Conformance to these provisions and compaction in a manner and to a point of

consolidation approved by the Engineer will be considered as fulfilment of the
requirements for the type of compaction shown on the drawings.
f) Normally, compaction tests will not be performed in these areas but the Engineer
reserves the right to test compaction in some other manner if he deems a test
necessary to ensure consolidation. Each layer must be approved by the Engineer
before the next layer is placed.
g) Embankments, which are formed of materials that contain rock but also sufficient
compatible material other than rock or other hard material to make rolling feasible,
shall be placed and compacted in the manner and to the point of consolidation
h) Moisture shall be added as directed by the Engineer. Compaction tests will be

made wherever the Engineer determines they are feasible and necessary. Each
layer must be approved by the Engineer before the next layer is placed.
Table 2.18-4: Rock fill material characteristics

Bulk specific gravity (ASTM C127 & C128) Not less than 2.65
Absorption (ASTM C127 & C128) Not more than 2%
Los Angeles Abrasion (ASTM C131 or C535) 30% maximum
Loss of magnesium sulphate soundness 10% maximum

(ASTM C88 5 cycles)
2.19 STABILISING CRUSHED MATERIAL
a) In the event the foundation on which the embankment or the subgrade materials
will be laid is saturated by water and unstable, the Engineer may decide to lay
crushed granular material to stabilise the foundation. Stabilising crushed material
shall not be laid directly on ground soil but it shall always be laid on geotexti1e
fabric covering the area to be stabilised as shown on the drawings or directed by
the Engineer.
b) Such stabilising crushed material when tested in accordance with BS 812:Part

103: Section 103.1: 1985 (Clause 7.2 or 7.3) or BS 1377 Part 2: 1990 method 9.2
or 9.3 latest edition shall have the following grading:
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Table 2.19-5: Stabilising crushed material grading

Sieves (mm) % Passing
50 100
25 80-100
12.5 60-85
5 40-70
2 20-50
0.85 5-25
0.425 0-10
0.180 0-2
c) The stabilising crushed material shall have the following characteristics:
Table 2.19-6: Stabilising crushed material characteristics

Bulk specific gravity (ASTM C127 & C128) Not less than 2.65
Absorption (ASTM C127 & C128) Not more than 2%
Los Angeles Abrasion (ASTM C131 or C535) 30% maximum
d) The stabilising crushed material will be laid in layers of 15 cm and compacted

until the foundation is fully stabilised such that the total thickness of the stabilising
layer shall not be less than 30 cm. Only after inspection and approval by the
Engineer the Contractor may be allowed to continue the construction of the
embankment with other layers of embankment material and/or subgrade material.
The Engineer may decide, after having taken the levels of the existing water table
in the area, and keeping in consideration the finished road levels, to excavate
portions of the foundation saturated by water, disposing of the excavated
material, and replacing it with stabilising crushed material.
e) Before starting any stabilising of the foundation the Engineer will instruct the
Contractor specifying the areas to be stabilised and the final levels to be reached
with the stabilising crushed material.
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f) The surface to receive the geotextile fabric shall be prepared to a relatively

smooth condition free of obtrusions, depressions, and debris. The geotextile
fabric shall not be laid in a stretched condition, but shall be laid loosely with the
long dimension parallel to the centreline of the roadway. In the event that the
width of the proposed area for fabric requires more than one panel width of fabric,
the panels shall be overlapped a minimum 15 per cent of the panel width.
Longitudinal joints in the fabric shall have an overlap of 50 cm. To prevent
slippage of the overlapping fabric, the areas of overlap shall be stabilised as
approved by the Engineer with pins, anchor blocks, or aggregate piles. In the
event construction machinery is used to place the fabric, the working platform for
the machinery shall be the soil and not the previously laid fabric.
g) Prior to placement of the granular material (stabilising crushed material) the

Contractor shall spread a layer of sand over the geotextile fabric as directed by
the Engineer. The aggregate material shall not be dumped directly on the fabric,
nor shall haul trucks be run on the fabric. The aggregate shall be spread by a
wheeled front-end loader.
h) The blade or bucket shall be kept sufficiently high so that the aggregate is not
being pulled over the fabric, but being dropped at a minimum height to the
i) Fabric damaged or displaced before or during installation or during placement of

overlaying aggregate material shall be replaced or repaired to the satisfaction of
the Engineer at the Contractor's expense.
2.20 EXCAVATING AND FILLING FOR STRUCTURES
a) This work shall consist of all excavation for the construction of buildings, tanks,
structures, minor structures, culverts, headwalls, catch basins, manholes, inlets
and retaining walls and shall include all necessary clearing and grubbing, all
necessary bailing, drainage, pumping, sheeting, strutting and the construction of
coffer dams or cribs, if found necessary, and their subsequent removal; also the
disposal of all material obtained from such excavation and backfilling to the level
of the original ground; it shall include the removal of that portion of existing
structures below the ground which is necessitated by the construction of the new
structure. The line and level of the structural excavation shall be as shown on the
drawings or as may be directed by the Engineer.
b) Prior to commencing any structural excavation work 1.5 metres or more in depth,
the Contractor shall design and submit to the Engineer for review and approval,
within a minimum period of 1 week before the intended commencement date,
detailed working drawings of the structural excavation support member materials,
sizes, spacing and engineering calculations to validate their design, including the
maximum theoretical deflections of the support members. The system shall be
designed in such a manner that no raked struts or any other support members
extend through surfaces exposed in the finished construction, and no shoring or
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bracing is placed under permanent structures. Before commencing the

excavation:
(i) The structure shall be pegged out correctly
(ii) Natural ground levels shall be agreed with Engineer.
c) The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation and
removal and concrete placement, the anticipated equipment loads, surcharge
loads of any description, the maximum design loads to be carried by various
members of the support system and strut preload forces.
d) If the structure support system proposed includes tieback anchors, the

Contractor's submittal drawings shall show the profile of the soil in which each
anchor is to be installed, the design load for the full depth of the excavation, the
maximum design and proof loads, surcharge loads of any description; equipment
loads, forces at various stages, support during installation and removal, and the
criteria proposed for deformations under proof loads. Where a proposed system
of tie back anchors projects beyond the vertical projection of the Contract limit
lines shown on the Drawings on to the adjoining property, the permission of the
owner shall be obtained in writing and such permission submitted to the Engineer
at the time the shop drawings of the support systems are submitted.
e) At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the hydrostatic
pressure and lower the ground water levels below excavation levels, as required
for the safe and proper execution of the work and which will result in obtaining a
stable, dry subgrade for the execution of subsequent operations. The Contractor
shall design dewatering methods and settling basins so that no critical amounts of
soil, sand or silt are removed during either the initial operations or the
construction operations. Complete working drawings showing the type of
dewatering and ground water control system proposed shall be submitted to the
Engineer for his review.
f) The Contractor's submittal drawings shall show the arrangement, location and
depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedures to be followed shall
be shown, together with the standby equipment, standby power supply and the
proposed location or locations of points of discharge of water. Any required
dewatering system design shall also include the measures taken to prevent
damage due to settlement of pavement, utilities, sewers, buildings and other
structures outside the excavation but within the area affected by the procedures.
g) The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Structural
Engineer approved by the Engineer specialising in this type of design work.

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Approval of the designs and shop drawings shall not relieve the Contractor of the
adequacy and performance of these temporary works.
h) Pre-Construction Inspection-prior to the beginning of construction, the Contractor

and the Engineer shall make a detailed inspection of all adjacent buildings,
pavements, wells and other structures in order to determine its pre-construction
condition and the Contractor shall prepare, for the Engineer's approval, a typed
Inspection Report of the findings.
i) The Report shall include photographs, drawings and sketches with levels and
dimensions illustrating the structures condition, noting in particular any existing
damage or structural inadequacy. Deficiencies and damage shall be suitably
marked on the structure such that it is not permanently defaced.
j) Three copies of the Report shall be submitted for the approval of the Engineer.
Once approved, five additional copies shall be supplied to the Engineer.
k) The Contractor shall notify the Engineer sufficiently in advance of the beginning of
any excavation so that cross-sectional elevations and measurements may be
taken of the undisturbed ground. The natural ground adjacent to the structure
shall not be disturbed without the permission of the Engineer.
l) Trenches or foundation pits for structures or structure footings shall be excavated

to the lines and grades or elevations shown on the drawings, or as ordered by the
Engineer. They shall be of sufficient size to permit the placing of structures or
structure footings of the full width and length shown. The elevations of the
bottoms of footings, as shown on the Drawing shall be considered as approximate
only and the Engineer may order, in writing, such changes in dimensions of
elevations of footings as may be deemed necessary, to ensure a satisfactory
foundation.
m) Unless otherwise provided for in the Drawings or Contract Documents or directed

by the Engineer structural excavation shall be carried out for a width of at least
500mm beyond the horizontal outside limits of the foundation, footing, box culvert
or structural member to which the excavation relates. Concrete blinding or sub-
foundations are not to be considered as structure for the purpose of defining such
excavation.
n) If during the progress of the work, loose or improperly compacted soil is

encountered below the structural foundation levels, or adjacent thereto, which is
the result of prior removal of utilities or structures, such material shall be
completely removed within the limits as directed by the Engineer, backfilled with
suitable material and it should be not less than 95% of the maximum dry density
as determined by BS 1377 Part 4:1990 (method 3.5 or 3.6). Any previous
excavations encountered which would in the opinion of the Engineer be
detrimental to load distribution of new foundations to the under laying soil, shall
be excavated and backfilled with Class C 25/20 concrete.

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o) After each excavation is completed, the Contractor shall notify the Engineer, for
approval of the depth of excavation and the character of the material, prior to
further structural works. Any over excavation shall be backfilled with Class C
25/20 concrete at the Contractors expense.
p) In-situ plate bearing test shall be carried out in all formation level of each major
RCC structure is accordance with BS 5930 : CL 31 or ASTM D1194/D1196 test
methods and should satisfy that the safe bearing capability of the foundation soil.
q) All rock or other hard foundation material shall be cleaned of all loose material
and cut to a firm surface, either level, stepped, or serrated as directed by the
Engineer. All seams or crevices shall be cleaned and grouted. All loose and
disintegrated rock and thin strata shall be removed.
r) When the footing is to rest on material other than rock, excavation to final grade
shall not be made until just before the footing is to be placed and special care
shall be taken not to disturb the excavation. When the foundation material is soft
or otherwise unsuitable as determined by the Engineer, the Contractor shall
remove the unsuitable material and backfill with approved granular material. This
foundation fill shall be placed and compacted in 150mm layers up to the
foundation elevation and compacted to not less than 95% of the maximum dry
density as determined by BS 1377 Part 4 : 1990 (method 3.5 or 3.6).
s) The placing of concrete shall follow as closely as practicable the structural

excavation.
t) Control of Ground Water- Prior to the commencement of construction at any

particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area which in
the opinion of the Engineer is likely to be affected by the dewatering. The number,
location and depth of all standpipes shall be to the satisfaction of the Engineer.
(i) The Contractor shall check ground water levels at weekly or where
instructed by the Engineer, more frequent intervals and submit within 24
hours written reports to the Engineer in a form to be agreed.
(ii) In the case of uncontrolled flow of water into any excavation, the Engineer
reserves the right to order an immediate cessation of work and to order the
Contractor to take immediate action to control the inflow of water. Such
actions and remedial works shall be to the Engineer's approval.
u) Notification of Damage - The Contractor shall notify the Engineer immediately of

any movement or any damage not noted in the pre-construction report, to any
structure. The Contractor shall immediately cease his construction operations in
the vicinity and shall take immediate action to prevent further movement or
damage. The Contractor shall keep the Engineer fully informed of all such action.

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v) Remedial and Preventive Works - Should remedial works be necessary due to

damage caused to the structure or should the Engineer direct the contractor to
carry out any works necessary to prevent damage to the structure due to the
Contractor's construction works, the Contractor will present, without delay,
detailed drawings and specifications, as necessary, showing his proposed
remedial or preventive works for the Engineer's approval.
In either case the Contractor will suspend all construction activities in the vicinity
of the structure until such time as the remedial or preventive works are carried out
to the Engineer's satisfaction at the Contractor's expense.
w) Post Construction Inspection - On completion of, but prior to final acceptance of

the works, the Contractor and the Engineer shall re-examine the structure to
determine any change from the original conditions. The Contractor shall supply to
the Engineer for approval five copies of a report describing measures he
proposes to take to correct any damage which resulted from the construction of
the works. The approved corrective measures shall be carried out by the
Contractor at his expense, to the Engineer's satisfaction before final acceptance
of the works.
x) Utilisation of Excavated Materials - All excavated material determined as suitable

by the Engineer, shall be utilised as backfill or roadway fill. The surplus material,
shall be disposed of as specified in sub-section 2/7 para 2. Excavated material
shall not be deposited, at any time, so as to endanger the partly finished structure
or cause an obstruction of any kind. All unsuitable material shall be disposed of to
approved tips.
y) Backfill - Excavated areas around structures shall be backfilled with excavated

materials or imported granular material approved by the Engineer. Backfill
materials shall be placed in horizontal layers not exceeding 150mm in depth after
compaction to not less than 95% of the maximum dry density as determined by
BS 1377 Part 4: 1990 (Method 3.5 or 3.6). The field density shall be determined
by BS 1377 1990 Part 9: 1990: 1990 (Method 2.1 or 2.2). Each layer of material
shall be moistened or dried as required to enable thorough compaction as
specified. Backfill shall be placed to the original ground level or as indicated on
the drawings.
z) Backfill or embankment shall not be placed behind the walls of concrete

structures or rigid frame structures until the top slab is placed and cured. Backfill
and embankment behind abutments when held at the top of the superstructure
shall be carried up simultaneously behind opposite abutments. Backfill shall be
carried up equally on either side of box culverts.
For frequency of testing of backfill material refer to sub-section 2/18.

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2.21 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS
2.21.1 Activities prior to excavation starting
a) Before an excavation is started:
(i) Ground levels shall be agreed at suitable intervals with the Engineer's
Representative.
(ii) Surface materials and conditions will be recorded in collaboration with the
Engineer's Representative and where appropriate the owners or occupiers
of the land.
(iii) The Contractor shall take photographs to illustrate existing damage or

conditions which may prove contentious at the time of reinstatement.
b) This information shall be neatly presented in bound volumes and submitted to the
Engineer. To this shall be added details of any existing natural or piped subsoil
drainage or other underground features as work proceeds.
c) Trial excavations may be ordered by hand or other methods to reveal sub surface
conditions of any kind. The Contractor shall submit a written report or sketch
drawings of data so obtained and the excavations shall not be backfilled without
approval.
2.21.2 Setting out
a) Before any structural excavation is commenced the Contractor shall define the
centre line or other agreed reference line of the Works and erect the necessary
profiles throughout their full length if so required by the Engineer.
b) The Contractor shall be responsible for obtaining all verifications from the Dubai
Municipality Survey Section and the Contractor shall bear all associated costs.
2.21.3 Topsoil and Surfacing Materials
Before commencing excavations or filling to an area, topsoil and other surfacing

materials shall be stripped and stored separately from the subsoil.Subsequent
spreading of topsoil shall be as directed on site.
2.21.4 Land Drains
Where pipelines are to be laid in agricultural land the surface and subsoil drainage
shall be maintained whether natural or artificial. Before commencing work the
Contractor shall ascertain from the owner or occupier of the land the location of any
existing land drains or mole drains.

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2.21.5 Hand Excavation
Where instructed or necessary for reasons of limited access or any other reason,
excavation shall be carried out by hand at no additional cost.
2.21.6 Support to Excavations
a) The sides and/or the bottom of excavations in excess of 1.2 metres shall be
adequately supported.
b) The Contractor shall provide the necessary support for excavations and shall
submit to the Engineer his proposals for the supporting of excavations by trench
sheeting or other approved means at least seven days prior to the
commencement of any excavation works. His proposals shall take into account
the nature of the ground to be excavated, the level of the water table at the site
and the proximity of buildings and roads.
c) If in the opinion of the Engineer the support proposed for the excavations by the
Contractor is insufficient then the Engineer will order the provision of stronger
support than that provided by the Contractor and in this event the Contractor shall
adopt the methods so ordered by the Engineer and shall have no claim against
the Employer for any costs incurred in adopting the additional measures.
d) Trench supports shall be so arranged to permit withdrawal during the placing of

the pipe bedding and backfilling so as to prevent voids.
e) The Contractor shall not remove temporary works supporting the excavations until
in the opinion of the Engineer the permanent work is sufficiently advanced to
permit such removal which shall be executed under the personal supervision of a
competent foreman.
f) All temporary works supporting the excavation shall be removed during backfilling
unless previous approval has been obtained from the Engineer. Where
temporary supports have been used in the excavation any such supports left in
because it is impracticable to remove them shall be left in at the expense of the
Contractor.
g) Should temporary supports need to be left in any excavation carried out in open
cut owing to the Engineer deciding that their permanent installation is necessary
for the stability of an adjacent structure or service the Contractor shall be
reimbursed in accordance with the provisions of the Contract.
h) Any advice, permission, approval or instruction given by the Engineer relative to

such support or the removal thereof shall not relieve the Contractor from his
responsibilities or liabilities under the Contract.
i) Timbering steel sheeting strutting and sheet piling for the support of excavations
where provided shall be fixed in accordance with BS 6031.

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j) Battered sides to trenches or other excavations will only be permitted if they can
be constructed within the limits of the site, without damage or interference to
existing services, properties or structures, without undue interference with
pedestrians and traffic and to slopes which are sufficiently flat to ensure stability
of the ground.
2.21.7 Dewatering
2.21.7.1 General
a) A high water table is expected on this site and the Contractor must take all
necessary measures to ensure proper dry conditions are maintained at all times
during construction.
b) The Contractor shall provide and maintain ample means and devices (including
spare units kept ready for immediate use in case of breakdowns) with which to
intercept and/or remove promptly and dispose properly of all water entering
trenches and other excavations. Such excavations shall be kept dry until the
structures, pipes, and appurtenances to be built therein have been completed. In
addition precautions shall be taken to prevent floatation of partially built
structures, completed structures to be filled on commissioning of the Works and
pipelines awaiting backfilling.
c) Dewatering methods proposed in the Contractor’s method statements may

include temporary drains, intercepting ditches, cut-off drains, sub drains, sumps,
wells, pumps, well points or other dewatering equipment and shall include all
other things necessary to keep water out of the excavations or to lower
groundwater around structures liable to floatation.
d) All necessary precautions shall be taken to prevent any adjacent ground from
being adversely affected by loss of fines through any dewatering process.
e) Method statements shall include proposals for disposal of the water arising from
dewatering systems.
f) All water pumped or drained from the work shall be disposed of in a suitable
manner without undue interference with other work, damage to pavements, other
surfaces, or property. Suitable temporary pipes, flumes, or channels shall be
provided for water that may flow along or across the site of the work. No such
water is to be disposed of into the existing sewer systems of the town or
otherwise without prior written approval of the Dubai Municipality Drainage and
Irrigation Department.
g) If permission is given to use new or existing pipes or culverts which are not part of
the live sewerage system, they shall be thoroughly cleaned of all silt and any
resulting damage made good after use.

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h) When the Contractor proposes to make use of existing dewatering pipelines,

ducts, etc., he shall satisfy himself as to their condition prior to his use of them. If
any of these items is found to be in an unsatisfactory condition then, before use,
the Contractor shall notify the Engineer who may give instructions for the item to
be replaced or repaired. Time taken to carry out such work will not be considered
as delay to the Contractor's operations.
i) During use the Contractor shall be responsible for the condition of the pipeline,
duct, etc., and any defect or failure shall be made good at the Contractor's
expense. Any delay to the Contractor's works caused by such defect or failure
shall be deemed as the Contractor's responsibility.
j) After use by the Contractor such pipeline, duct, etc., shall be handed back to the
Municipality in a condition not less than that at the commencement of use. Any
repairs or replacement required shall be at the Contractor's expense.
k) It cannot be guaranteed that permission will be given to use existing ducts and
pipelines.
l) All temporary works for control of water shall be sited clear of the Works, except
where temporary sub drains under the Works are approved in which case the
pipes shall be laid with a 75 mm surround of gravel, and the top surface of the
surround shall be covered with tarred felt cloth or other approved material.
m) Unless otherwise directed all temporary drains and sub drains shall be finally
sealed with concrete at approved intervals and all temporary ditches, sumps,
wells, etc., shall be refilled and reinstated as specified elsewhere.
n) In the exceptional event that lagoons for the storage of groundwater are
permitted, they must be suitably protected with fencing and attended by day and
night to prevent access by the general public and will not be sited adjacent to
buildings. Approved means of preventing the formation of mosquito larvae on the
surface of the lagoons will be employed.
o) All necessary precautions shall be taken to prevent any groundwater from

entering mains to be used for the conveyance of potable water.
2.21.7.2 Temporary Under drains
a) Temporary under drains, if used, shall be laid in trenches, beneath the grade of
the structure. Trenches shall be of suitable dimensions to provide room for the
chosen size of under drain and its surrounding gravel.
b) Under drains, if used, shall be laid at an approved distance below the bottom of
the normal excavation and with open joints wrapped in geotextile, and entirely
surrounded by graded gravel, or crushed stone to prevent the admission of sand
or other soil into the under drains.

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c) The distance between the bottom of the pipe or structure and the top of the bell of
the under drain pipe shall be at least 8 cm. unless otherwise permitted. T
d) he space between the under drain and the pipe or structure shall be filled with
screened gravel or crushed stone which shall be rammed if necessary and left
with a surface suitable for laying the pipe or building the structure.
2.21.7.3 Well Point Drainage System
a) Where the nature of the Works necessitates, the Contractor shall dewater the
excavations by means of an efficient well point drainage system which will drain
the soil and prevent saturated soil from flowing into the excavation.
b) The well points shall be designed especially for this type of service. The pumping
unit shall be designed for use with the well points, and shall be capable of
maintaining a high vacuum and of handling large volumes of air and water at the
same time.
c) If required by the nature of the Works, the installation of the well points, pumps,
surge tanks, settlement tanks, geotextile and other such requirements shall be
done under the supervision of the competent representative of the manufacturer.
d) The Contractor shall do all special work such as surrounding the well points with
sand or gravel or other work which is necessary for the well point system to
operate for the successful dewatering of the excavations.
e) Material to be used in the well point system is to be corrosion resistant where

possible.
2.21.7.4 Submittal and approval of dewatering activities
a) Submit working drawings and data for review and acceptance showing the
intended plan for dewatering operations, where deemed necessary by the
Engineer.
b) Include details of locations and capacities of dewatering wells, well points, pumps,
sumps, collection and discharge lines, standby units, water disposal methods,
monitoring and settlement.
c) Submit these entire not more than 30 days prior to start of dewatering operations.
d) Draw the static water level down to a minimum of 300mm below the bottom of the
excavation so as to maintain the undisturbed state of the foundation soils and to
allow for the placement of any fill or backfill to the required density.
e) Install and operate the dewatering system so that the groundwater level outside
the excavation is not reduced to the extent that would damage or endanger
adjacent roads, structures or property.
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f) Establish at several site locations, approved by the Engineer, groundwater level

monitoring stations, e.g. open tube piezometers which can be observed during
the work. Also, provide settlement gauges as directed, accepted and designated
by the Engineer at several locations to monitor the settlement of new and existing
facilities.
g) Perform dewatering so that no flow of water occurs along the pipe zone material.
Use where applicable cut-off walls or other agreed methods to reduce the
potential groundwater flow along pipe trenches. Submit to the Engineer for his
approval details of the proposed method of working and temporary works
installations to achieve this
h) Perform the restoration of groundwater to its original static level so as to maintain

the undisturbed state of the natural foundation soils, prevent disturbance of
compacted fill or backfill and prevent flotation or movement of structures,
pipelines and sewers.
i) Do not remove any dewatering systems without the Engineer’s acceptance.

Maintain monitoring and settlement measurement systems in operation until
removal is accepted by the Engineer. Where necessary, maintain these until final
compaction is completed. Well points and like items may be abandoned to the
extent accepted by the Engineer.
2.21.8 Formation
a) Damage to the formation shall be prevented by bottoming up with hand

excavation immediately before placing concrete or pipe laying. Any damaged
formation shall be excavated and refilled with concrete or selected material as
instructed.
b) The formation of excavations for pipelines shall be dry, even and free of stones
and other protrusions.
c) No permanent works of any kind shall be constructed on an excavated surface

until the formation has been approved by the Engineer’s Representative.
2.21.9 Excavation at or near roads
2.21.9.1 Safety
a) When excavating at or near roads, to protect persons from injury and to avoid
interference with traffic, adequate barricades, construction signs, torches, guards,
flashing lights, etc., as required by the Engineer shall be provided and maintained
during the progress of the construction work (in accordance with the requirements
of the Roads & Transport Authority and Dubai Traffic Police).
b) All materials, stockpiles and equipment shall be placed in such a way that no
obstruction or interference to traffic is made and that these are enclosed by
fences or barricades and protected by lights.
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c) All excavations shall be protected on all sides by an approved temporary yellow

plastic safety fencing, barricades and lights. The yellow plastic safety fencing
shall be manufactured of durable HDP polymer with Ultra Violet stabilizers. The
safety fencing shall be a minimum of 1.0 metre high.
2.21.9.2 Description
a) The Contractor shall make excavations in such a manner and to such minimum
widths as will give adequate room for building the structures or laying and jointing
the piping; shall furnish and place all sheeting, bracing, and supports; shall carry
out all coffer damming, pumping, and draining, and shall render the bottom of the
excavations firm and dry and acceptable in all respects.
b) In no case, except with the approval of the Engineer, shall the earth be ploughed,
scraped, or dug by machinery so near to the finished subgrade as to result in the
disturbance of material below said subgrade, the last of the material to be
excavated shall be removed by hand immediately before the placing of the pipe,
masonry, or other structure.
2.21.9.3 Extent of Open Excavation
The extent of open excavation at any one time will be controlled by the conditions, but
shall always be confined to the limits prescribed by the Engineer.
2.21.9.4 Separation of Surface Materials
a) The Contractor shall remove only as much of any existing pavement as is

necessary for the work. The Engineer may require that the pavement be cut with
pneumatic tools, cold planer, milling machine or the like without extra
compensation to the Contractor, when in the opinion of the Engineer it is
necessary to prevent damage to the remaining road surface. Where pavement is
removed in large pieces, it shall be disposed of before proceeding with the
excavation.
b) From areas within which excavations are to be made, loam and topsoil shall be
carefully removed and separately stored to be used again as directed, or if the
Contractor prefers not to separate surface materials, he shall furnish, as directed,
loam and topsoil at least equal in quantity and quality to that excavated at no cost
to the Works.
2.21.9.5 Sheeting and Bracing
a) In addition to the general requirements of Clause 2.21.6 the Contractor shall

furnish, put in place, and maintain such sheeting, bracing, etc., as may be
necessary to support the sides of the excavation and to prevent any movement of
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earth from beneath the adjacent road surface which could in any way diminish the
width of the excavation to less than that necessary for proper construction, or
could otherwise injure or delay the work, or endanger adjacent road and
structures. If the Engineer is of the opinion that at any point sufficient proper
supports have not been provided, he may order additional supports placed at the
Contractor's expense.
b) For any excavations in or adjacent to roads all trenches must be supported by an

approved method to ensure no settlement of roads either during construction,
when withdrawing supports or thereafter.
2.21.9.6 Bridging Trenches
The Contractor shall, at his own expense, provide suitable and safe bridges and other
crossings where required for the accommodation of travel, and to provide access to
private property during construction, and shall remove said structures thereafter.
2.21.9.7 Road Signs
a) All existing road signs, street name plates and the like affected by the Works are
to be carefully taken down and stored.
b) Signs to be re-erected shall be cleaned, provided with new fixings where

necessary and the posts repainted as required.
c) Redundant signs shall be transported to the stores or depots of relevant

Authorities.
d) Any sign, street name plate or the like damaged by the Contractor during his
operation shall be repaired or replaced at the Contractor's cost.
2.21.10 Surface condition of excavated area
a) Where concrete is to be placed on an excavated surface other than rock, special

care shall be taken not to disturb the bottom of the excavation. When the nature
or condition of the bearing material upon which concrete is to be placed is
determined to be such that the use of heavy excavating equipment will reduce the
stability of the soil, the final half meter of excavation to grade shall be performed
either by means of light equipment or by hand labour methods.
b) Where rock, in either ledge or boulder formation or other unyielding material, is

encountered in one portion of structural excavation for a box culvert and yielding
material (with bearing capacity less than 1000 kN/m2 - determined by appropriate
tests) is encountered in an adjacent area of the structural excavation for the same
box culvert, such unyielding material shall be removed for a minimum depth of
half meter below grade and replaced with special backfill.
c) Where such unyielding material is encountered in excavation other than for box
culverts or where an entire excavation for a box culvert bears on such materials,
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the rock or other unyielding material shall be cleared of all loose fragments and
cut to a firm surface as directed.
d) The placing of concrete shall follow as closely as practicable the structural

excavation.
2.22 PIPELINE TRENCH AND THE RELATED STRUCTURES EXCAVATION
2.22.1 Excavation for Pipelines
a) Trenches for pipes shall be excavated to a sufficient depth and width to enable
the pipe and any specified or agreed joint, bedding, haunching and surrounding to
be accommodated. Trenches shall be of width as specified and as shown on the
drawing.
b) Where rock, in either ledge or boulder formation or other unyielding material is

encountered, such unyielding material shall be removed for a minimum depth of
half metre below grade and replaced with special backfill.
2.22.2 Excavation for Cables/Ducts
a) The Contractor in carrying out excavation for cables/ducts shall, where required,
erect and maintain an approved type of temporary yellow plastic safety fencing
around any work and shall provide fenced access ways across the trenches, for
public access to DM Health & Safety requirements.
b) The bottom of the trench shall be accurately graded. Care shall be taken not to
excavate below the depths indicated. Where rock is encountered, the rock shall
be excavated to the required depth. Uneven surfaces of the bottom of trench shall
be excavated 150 mm deeper. Such depth in rock shall be backfilled with
approved fill material and compacted as specified and/or as directed by the
Engineer.
c) Whenever unsuitable soil is encountered, which in the opinion of the Engineer is

to be removed, it shall be removed to the depth required and the trench backfilled
to the proper grade with approved fill material and compacted.
d) The width and depth of the trenches for electrical and telephone cables/ducts
shall be as specified in the relative drawings or as ordered by the Engineer.
Banks may be sloped or widened to facilitate placement of cables, but not the
extent that will cause interference with other utilities and structures. No battering
of trenches shall be allowed under existing carriageways, unless otherwise
agreed by the Engineer.
2.22.3 Excavated Material for Pipe Trench
a) All excavated material will remain the property of the Employer unless designated
as surplus to the Contract requirements in which case it will be removed from site
immediately.
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b) All excavated material from the pipe trench shall be deposited so that it will cause
as little damage and inconvenience as possible.
c) Excavated material for use as backfill in trenches shall be as approved. Different

classes of material shall be handled and deposited separately.
d) The excavated material, if found unsuitable as trench backfill, shall be removed

from site and shall be replaced with suitable imported backfill to the approval of
the Engineer.
2.22.4 Replacement of Unsuitable Material
Where exceptionally poor ground conditions and unsuitable materials are

encountered at the limits (formation level) shown for structural excavation, the
Contractor shall, at the direction of the Engineer, excavate down to firm ground or
300 mm below formation, whichever is less. The extra excavation shall be backfilled
with either Class C 25/20 concrete or special backfill in accordance with clause 3/8
Section of pavement construction under road specifications( refer Appendix).
2.22.5 Disposal of Material
a) The Contractor shall seek approval for all the proposed disposal sites from the
Dubai Municipality before work commences and disposal at such sites shall be at
no extra cost to the Employer.
b) No excavated material shall be wasted without written permission from the

Engineer, and when such material is to be wasted, it shall be hauled to the
approved tip or as otherwise directed by the Engineer. Excavated materials
wasted by the Contractor without written permission of the Engineer shall be
replaced by the Contractor at his own expense.
c) The Contractor shall adhere rigidly to the requirements of Dubai Municipality

Circulars on the temporary storage and disposal of excavation material. These
include but are not limited to:
(i) All material shall be stockpiled at an approved location and surrounded with
approved barricades. The Contractor shall also display his name and
contact telephone number.
(ii) Certain separate areas will be designated for the disposal of hard debris
such as building rubble, broken concrete, kerbing, road pavement and the
like. The Contractor shall use only these designated areas and shall keep
these disposal areas neat and tidy at all times.
2.22.6 Cofferdams
a) Suitable and practically watertight cofferdams shall be used wherever water

bearing strata are encountered above the elevation of the bottom of the
excavation.
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b) The Contractor shall, on request, submit detailed drawings for approval showing
his proposed method of cofferdam construction and other pertinent features not
shown in detail on the Drawings. No construction shall be started until such
Drawings are approved, however, such approval shall not relieve the Contractor
of any responsibility for the successful completion of the construction.
c) No timber or bracing which will extend into the concrete shall be left in cofferdams
or cribs.
d) Any pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of any portion of the concrete material being
carried away. No pumping will be permitted during the placing of concrete or for a
period of at least 12 hours thereafter, unless it is done from a suitable sump
separated from the concrete work by a watertight wall. Pumping to remove water
from a sealed cofferdam shall not begin until the seal has set sufficiently to
withstand the hydrostatic pressure.
e) Cofferdams or cribs, including all sheeting and bracing, shall be removed by the
Contractor after the completion of the substructure. This removal work shall be
carried out in such a manner as not to disturb or mar the concrete.
2.22.7 Backfilling Pipe Trench Excavations and the Related Structures
2.22.7.1 General
a) Backfilling around structures and in pipe trenches shall be carried out as detailed
below except where otherwise designated/directed.
b) The Contractor shall backfill all excavations in an expeditious manner to minimize

disruption to the general public.
c) Backfilling of trenches other than in roads and paved/tiled areas shall normally be
carried out using selected excavated materials similar to the in-situ materials in
which the trench or structure is being constructed.
d) Special backfill shall be used where designated or directed.
e) Where the excavation is near an existing structure liable to subsidence, where

part of the Works may later be constructed over or near it or in emergencies the
Contractor may be instructed to backfill with concrete.
f) The following test shall be carried out :
Table 2.22-7: Backfill tests

Parameter Standard Limit value
Acid soluble chloride BS 1377: P3 1990 M7.3 2% max

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Parameter Standard Limit value
Acid soluble sulphate BS 1377: P3 1990 M5.5 2% max
Organic matter contents BS 1377: P3 1990 M3 2%max
Carbonate contents BS 1377: P3 1990 M6.3 30 to 40%

AMD 9028:1996
2.22.7.2 Selected Backfill for back filling trench excavation and the related structures
a) Material for backfilling may be selected from any part of the site and methods of
selection may include sieving to remove large particles or methods of hand or
machine sorting together with soil classification and soil property testing.
b) Backfilling with selected material shall be carried out as defined below.
(i) Degree of Compaction Requirements:
In-situ density shall not be less than 95% of the maximum dry density for
depths less than 1.5 m from original ground level or finished formation level.
In-situ density shall not be less than 90% of the maximum dry density for
depths greater than 1.5 m from original ground level or finished formation
level.
(ii) Cohesive Soils
Cohesive soils shall be placed in layers not greater than 150 mm thick
(compacted thickness) and compacted such that throughout each layer
placed the Insitu dry density is not less than 90% or 95% of the maximum
dry density of the soil as determined by BS 1377:Part 4:Test 3.5, as
required.
If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill
in layers of greater thickness, but not exceeding 250 mm, provided the plant
utilised is that used for the trials.
The placement moisture of the soil shall be within the range 2% above to
2% below OMC of the soil.
(iii) Determination of moisture content of Soil – Calcium Carbide (Speedy)

Method:
The moisture content of soil may be determined in the field by the calcium
carbide gas pressure test method (Speedy) in accordance with ASTM
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D4944. All calibration and testing shall be carried out by DM-DCL or a

suitably accredited laboratory in accordance with DM Administrative
Decision No. 160 for 2000.
(iv) Granular Soils
Granular soils shall be placed in layers not greater than 150 mm thick
(compacted thickness) and compacted such that throughout each layer
placed the in situ dry density is not less than 90% or 95% of the maximum
dry density as determined by BS 1377:Part 4:Test 3.5 or 3.6 on the same
soil, as required.
If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill
in layers of greater thickness, but not exceeding 250 mm, providing the
plant utilised is that used for the trials.
Unless otherwise directed the moisture content shall be maintained and if

necessary adjusted by approved means to fall within ±1.5% of the optimum
moisture content.
(v) Testing of Pipe Trench Backfill and the related structures (MH’s , IC’s ,
PSTs etc..)
Tests to determine the optimum dry density of the backfill material shall be
carried out as directed, the frequency depending on consistency of material
and test results. Unless directed otherwise on site testing for density and
moisture content of in situ soils shall be at the minimum rate of :
(1) One test per backfill layer for each structure.
(2) One test per backfill layer for every 30 linear metres of pipeline trench
backfill laid in one operation.
or
(3) Three field density tests for each 900 m² or less.
(vi) Backfill for a Replacement Land Drain
Where a land drain passes through an excavation the backfill shall first be
taken up to form a bed for replacement pipes. The severed drains shall then
be exposed at each side of the trench to allow for connection and laying of a
new drain across the excavation. This new drain shall be of similar pipes of
the same diameter as those in the existing drain. Before any further
backfilling is done the Contractor shall notify the owner or occupier to
enable him to inspect the reinstated land drain. The replacement drain shall
be surrounded with pipe bedding to a minimum thickness 150 mm before
further backfilling.
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Immediately after completion of in-situ-density tests, summary sheets, in an

approved format, are to be updated and original test results submitted.
2.22.7.3 Special Backfill
a) The material used for special backfill shall be obtained from designated and
approved sources.
b) Special backfill complying with the properties of Aggregate Road base Material
specified in Clause 3/8 of Section 3 pavement construction of the
Specifications(refer appendix) shall be placed as fill or backfill in the areas
required and in reasonably close conformity to the lines, grades and dimensions
shown on the Drawings. Special care shall be taken to keep rocks away from
structures.
c) The materials shall be placed in layers of not more than 20 centimetres in depth
before compaction, and each layer shall be compacted by means of mechanical
or pneumatic tamping devices or other suitable equipment to density of at least 95
per cent of the maximum dry density as determined by BS 1377:Part 4:Test 3.6.
The field density test shall be carried out in accordance with BS 1377:Part 9:Test
2.2, as required.
d) Water shall be added to the material, by pre-wetting or by applying uniformly to

each layer, when required for compaction, but only of sufficient quantity to ensure
proper compaction.
e) The layers of material placed around structures shall be placed on opposite sides
to approximately the same elevation at the same time.
f) Special care shall be taken in placing and compacting material under haunches of
all pipe to prevent moving or raising the pipe from its bedding.
g) Material shall not be placed against any concrete abutment, wing wall, retaining
wall, box culvert or similar structure until the concrete has been in place at least
14 days, unless otherwise authorised.
2.22.8 Filter Material
When required, filter material shall be placed in backfilling structures in accordance

with the details shown on the Drawings. Filter material shall conform to the specified
requirements for Fine Aggregate.
2.22.9 Backfilling of Trenches for Cables/Ducts
a) After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer being
well compacted by hand with iron rammers weighing not less than 5 kg, until the
trench has been filled to a height of 300 mm above the top of the cable/duct.

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b) The remainder of the trench shall then be refilled in compacted layers not
exceeding 200 mm in thickness, each layer being well compacted with power
rammers, vibrating plate compactors or other mechanical means of a type to be
approved until the ground is thoroughly consolidated up to the required level for
surface reinstatement. Each layer shall be compacted to 95% of its maximum dry
density. Should the quantity of the excavated materials be not sufficient, due to
unsuitability or otherwise, for the process of backfill and fill, the Contractor shall
obtain the quantity required of such backfill and fill from approved borrow pits and
transport same to the site of work at his own expense.
c) Trenches shall not be backfilled until all required tests are performed and until the
Engineer has verified that the cables, etc., have been installed in accordance with
the Specifications and Drawings.
d) Lumps and clods shall be broken up before use. Materials shall not be dropped
from a height and where directed water shall be added to assist in adequate
consolidation.
e) Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided according
to an approved drawing or as ordered by the Engineer.
2.22.10 Reference Standards
a) Modified AASHTO T180 - Moisture Density Relations of Soils Using a 4.54 kg

Rammer and a 457 mm Drop.
b) ASTM D698 Test Methods for Moisture Density Relations of Soils and Soil
Aggregate Mixtures, Using 2.49 Kg Rammer and 304.8 mm Drop.
c) ASTM D1556 Test Method for Density of Soil in Place by the Sand Cone
Method.
d) ASTM D1557 Test Methods for Moisture Density Relations of Soils and Soil
Aggregate Mixtures Using 4.54 Kg Rammer and 457 mm Drop.
e) ASTM D2167 - Test Method for Density and Unit Weight of Soil in Place by the
Rubber Balloon Method.
f) ASTM D2487 - Classification of Soils for Engineering Purposes.
g) ASTM D2922 - Test Methods for Density of Soil and Soil-Aggregate in Place by
Nuclear Methods (Shallow Depth).
h) ASTM D3017 - Test Method for Moisture Content of Soil and Soil-Aggregate in
Place by Nuclear Methods (Shallow Depth).
i) ASTM D4944

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j) BS1377 – Part 1 to Part 9 Methods of Test for Soils for Civil Engineering
Purposes.
k) Dubai Municipality Specification for Backfilling of Trenches and Excavations in

Asphaltic Roads, Tiled/Paved Parking and Roads.
l) BS 6031:1981 - Code of Practice for Earthworks.
2.23 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT
2.23.1 General
a) Where new pipes, mains, cables/ducts, etc., are to be laid alongside, over or
under the existing, the Contractor shall take care to interfere as little as possible
with the existing services and connections thereto and any damage shall be
repaired by the Contractor to the approval of the appropriate Authority or by
appropriate Authority at the cost of the Contractor.
b) The Contractor shall make all arrangements for protecting existing services and
for temporarily diverting them to maintain the services without interruption.
c) Existing services, pipes, mains, ducts, etc., exposed in trenches for new work
shall be protected in accordance with the requirements of the relevant Authority
before trenches are refilled.
d) The Contractor shall lay cables, fittings, specials, etc., under hedges, fences,
walls, etc., as necessary.
e) Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in an
approved manner and fenced on each side with post and rail stock proof fences
finished on top with one strand of galvanised barbed wire, or otherwise protected
as required by the owners or occupiers and the Engineer.
f) Where fences or walls are damaged or destroyed the whole shall be restored and
reinstated with like materials to the satisfaction of the owners or occupiers and the
Engineer.
g) The Contractor shall ensure that no trees are damaged or permanently removed
in carrying out the Contract except where directed due to the presence of
permanent works.
2.23.2 Reinstatement of Unpaved Land
a) In general the reinstatement of stripped areas of unpaved land shall restore the
ground to a condition not inferior to that which existed before the site was
occupied.
b) The compacted backfill shall be taken up to a level which allows for settlement. In
arable, grassed and similar areas the surface to be top soiled shall then be
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loosened to a depth of 200 mm and topsoil replaced on it to the specified depth

without compaction using approved topsoil of comparable quality to make up any
deficiency.
c) Areas where grass is to be sown shall be worked to a fine tilth, levelled, graded
and rolled with a light roller. The seed shall be sown evenly at the specified rate
of application in the proper season and in suitable weather conditions, and the
areas again rolled. Restoration and re seeding of any areas where the new grass
is inadequate shall be carried out as instructed.
d) As an alternative to seeding the 'dibbing in' at 200 mm centres of 'Bugunda' or

similar tropical grass tufts may be required.
e) The grass shall be well watered four times a day and the Contractor will be
required to keep the grass cut short until the Defects Liability Certificate has been
issued.
2.23.3 Reinstatement within Road Corridors
Trenches and other excavations within road corridors may be opened in four types of
ground:
(1) in paved carriageways
(2) in footpaths and other paved areas (other than carriageways)
(3) in grassed verges and planted areas
(4) in unmade ground which does not fall into any of the above three categories.
In addition there are four classes of carriageway construction as follow:
(5) Estate roads: single carriageway
(6) Main access: single/dual carriageway
(7) Primary distributors
(8) Main arterials/highways, etc.
All reinstatement works falling into the above categories/classes shall be carried out
either in compliance with the current Local Order and any subsequent revision thereof
issued by Dubai Municipality or in compliance with the details shown on the Contract
Drawings, whichever is the greater in either construction depth or asphalt thickness.
2.23.4 Reinstatement of Other Surfaced Areas
Surfaced areas not in road corridors shall be reinstated using materials similar to and
not inferior to those existing prior to commencement of the Works.

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2.23.5 Excavation and Reinstatement in Developed Reservations
The Dubai Municipality Horticulture Section will remove any trees, bushes and plants
from developed reservations that they wish to preserve prior to the commencement of
work by the Contractor. The Contractor must allow in his rates for the removal and
disposal of any remaining trees, bushes and plants necessary for the execution of the
Works and to keep sweet soil separate in accordance with the current Local Order.
The reinstatement of the developed reservation shall be in accordance with Dubai

Municipality’s requirements.
2.24 PROTECTION TO EMBANKMENT SLOPE
This work shall be carried out as specified in CL 5/27, Section of ancillary works
under road specifications ( refer Appendix).
2.25 CEMENT-STABILISED AGGREGATE CAPPING LAYER
This work shall be carried out as specified in CL 5/44, Section of ancillary works
under road specifications ( Refer Appendix).
2.26 BACKFILLING AROUND STRUCTURES
2.26.1 Definition
Principal work in this sub-section includes backfilling around tanks, building

structures, footings or other minor structures.
2.26.2 Backfill
a) All structural backfills shall have uniform moisture content within the range of ±2%
of optimum moisture content (OMC) recorded in the compaction test.
b) Equipment for placing of backfill shall produce the specified compaction, type and
capacities as required and approved by the Engineer.
c) All working areas shall be protected from damage by water.
d) Site drainage shall be maintained at all times
e) Heavy equipment shall not be operated within 1m of any structure
f) Vibration rollers shall not be used within 1.5 m of any structure
g) Vibration rollers weighing in excess of 4 tonnes (gross) shall not be used within
the project work premises.
2.26.3 Backfill Materials
2.26.3.1 Structural Backfill

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a) Selected from locally excavated material or imported borrow material shall

conform to the requirements specified.
b) Shall consist of uniform readily compactible material
c) Free from vegetable matter, building rubbish and frozen material, or materials
susceptible to spontaneous combustion.
d) To be free from plastic fines and weakly cemented lumps of sand.
2.26.3.2 Water
Water used for compacting fill or for washing crushed stone shall be clean and free
from oil, grease, organic matter, suspended fine sediment and other deleterious
substances.
2.26.4 Control of Water
All excavation and construction of structures and backfill shall be carried out in the
dry as described in Section “Earth-works and Site Preparation”.
2.26.5 Inspection by Engineer
As specified in Clause 2/8.6
2.26.6 Backfilling - Placement
a) Earth backfill shall not be placed until the required excavation and foundation
preparation have been completed and the foundation and / or structure to be
backfilled has been inspected and approved by the Engineer.
b) Backfill shall be placed in approximately horizontal layers of thickness that can be

uniformly compacted by the equipment used but of maximum 200 mm loose
thickness.
c) Hand compacted backfill, including backfill compacted by manually directed

power tampers, shall be of maximum 100 mm loose thickness.
d) Backfill adjacent to structures shall be placed in a manner which will prevent

damage to the structures and will allow structures to assume the loads from the
backfill gradually and uniformly.
e) Height of the backfill adjacent to a structure shall be increased at approximately

the same rate on all sides of the structure.
2.26.7 Backfilling - Compaction
Unless otherwise shown on the drawings, backfill shall be compacted using the
minimum 8 passes with a roller to not less than 95% of MDD.
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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 3
CONCRETE WORKS
DM/SRPD Section 3 Concrete Works Rev 00 June

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SECTION 3
CONCRETE WORKS
CONTENTS
3 CONCRETE WORKS ......................................................................................................... 1
3.1 GENERAL...................................................................................................................... 1
3.2 MATERIALS .................................................................................................................. 1
3.2.1 Cement, Cementitious Materials and Aggregates ................................................ 1
3.2.2 Water and Admixtures ........................................................................................ 18
3.2.3 Polypropylene Fibre Mesh Micro-Reinforcement ................................................ 23
3.2.4 Concrete Mixes and Specification ...................................................................... 24
3.3 CONCRETE MIX DESIGN ........................................................................................... 37

3.3.1 General – Samples of Aggregate ....................................................................... 37
3.3.2 Concrete Mix Design Submittal and Method Statement ..................................... 37
3.3.3 Design Mixes for New Batching Installations ...................................................... 41
3.3.4 Trial Mixes for Concrete ...................................................................................... 42
3.3.5 Design Mixes from a Continuing Source ............................................................ 45
3.3.6 Slump, Flow, Temperature and Air Content Testing of Fresh Concrete at Site .. 45
3.3.7 Consistency Testing (Slump & Flow) .................................................................. 48
3.3.8 Durability Tests ................................................................................................... 48
3.3.9 Other Tests ......................................................................................................... 48
3.3.10 Method Statements ............................................................................................. 49
3.3.11 Prescribed Mixes for Minor Works ...................................................................... 49
3.4 PLANT TRIALS WITH APPROVED CONCRETE MIX DESIGN ................................ 50

3.4.1 Quality Control .................................................................................................... 53
3.4.2 Minimum Routine Concrete Testing ................................................................... 59
3.4.3 Routine concrete coring and testing ................................................................... 61
3.4.4 Test on Hardened Concrete ............................................................................... 62
3.4.5 Non – Compliant Concrete ................................................................................. 62
3.5 CONCRETE DESIGN LIMITS ..................................................................................... 63

3.5.1 Limits of Specifications ....................................................................................... 63
3.5.2 Measurement of Ingredients ............................................................................... 64
3.5.3 Making Concrete ................................................................................................. 64
3.5.4 Mixing Concrete at Batching Plant and the Procedure to deliver the Concrete to
Site 66
3.5.5 Waterproof Concrete .......................................................................................... 69
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3.5.6 Self-Compacting Concrete .................................................................................. 71

3.5.7 Precast Concrete ................................................................................................ 74
3.5.8 Under Water Concrete ........................................................................................ 90
3.5.9 Concreting Deep lifts and large Volume Pours ................................................... 94
3.5.10 Cementitious Mortar, Grout & Anchoring System ............................................. 104
3.6 FORMWORK AND CONCRETE PRACTICE ............................................................ 107

3.6.1 Shop Drawing ................................................................................................... 107
3.6.2 Blinding Concrete (Sealing Coats) .................................................................... 108
3.6.3 Design and Construction of Formwork ............................................................. 108
3.6.4 Type of Formwork ............................................................................................. 110
3.6.5 Tolerances and Finishes of Concrete Surfaces ................................................ 111
3.6.6 Tolerances for Unexposed Surfaces ................................................................ 112
3.6.7 Preparation of Formwork for Concreting ........................................................... 112
3.6.8 Approval of Formwork before Concreting ......................................................... 113
3.6.9 Removal of Formwork ....................................................................................... 113
3.6.10 Formation of Holes for Fixing ............................................................................ 113
3.7 BATCHING, TRANSPORTING, PLACING & COMPACTION OF

CONCRETE ............................................................................................................... 113
3.7.1 General ............................................................................................................. 113
3.7.2 Ready Mixed Concrete ..................................................................................... 114
3.7.3 Time of Transport ............................................................................................. 114
3.7.4 Concrete Placement ......................................................................................... 115
3.7.5 Compaction of Concrete ................................................................................... 116
3.7.6 For underwater Concrete .................................................................................. 117
3.7.7 Placing of Concrete in Water (Tremie Concrete) .............................................. 117
3.7.8 Concreting in High Temperatures ..................................................................... 118
3.7.9 Concrete Curing and Protection ....................................................................... 119
3.7.10 Concrete in Adverse Weather ........................................................................... 121
3.7.11 Batching of admixtures ..................................................................................... 121
3.7.12 Concreting at Night ........................................................................................... 121
3.7.13 Striking Formwork ............................................................................................. 121
3.7.14 Re-use of Formwork ......................................................................................... 123
3.8 GRANOLITHIC CONCRETE SCREEDS TO FLOORS, SURFACINGS,

BENCHINGS AND CHANNELS ................................................................................ 123
3.8.2 Inspection of Concrete ...................................................................................... 124
3.8.3 Repairs to Concrete .......................................................................................... 124
3.8.4 Supervision of Concrete Work .......................................................................... 124
3.8.5 Cracks in Concrete Structures .......................................................................... 124
3.8.6 Quality of Finish ................................................................................................ 124
3.8.7 Classes of Finish Formed Surfaces .................................................................. 125
3.8.8 Classes of Finish Unformed Surfaces .............................................................. 125
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3.8.9 Defective Concrete ........................................................................................... 126

3.8.10 Concrete Surface Repairs ................................................................................ 127
3.9 JOINTS IN CONCRETE STRUCTURES ................................................................... 129

3.9.1 Construction Joints ........................................................................................... 129
3.9.2 Movement Joints ............................................................................................... 132
3.9.3 Expansion Joints ............................................................................................... 132
3.9.4 Water Bars ........................................................................................................ 132
3.9.5 Bond Breakers .................................................................................................. 136
3.9.6 Joint Fillers for Expansion Joints of Water Retaining Structures ...................... 137
3.9.7 Expansion Joint Filler for Precast Units ............................................................ 137
3.9.8 Submittals for Sealants ..................................................................................... 137
3.9.9 Environmental Conditions ................................................................................. 138
3.9.10 Pre-Installation Meeting .................................................................................... 138
3.9.11 Sample Application ........................................................................................... 139
3.9.12 Delivery, Storage and Handling ........................................................................ 139
3.9.13 Materials - General ........................................................................................... 139
3.9.14 Types of Area and application other than Water Retaining Structures ............. 141
3.9.15 Joint Sealing in water retaining Structures ....................................................... 145
3.9.16 BOND BREAKING COMPOUND FOR DOWEL BARS .................................... 146
3.9.17 Expansion Joint Sealing Compound ................................................................. 146
3.9.18 Properties of Sealant to fix GRP MH Liners...................................................... 148
3.9.19 Dowel Bars ....................................................................................................... 149
3.9.20 Bond Breaker Tape ........................................................................................... 149
3.9.21 Sealing Strip Membrane Based On Hypalon-Elastomer ................................... 149
3.9.22 Slip Membrane and Installation ........................................................................ 150
3.10 REINFORCEMENT STEEL ....................................................................................... 150

3.10.1 General ............................................................................................................. 150
3.10.2 Material Specifications ...................................................................................... 151
3.10.3 Testing of Reinforced Steel .............................................................................. 154
3.10.4 Construction of Reinforcement ......................................................................... 155
3.10.5 Placing Reinforcement ...................................................................................... 157
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3 CONCRETE WORKS
3.1 GENERAL
The applicable standards for all concrete work shall be BS EN 1992-1-1:2004, BS

8500 – 1 & 2: 2006 with amendment No. BSEN 206 –1, BRE Special Digest No.1:
2003 and CIRIA guide to Concrete Construction in the Gulf Region. Concrete for
water retaining structures shall be as per BS EN 1992-3:2006.
Concrete work shall consist of furnishing all materials and constructing structures of
the forms, shapes and dimensions shown on the Drawings or as directed, using
Portland Cement concrete, in accordance with the details shown on the Drawings
and these Specifications.
Portland cement concrete shall consist of a mixture of Portland Cement, fine

aggregate, coarse aggregate, water and additives when required. The mixture shall
be proportioned, mixed, placed and cured in accordance with the requirements of BS
EN 1992-1-1:2004. Where an additional clause conflicts or is inconsistent with the
requirements of BS EN 1992-1-1:2004, the additional clause shall always prevail. The
concrete mixes shall be designed mixes for special or ordinary concrete as defined in
the above standards, the design requirements of which are laid down in this
Specification.
3.2 MATERIALS
3.2.1 Cement, Cementitious Materials and Aggregates
3.2.1.1 Portland Cement
Suitable type of cement shall be used in conformity with the above relevant
applicable standards, and DM administrative note no: 01/1990.
The choice of cement type to be used for underground structures shall depend on the
classifications of soils for chemicals aggressive to concrete. The tenderer shall verify
the characteristics of different types of Portland cement and blended cements and
consider in his offer the usage of OPC/SRPC/MSRPC/Blended cement with mineral
additions may be required for underground /above ground structures. For above
ground structures normal OPC made to BS 12 shall be used.
3.2.1.2 Ordinary Portland Cement
Ordinary Portland Cement (OPC) shall comply with BS EN 197-1:2000 (Strength

Class 42.5N or ASTM C150 Type 1). The tri-calcium aluminate content shall lie within
the range of 4% to 13% when tested as per BS EN 196:2 (2005).
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3.2.1.3 Sulphate Resisting Cement
Sulphate Resisting Cement (SRPC) shall comply with BS 4027: 1996 or ASTM C150
Type V (Strength Class 42.5N). The limit for tri-calcium aluminate content is 3.5%
max. when tested according to the test method BS EN 196: Part 2 (2005).
3.2.1.4 Moderate Sulphate Resisting Cement
Moderate sulphate resisting cement (MSRPC) shall comply with ASTM C-150 type 2
1990 Strength class 42.5 N. The tri-calcium aluminate content shall be within the
range 4% - 8% when tested according to the test method BS EN 196: Part 2: 2005.
3.2.1.5 Cementitious Materials
Cement plus ‘GGBS’ or cement plus ‘GGBS’ plus microsilica fume or cement with
water proof powder plus admixture.
Combinations manufactured in the concrete mixer from Portland cement to BS EN

197-1:2000 and ground granulated blast furnace slag (GGBS).
a) The ‘GGBS’ shall comply with BS EN 15167 part1 & 2 : 2006 , in addition to the
following requirements, unless otherwise approved by the Engineer.
(i) Raw material (slag) is limited to one source. Slag supplied or blended from
several different plants or steel mills will not be accepted unless approved
by the engineer.
(ii) ‘GGBS’ shall be supplied to the concrete batching plant in bulk powder
form.
(iii) Inter-ground slag cements shall not be used.
(iv) Pre-blended slag cements shall not be used.
b) The combination proportion shall not exceed 50% slag by mass of nucleus. Slag
with Al2O3 content over 14% shall be used only with Portland cement having C3A
content less than 10% i.e. SRPC or MSRPC.
[OR]
c) Combinations manufactured in the concrete mixer from Portland cement made to

BS EN 197-1:2000 or BS 4027 and the concentrated water proofing (CWP)
powder approved by BSI or equivalent.
d) C.W.P Powder shall be a multi-component waterproofing, plasticising,

permeability reducing, corrosion inhibiting hydrophobic admixture approved by
BSI or equivalent. The system produces concrete with enhanced durability and
improved protection against reinforcement by minimising the water/cement ratio
of the concrete mix resulting in the reduction of the capillary network of the cured
concrete and providing hydrophobic action that protects resulting concrete against
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water ingress in absorption or hydrostatic pressure. CWP powder shall be

compatible with all types of cement for making water proof concrete.
[OR]
a) Combinations manufactured in the concrete mixer from Portland cement made to

BS EN 197-1:2000 / BS 4027 and microsilica (MS) conforming to ASTM C1240.
b) Microsilica shall comply with an internationally recognised standard, in addition to

the following requirements, unless otherwise approved by the Engineer.
(i) Raw material (Microsilica) is limited to one source. Microsilica supplied by

more than one vendor will not be accepted, unless approved by the
Engineer.
(ii) Microsilica shall be supplied to the concrete bacthing plant in bulk powder
form.
c) The percentage addition of microsilica shall not exceed 10% by weight of the
Cementitious materials.
NOTE: The performance of the above blended cements has not yet been
evaluated in the environment of the Gulf region. Therefore the usage of blended
cement with mineral additions will require written approval of the Engineer who must
be satisfied that proposed blended cements are suitable for the intended use and the
concrete production plant technical supervision at site, testing and quality control
facilities to be of an exceptionally high standard.
3.2.1.6 Conformity procedure for Combination of Cementitious Materials
a) Suitability of specific source of addition and limits on the proportions of additions

to be used in combination with specific source of Portland cement shall be
established so as to ensure the conformity criteria for strength classes are met.
b) The Contractor shall undertake the procedures set out in Annex A of BS 8500 – 2:
2006 and declare the conformity of combination to count fully towards the cement
content and strength class 42.5 N. A third party certification with test data for the
proportions selected in the mix is required to justify the strength class of blended
cement.
c) Cement shall be certified by the manufacturer as complying with the requirements

of the relevant BS or appropriate standards. Before ordering cement, the
contractor shall submit details of proposed supplier and information on the
proposed methods of transport, storage and certification for approval and show
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that the quantity and quality required can be attained and maintained through the
construction period.
d) Representative samples of the proposed cement to be taken and forwarded to an

independent laboratory approved by the Engineer for analysis before the source
is approved.
e) Locally produced ‘GGBS’ and ‘microsilica’ produced as a separate material stored

in silos and handled in a similar manner to cement only will be permitted.
f) Having obtained approval, the Contractor shall not change the agreed
arrangements without permission.
g) Each consignment of cement shall be accompanied by a certificate showing the

place of manufacture and the results of standard tests carried out on each day’s
bulk production and also at monthly intervals during storage.
Table 3.1: Characteristics of different types of Portland and blended cement

Type of Cement Relevant Resistance to Chemical Protection of Rate of gain of
Specification Sulphate attack reinforcement strength and rate of
against chloride – heat evolution
induced corrosion
Portland cement BS 12 Not resistant: aggregates The protection given Taken as ‘normal’ for
or ASTM Type 1 should be virtually free by this cement is comparative purposes
ASTM C 150 from sulphates and taken as ‘normal’ for
concrete should be comparative
isolated from purposes.
groundwater.
ASTM Type II ASTM C150 Partially resistant If this cement Lower than Portland
contains 5% or more cement
(no BS equivalent) of C3A it may give
near normal
protection
Rapid- hardening BS 12 ASTM Same as Portland Same as Portland Hydration usually too
Portland cement C150 cement cement rapid for use in hot
or ASTM climates
Low-heat Portland BS 1370 May be more resistant Less than normal if Lower rate of heat
cement or ASTM ASTM C 150 than Portland cement if C3A content is lower evolution, strength gain
Type IV C3A content is lower, but than that of Portland and lower final strength
the specification does not cement than Portland cement
guarantee this.
Sulphate- resisting BS 4027 Moderately resistant This cement contains Lower rate of heat
Portland cement ASTM C150 little or no C3A and evolution and strength
or ASTM Type V gives significantly gain than Portland
less protection cement or Type I, but
against chloride – usually not as low as
induced corrosion low-heat Portland

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Type of Cement Relevant Resistance to Chemical Protection of Rate of gain of

Specification Sulphate attack reinforcement strength and rate of
against chloride – heat evolution
induced corrosion
than Portland cement cement or ASTM Type

or ASTM Types I or II IV
High slag blast BS EN 197- Properties vary but Low permeability to Gains strength slower
furnace cement 4:2011 sulphate resistance will chloride and high but continues to gain
be equivalent to Type V binding capacity strength at later ages.
or SRPC if 70% or more Low heat evolution
GGBS is used equivalent or lower than
low-heat Portland
cement Type IV
depending on GGBS
content.
Portland blast BS EN 197- Properties vary, but Good Impermeability Gains strength and
furnace cement 4:2011 sulphate resistance could to chloride evolves heat more
and low-heat be equal to or better than penetration and slowly than Portland
Portland blast ASTM Type II binding capacity cement but not as
furnace cement depending on GGBS slowly as low-heat
content Portland cement or
ASTM Type IV, unless
made to a low-heat
specification
Other cements The properties of these cements depend on the materials they are made from and on the
containing GGBS proportions of GGBS or Pozzolana incorporated in them.
or Pozzolana
incorporated in the
cement during
manufacture.
Unless otherwise approved by the Engineer all cements shall comply with the
following requirements:
h) The strength class of cement or blended cement shall not be lower than 42.5 N
(L.A)
i) The chloride content of cement shall not exceed 0.10% by weight when tested in
accordance with BS EN 196: Part 2 (2005)
j) The heat of hydration at 7 days shall not exceed 290KJ/kg when tested in
accordance with BS 4550: Part 3, Section 3.8.
k) The cement shall be low alkali type having a total acid soluble alkali level
measured as Na2O + 0.658 K2O shall not exceed 0.6% by weight determined by
the test method described in BS EN 196: Part 2: 2005.

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l) The specific surface (fineness) shall not be greater than 375 m²/kg and not less
than 280 m²/kg when tested in accordance with BS EN 196-6: 2010.
m) The temperature of cement at the time it is added into the Concrete shall not
exceed 75C.
n) The contractor shall complete a Technical Schedule for each proposed source
and type of cement. The information in this schedule shall be provided for every
proposed manufacturer’s works likely to supply cement. Preliminary and
secondary sources of the required cements shall be proposed and only an
approved source shall be brought onto the site.
o) The cement shall be of approved manufacture and shall be delivered in bags with
seals unbroken, or delivered in bulk in approved containers which shall bear the
manufacture’s name, cement type and the date of manufacture. Test certificates
from the manufacturer or supplier shall be submitted for each consignment and
shall indicate the result of the tests for compressive strength, setting time,
soundness and fineness etc. carried out in accordance with the requirements of
the relevant BS or ASTM standards. Further tests may be required by the
Engineer after the cement is delivered and stored on the site. The failure of any
sample to satisfy the BS or ASTM requirements shall entitle the Engineer to reject
the entire consignment from which it was taken.
p) Cement shall be stored immediately upon receipt at site in such a way to keep it
away from water and moisture at all times. The Contractor shall provide a method
statement for the storage of cement which shall be approved and implemented
before any cement is delivered to site.
q) Cement consignments shall be used in the order in which they were delivered.
Any consignment not used within 2 months from the date of manufacture will not
be allowed to be used in the Works.
r) No cement from any consignment shall be used in permanent works without the
approval of the Engineer. Cement which the Engineer considers to have
deteriorated in any way shall not be used and shall be removed from site without
delay.
s) One brand of cement as approved by the Engineer shall be used throughout the
Works unless otherwise authorised by the Engineer in writing. Differing types of
brands shall not be mixed together for use in the Works.
t) The type of cement required for each structure will normally be stipulated
elsewhere in the Contract Documents. Where no such stipulation exists, and
unless otherwise directed by the Engineer, cement shall be used as follows:
(i) Ordinary Portland cement for reinforced concrete above ground level.

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(ii) Sulphate resisting Portland cement for reinforced concrete below ground
level and for unreinforced concrete.
(iii) Moderately sulphate resisting Portland cement, where there is considered

by the Engineer to be a risk of both chloride and sulphate attack.
u) Samples of cement shall be taken in the presence of the Engineer on request, for
testing in an approved independent laboratory and the Engineer shall have
access to cement store at all reasonable hours.
3.2.1.7 Testing Cement
The contractor shall store the cement so that separate consignments can be identified
until the results of the testing are available. Tests should be carried out for the
properties listed in the following table with test methods and limits to BS or ASTM as
appropriate:
Table 3.2: Properties of Cement

Property Test method Permissible Limits
Sampling BS EN 196-1 :
2005
Type of Cement BS 1881 : P 124 SRC MSRPC OPC
Strength @ 28 BSEN 196 : Part > 42.5N >42.5N 42.5N

days 1:2005
Fineness BSEN 196 : Part 280-375 280-375 280-375

6:2010 m²/kg m²/kg m²/kg
Heat of Hydration BS 4550: P3 : 290 KJ/kg as 290 KJ/kg as 290 KJ/kg as

Section 3-8:1978 per Spec: per Spec per per Spec
requirement requirement requirement
Setting Time BSEN 196 : Part As per As per As per

3:2005 +A1:2008 standard standard standard
requirement requirement requirement
Soundness Ditto Ditto Ditto Ditto
Reactive Alkali BSEN 196: Part  0.60%  0.6%  0.6%

Level as Na2O 2: 2005
Equivalent

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Property Test method Permissible Limits
Chloride Content BSEN 196: Part  0.10%  0.10%  0.1%

2: 2005 CL: 14
Loss on Ignition BSEN 196 : Part As per As per As per

2 : 2005 Standard Standard Standard
Requirement Requirement Requirement
Insoluble Residue BSEN 196 : Part As per As per As per

2 : 2005 Standard Standard Standard
Requirement Requirement Requirement
Tri-calcium BSEN 196 : Part 3.5% Maxi: 4 – 8% 4-13%

Aluminate 2 :2005
Content
SiO2, MgO, BSEN 196 : Part As per As per As per

A12O3, Fe2O3, 2: 2005 Standard Standard Standard
contents Requirement Requirement Requirement
SO3 BSEN 196 : Part <2.5 <3 <3.5

2 :2005
3.2.1.8 Aggregates for Concrete
(1)Aggregate Sources
Primary and secondary sources of both coarse and fine aggregate shall be proposed.
In assessing the Contractor’s request for approval to a proposed source of aggregate

the Engineer will normally require to:
a) Accompany the Contractor to the source for examination of the types of deposit
and the methods of extraction, stockpiling, loading and quality control.
b) Supervise the sampling of aggregates both at the point of production and at the
stockpiles.
c) Inspect test report of physical, chemical, aggregate carbonate range and

petrological analyses of the samples carried out by an approved independent
laboratory.
d) In order to reduce the ‘THAUMASITE form of Sulphate Attack’ (TSA) on below

ground concrete, the coarse and fine aggregate containing certain Dolomitic

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(Calcium Carbonate) or Dolomite (Magnesium Carbonate) type of limestone

aggregates shall not be incorporated in the proposed concrete mix design.
e) Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall also not to be
used.
The concrete producer shall assess the carbonate range of the proposed aggregate
combination by test as specified in BRE Special Digest No. 1: 2003, Part 2: Cl 2.2
and App.3 Cl. A-3.1 and confirm that the source and type of aggregate are well within
the restricted ‘ACR’ (Aggregate Carbonate Range) levels specified in Table 4 of BRE
Digest No.1, Part 3.
(2)Aggregates – General Requirements
a) Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS EN 12620:2002 + A1 :2008
and BSEN 13055-1 “Concrete aggregates from natural sources” and the fine
aggregate shall also comply with Dubai Municipality Administrative Order No.
143/91.
b) The aggregates used in the permanent works shall be naturally occurring or

crushed materials obtained only from approved sources.
c) Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the
necessary tests and analysis to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.
d) The results of these tests etc shall be submitted to the Engineer and his approval
shall be obtained before any of the material is used in the works. Part of each
sample will be required for concrete trial mixes and part shall be retained for
comparison with subsequent deliveries.
e) Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS EN 932-1:1997.
f) The maximum size of the aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the member for which the concrete is to be used and
not larger than 3/4 of the maximum clear distance between reinforcing bars.
g) Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
h) Coarse aggregate shall be crushed aggregate obtained from a quarry approved

by the Engineer.

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i) Unless otherwise authorised by the Engineer coarse aggregate shall be delivered

to site in separate sizes according to the maximum specified aggregate size for
each grade of concrete.
j) Aggregates shall meet the requirements of Table 3.3
k) The frequency of testing of aggregates shall be in accordance with Table 3.4 or

as directed by the Engineer.
(3)Aggregates – Sampling and Testing
a) When an aggregate source has been approved, representative samples shall be

taken of each aggregate type and retained on site for reference purposes by both
the Engineer and the Contractor.
b) Fresh samples shall be taken and be analysed regularly throughout the Contract
Period to demonstrate consistency of quality and of gradings. The frequency of
such sampling will be dependent on the continued adequacy of the samples as
demonstrated by the results of the analysis, but shall be not less than the
frequency test period specified.
c) Aggregates shall be hard, strong and durable and shall contain no harmful
material that will adversely affect the strength and durability of the concrete or
attack steel reinforcement.
d) Aggregates shall not be composed of or contain any inclusions of materials likely

to cause staining or otherwise to disfigure finished concrete surfaces.
e) The properties of the aggregates shall be such that the drying shrinkage when
prepared and tested in an approved laboratory shall not exceed 0.045% and the
limit specified in clause 5.7.2 of BS EN 12620 unless the Engineer relaxes this
requirement to suit local supply constraints. It should be noted that this test
involves a testing period of about eight weeks.
f) Aggregates for use in concrete or mortar that will be subject to wetting, extended
exposure to humid atmosphere, or contact with moist ground shall be examined
for constituents which may be potentially reactive with alkalis. If accelerated tests
indicate that reactivity is likely then testing shall be extended to the Mortar Bar
Test (which can take in excess of six months to complete) unless the Contractor
proposes an alternative source of aggregate.
g) If such constituents are present in a proposed aggregate the Contractor shall

arrange for the necessary testing to assess total acid ,soluble alkali contents from
all sources. These shall include: the cement; the mixing water; water which will be
in contact with the concrete or mortar; and those additionally present in the
aggregates.
DM/SRPD Section 3 Concrete Works Rev 00 June Page 10 of

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h) The Engineer will then assess the risks of localised or general, long term
expansion of the concrete and will give a ruling as to whether the aggregate
source should be rejected or whether the aggregate may be used with low alkali
cement.
(The Tenderer should note that past tests on aggregate from the Siji area have not
complied with the shrinkage limit of 0.045% stated above).
(4) Fine Aggregates
a) Except where otherwise approved on the basis of evidence of acceptable

performance in concrete the grading of a fine aggregate, or of a combined fine
aggregate, shall comply with the limits in the approved standard.
b) Fine aggregates shall be natural sand, manufactured crushed rock sand, or a

combination of both. The Contractor shall note that the term 'manufactured
crushed rock sand' does not include crushed rock fines which are by-products of
coarse aggregate production. A combination of natural sand and manufactured
crushed rock sand will only be permitted where the two materials are separately
batched and where each material separately complies with the requirements of
this Specification. In addition the evidence of full scale comparative site trials shall
clearly demonstrate that a combined fine aggregate provides improved concretes
in relation to the use of either material as a sole fine aggregate.
c) The organic content of fine aggregate shall be determined in accordance with an

approved standard test procedure. The Engineer will decide on the basis of trial
mixes whether failures to meet the limits of the approved standard are sufficient
grounds to reject the sample.
(5)Aggregates used for Granolithic Concrete
Aggregates for granolithic concrete shall be selected for hardness, surface texture
and particle shape as being suitable for use as a wearing finish and shall consist of
crushed rock which exhibits a 10% fines value of not less than 250 kN. They shall not
contain deleterious substances such as clay, flaky, elongated or laminated particles,
coal or other inorganic impurities, iron pyrites or soluble salts.
(6)Aggregate Grading
i. Fine Aggregates for Concrete
Fine aggregate shall be clean sharp natural and / or crushed sand and shall be within
BS EN 12620:2002+A1:2008 zones ‘C’ and ‘M’ only.

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The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified. Each batch of aggregate
delivered to site shall be kept separate from previous batches and shall be stored for
at least 3 (three) working days before use to allow inspection and tests to be carried
out.
ii. Coarse Aggregates for Concrete
Coarse Aggregate shall be crushed rock prepared as single sized aggregate and
blended to produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS EN 12620:2002+A1:2008.
iii. All-in Aggregates for Concrete
a) Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions as specified in BS EN 12620:2002+A1:2008 .
b) The combined aggregate gradation used in the work shall be as specified, except
when otherwise approved or directed by the Engineer. Changes from gradation to
another shall not be made during progress of the work unless approved by the
Engineer.
c) All aggregates shall be produced to the grading limits in the approved standard.
d) Grading shall be consistent for all deliveries and the proportion of coarse and fine
aggregate shall be selected to comply with the requirements of Clause 3.2.1.8
(Aggregate for Concrete).
e) The coarse aggregate shall be graded to the larger aggregate from 20 mm to 4

mm.
f) For blinding grade and mass concrete the coarse aggregate may be either an all-
in grading or a combination of single size grading.
g) For granolithic concrete the aggregate shall be produced by combining coarse

and fine grading for use for floors but all-in aggregate may be permitted for
benching.
Table 3.3: Limits for Physical, Chemical and Mechanical Properties of

Aggregates for Concrete
Sr. Requirement Test Methods Permissible Limits
BS / ASTM Fines Coarse
1. Moisture content in BS 812: Part 109 Standard Standard

coarse and fine aggregate

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2. Grading BS EN 933-1 :2012 Standard Standard

(dry)
3. Loose bulk density & BSEN 1097-3 Standard Standard

voids
4. Material finer than 0.063 BS EN 933-1 :2012 Max. 3% Max. 1%

mm - natural, uncrushed. (wet) (Natural)
Crushed rock ,, Max 7% Max 1%
5. Clay lumps and friable ASTM C142:1997 Max 1% Max 1%

particles
6. Light weight pieces ASTM C123 Max 0.5% Max 0.5%
7. Organic impurities for fine ASTM C40: 1999 The colour of the N/A
aggregate supernatant
liquid is lighter
than standard
colour solution.
8. Water absorption ASTM C128: 2001 Max 2.3% Max 2%
ASTM C127: 2001
9. Specific gravity ASTM C128:2001 Min 2.6 Min 2.6
ASTM C127: 2001
10. Shell content in BS EN 933-7:1988 Note 1

aggregates:
Coarser than 10 mm
Max 5%
11. Particle shape:
Flakiness index BS812: Part 105.1 N/A Max 25
or BSEN 933-
3:2012
Elongation index

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BS812: Part 105.2 Max 25
The index shall be max.

25 for combined
aggregates but should not
exceed more than 30 for
individual sizes.
Partially crushed faces of DMS 8: 2001 N/A 100%

coarse aggregate shall be
100% with at least one
crushed face.
12. Acid Soluble Chlorides, Cl
For reinforced concrete BSEN 1744-1: 2009

made with
SRPC cements Max: 0.03% Max

0.01%
OPC & MSRPC cements Max: 0.03% Max

0.02%
For mass concrete made
with SRPC cements Max: 0.03% Max

0.02%
OPC & MSRPC cements Max: 0.03% Max

0.04%
For pre-stressed concrete Max: 0.03% Max

and steam cured 0.01%

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structural concrete
13. Acid Soluble Sulphates, BSEN 1744-1: 2009 Max: 0.3% Max
SO3 0.30%
14. Acid soluble material in BS812: Part 119 N/A

fine aggregate
15. Soundness, MgSO4 (5 ASTM C88:1999 or Max 12% Max 12%

cycles) BSEN1367-2
16. Mechanical Strength
10% fines value or BS812 Part 111 N/A Min 150

KN
Impact value BS812 Part 112 N/A
Max 30%
Los Angeles Abrasion ASTM C131:2001 N/A

Max 30%
ASTM
C535: 2001
17. Drying Shrinkage BS812 or N/A Max

0.045%
BSEN 1367-4
18. Potential reactivity
Note 2
Of Aggregates, chemical ASTM C289 Innocuous Innocuous

method of cement
aggregate combination
ASTM C227 6 month
expansion 0.10%
max
19. Alkali content of BSEN 1744 1:2009

aggregates Na2O Eq.

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20. Aggregate Carbonate BRE Special Min : 0 Min : 0

range CaCO3 equivalent Digest No.1 & 2,
Max: 2 Max :12
2.2 and App:3 Cl
A-3.1
BS812: P102 Cl 5 Both
coarse and
BS812: P104:1994 fine
BSEN196-2:2005 & fraction
BSEN 932-1 combined
Min: 0
Max 2-
12%
Or Carbonate content by BS EN 12620:2002

petrographic procedures + A1 :2008
as optional
BS812 P104:1994
Notes:
1. There is no requirement of shell content in sands passing 5 mm sieve size.
2. Aggregates may initially be assessed for its reactivity in accordance with ASTM C289 and if potential
reactivity is indicated, then mortar bar tests in accordance with ASTM C227 shall be carried out.
Table 3.4: Frequency of Routine Tests on Aggregates

Sr. Kind of Requirement / Test Method Test Frequency Rate
1. Grading – BS 812: 1990 P103 / BS EN 12620 Per 1000m³
2. Moisture content in coarse and fine aggregate (by Daily – for fine aggregate
micro-oven dry method) or speedy moisture test Daily - if coarse aggregates
method are wet.
3. Material finer than 0.063 mm – BS 812: 1989 1000 m³

P103.1 / BS EN 12620
4. Clay lumps and Friable particles – ASTM C142 Per 4000 m³

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5. Organic impurities ASTM C 40:1999 Per 2000 m³
6. Water absorption ASTM C128: 2001/C127:2001 Ditto
7. Specific Gravity – ASTM C128: 2001/C127: 2001 Ditto
8. Shell content – BS EN 933-7:1988 / BS EN 12620 Ditto
9. Particle shape BS 812: 1990 P 105.1 Ditto
10. Acid soluble Chlorides, Cl
Qualitative – BS EN 1744-1:2009 / BS EN 12620 Per 1000 m³
Quantitative – BS EN 1744-1:2009 / BS EN 12620 Each 12 concrete days if

result is more than 75% of
the limit and each month if
result is less than 75% of the
limit.
11. Acid soluble sulphates Per 1000 m³ or each 24

concrete days if result is
S03 – – BS EN 1744-1:2009/ BS EN 12620 more than 75% of the limit
and each 2 months if result
is less than 75% of the limit
whichever is less.
12. Soundness, Mg S04 (5 cycles) ASTM C88: 1999 Each 48 concrete days or
4000m³
10% fines or impact value BS 812 Parts 111, 112 Each 72 concrete days or
6000m³
Ditto
Los Angeles Abrasion – ASTM C131/C535
14. Moisture variation in sand by moisture meters Twice daily

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15. Drying shrinkage BS EN 1367-4:2008 At the start of the project and

whenever there is a change
in the source of supply.
16. Potential Reactivity of aggregates (ASTM C295, At the start of the project and
C298) whenever there is a change
in the source of supply.
Of Carbonate (ASTM C586)
Of Cement aggregate combination (ASTM P214

and C227)
17. Aggregate carbonate range CaCO3 equivalent Ditto
Note: Drying shrinkage, potential reactivity of aggregates and the carbonate range shall be determined
initially at the start of the project or whenever there is a change in the source of supply.
3.2.1.9 Grading of Aggregates
Fine / coarse aggregate for concrete shall conform to the gradings as per BS EN
12620:2002+A1:2008 & tested as per BS EN 933-1:2012.
3.2.2 Water and Admixtures
3.2.2.1 Water - General
a) Water for washing aggregate and for mixing or curing of concrete shall be fresh,
clean and substantially free from oil, acids, alkali, sewage, deleterious mineral or
organic matter. Water shall comply in all respects with BS 3148 or BSEN 1008. It
shall not contain impurities in sufficient amounts to cause discoloration of the
concrete.
b) Water used for concrete mixes, washing aggregates and washing of equivalent
shall be potable water and shall comply with the requirements specified unless
otherwise stated herein or in Table 3.5. The pH of water used in concrete work
shall be in the range of 7 – 9. Ice if used, shall be flake ice and shall be the
product of frozen water which complies with the acceptance criteria of Table 3.5
unless otherwise accepted by the Engineer. Every effort should be made to
protect water pipes and tanks from the sun, by burying, sharing, insulation and /
or painting white. The Contractor shall make his own arrangements and obtain
approval for the supply of water. Whenever required to do so by the Engineer, the
Contractor shall take samples of the water being used for mixing concrete and

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test them for quality as directed by the Engineer. No source of water shall be
used unless approved by the Engineer.
Table 3.5: Chemical Limitations for Mixing Water

Sr. Maximum Concentration Test Method Limit (mg/l)
1 Chloride (as Cl) ASTM D512:1989 or BSEN 196- 250

2 : 2005
2 Sulphates as SO4 ASTM D516:2002 350
3 Alkali carbonates and ASTM 513 or BS 1377: P3:1990 500

bicarbonates
4 Total Dissolved ions, ASTM D1888 or BS 1377: 2000

including 1, 2 & 3 above P3:1990
5 pH ASTM D1293:1999 Min 7/max 9
3.2.2.2 Minimum Test Requirements for Cement & Water for Concrete
a) Portland Cement: One 2 kg sample for quality test shall be taken from each 1700
bags or equivalent weight in accordance with BSEN 196-7.
b) Water: One 1-gallon sample shall be obtained prior to use from each source and
at least once every week for quality testing.
c) Monthly strength test on blended cement with cementitious material in

accordance with BS EN 196-1 and establish the strength criteria achieved
throughout the contract period.
3.2.2.3 Admixtures
Admixtures shall comply with one of the following standards, unless otherwise
a) ASTM C494, ASTM C260, ASTM C1017: as applicable
The Contractor shall provide at least the following technical data for each type of
admixture.
(i) Solid content
(ii) Specific gravity
(iii) The typical dosage and the effects of under dosage and over dosage.

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(iv) The generic type(s) of the main active constituent(s) in the admixture
(v) Whether or not the admixture contains chloride
(vi) Whether or not the admixture leads to the entrainment of air when used at
the proposed dosage.
(vii) Where more than one admixture is used simultaneously in the same
concrete, details shall be provided on their interaction and compatibility.
When admixtures are used in the Works very strict control is to be maintained to
ensure that the correct quantity of admixture is used at all times. The equipment
to be used for dispensing and the method of incorporating the admixture in the
concrete shall be to the approval of the Engineer. The dispensing unit shall be
translucent such that the operator can see the discharge of the admixture.
Where approved or specified air entrainment agents, admixtures, waterproof

powder or microsilica shall be used as a means of:
 Increased workability of the concrete without increasing water/cement

contents
 Controlled and limited retardation of setting
 Increasing concrete durability
 Reducing bleeding and associated settlement and cracking
 Increasing water proof properties
 Reducing heat of hydration
 Reducing water permeability

b) Hydrophobic Pore Blocking Admixture
Where directed by the Engineer a hydrophobic pore blocking admixture based on

Ammonium Stearates and Hydrocarbon Resin shall be used at no additional cost
to the Employer.
(i) Admixture is to be added at a rate recommended by the manufacturer at the

time of mixing.
(ii) Manufacturer’s representative is to be present for all additions of the

hydrophobic pore blocking compound to ensure correct dosage rates are
used.
c) For self-compacting concrete, hyper plasticisers and viscosity enhancing agents

shall be used to provide necessary workability.
d) Viscosity Enhancing Admixture

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The viscosity enhancing admixture having high workability and viscosity shall be
used for making self-compacting concrete that can become compact without
vibration even with strongly reinforced structures. It shall be chloride free and
compatible with all type of cement.
e) Corrosion Inhibiting Admixture
(i) The corrosion-inhibiting admixture shall be added in an aqueous solution

form at batching plant and shall be specially formulated for Gulf area of hot
weather. The manufacturers of this product shall be ISO 9001 and ISO
14001 certified. With the above certificates the manufacturer/supplier shall
submit documented case histories.
(ii) The corrosion inhibiting admixture product, when used in accordance with
the manufacturer’s recommendations, shall impart changes to three
important properties of concrete compared to similar concrete without the
product. The changes are increased corrosion resistance (durability); no
adverse effects on physical properties of concrete and effective even where
corrosion is active.
(iii) Corrosion inhibitor when used in accordance with the manufacturer’s

recommendation shall form a suitable alternative for compliance with design
to the relevant sections of BS 1881, ASTM C1202-91, and ASTM G109.
The corrosion inhibitor shall comply with international standards such as
ANSI / NSF standard 61 certification confirming the products compatibility
with potable water.
(iv) The corrosion inhibitor shall be incorporated into the mixing water for the
purpose of determining the water cement ratio of the concrete. The
corrosion inhibitor shall be added to all reinforced concrete works (piles,
substructures & superstructures)
In order not to affect the W/C ratio, the corrosion inhibitor dosage shall not
exceed 1.0 lit/m³. The addition shall be made at the concrete plant.
f) High Performance Concrete Super plasticiser based on modified Polycarboxylic

Ether
A high performance super plasticiser based on sulphonated melamine and

naphthalene formaldehyde condensates at the time of mixing shall be used for
ready mixed concrete for ‘precast units’. Normal dosage shall be as
recommended by the product manufacturer.
g) Anti-Washout Admixture
(i) Anti-washout liquid admixture specially developed for concrete placed under
water shall be used for all ‘underwater concrete’. It shall have superior

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resistance to washout of cement and fines. The minimum dosage use shall
be as recommended by the product manufacturer.
(ii) Samples of proposed admixtures shall, if required, be submitted to an

approved testing authority by the Contractor in order to ascertain its
suitability for use in the Works. The test shall be carried out for the
properties specified in Table 3-10.
(iii) The cost of such admixtures or water proof powder or microsilica and
polypropylene fibres shall be included in the cost of concrete and no extra
payment shall be made if they are used. The proportions of cement, fine
aggregate and water shall be determined by the Contractor before
concreting commences and submitted together with mix design test results
that are required by the Engineer based on the verification by DCL, for
approval and the Contractor shall not commence concreting before such
approval is given nor shall he alter or vary in any way the proportion of mix
unless he submits fresh test results and mix proportions to the Engineer for
approval.
(iv) Mix design of all classes of concrete shall be verified by DCL prior to
approval by the Engineer. The approval by the Engineer of such mix
designs does not in any way absolve the Contractor of any of the
requirements of the Specifications.
(v) If two or more admixtures are to be used simultaneously in the same mix,
they shall not be pre-blended before use and the required data shall be
provided to assess their interaction to ensure compatibility.
Table 3.6 – Testing Admixtures
Sr. Uniformity Test Test Method & Test method &

Requirements Requirements as per
as per ASTM BSEN 934
C494
1. Colour – Similar to manufacturer’s

description
2. Settlement – Not to exceed

manufacturer’s limit
3. Specific gravity Manufacturer’s Manufacturer’s stated

stated value value ±0.03
±10%
4. Solid content Ditto ±5% Ditto ±5%

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Sr. Uniformity Test Test Method & Test method &

Requirements Requirements as per
as per ASTM BSEN 934
C494
5. pH – Ditto ±1
6. Ash content – –
7. Chloride content – BSEN 480 – Part10
<0.1% or less than

manufacturer’s stated
value
8. Chlorine content – <0.1% or Ditto
9. Alkali content – BSEN 480-12
Manufacturer’s stated
value
10. Infra-red Spectrum Essentially similar Essentially similar to

to manufacturer’s manufacturer’s reference
reference
11. Air void BSEN 480-11 as BSEN 480-11 as

characteristics described in the described in the standard
standard
3.2.3 Polypropylene Fibre Mesh Micro-Reinforcement
a) Fibrous concrete reinforcement shall be 100% virgin polypropylene micro fibres

specifically manufactured and developed as crack controlling additives and so
certified by the manufacturer.
b) It is available in two grades designated by its fibre length, 10 mm and 50mm for
concrete and 6 mm for mortar. 10 – 50 mm fibre is designed for cementitious mix
wherein the maximum aggregate size shall be greater than 5mm and 6mm fibre
length for cementitious mortar mix wherein the aggregate size shall be less than
5mm. It shall be compatible with all types of cement and admixtures. It improves
the concrete finishing characteristics, plastic shrinkage cracks, durability, alkali
attack, increases impact, abrasion resistance and reduced risk of subsequent
damage. Over dosage of fibre will generally produce a reduction in workability
and an increase in the cohesiveness of the mix. The performance of fibrous

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concrete is to be assessed after conducting preliminary lab trial or plant trial using
the actual mix constituents under consideration to determine the effect of
concrete properties. Fibres may be monofilament or fibrillated. The minimum
dosage shall be 0.60 to 0.9 kg/m³ depending on fibre diameter or as
recommended by the product manufacturer.
Table 3.7 – Physical Properties of Polypropylene Fibre
Constituents Polypropylene (C3 H6)
Young’s modulus 3.5 KN/m m²
Alkali content Nil
Absorption Nil
Specific surface area 225 m²/kg
Specific gravity 0.90 gm/cm³
Fibre length 10-50mm
Melting point 160-170oC
Ignition point 590oC
Acid and salt resistance High
Chloride & sulphate content Nil
Fibre thickness 18 micron
3.2.4 Concrete Mixes and Specification
3.2.4.1 Definitions, Glossary and General Requirements
The following definitions are used in this Specification:-
Design Mix: a mix in which the Engineer specifies the strength required to ensure
durability and sets the limits for aggregate size, cement content and water cement
ratio. The Contractor or ready-mix manufacturer is responsible for the selection of the
mix proportions.
Prescribed Mix: a mix, for which the Engineer specifies the proportions by weight
and accepts the resultant strengths, provided the Contractor has produced a properly
mixed concrete containing the constituents in the specified proportions.

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Minimum Cement Content: the lowest permitted mean mass of cement present in
one cubic metre of fully compacted concrete.
Free Water / Cement Ratio: the ratio by mass of free water to cement where free
water is the water in the concrete mix in excess of that absorbed by the aggregates
which is available for the hydration of the cement and for workability of the fresh
concrete.
Moisture Content of the Aggregate: this is the mass of free water in the aggregate
expressed as a percentage of the mass of saturated surface dry aggregate and does
not include any absorbed moisture.
Density of Fresh Concrete: mass of a quantity of compacted fresh concrete divided

by its volume expressed in kg/m³.
Characteristic Strength: the value of compressive cubes strength below which 5%

of all possible strength measurements of the specified concrete are expected to fall.
Governing Strength: the value of average 28 days’ concrete cube compressive

strength obtained from the approved trial mix
Mean Strength: the mean strength of all the cubes tested.
Working Margin: the difference between the characteristic strength and the mean
strength.
Certified Average Alkali Content: the average of 25 consecutive determination of

equivalent alkali content carried out on samples each of which is representative of a
days production.
Declared mean alkali content: the alkali content expressed as the sodium oxide
(Na2O) equivalent, which is not exceeded without prior notice from the cement or
additive manufacturer.
Guaranteed alkali content: the alkali limit expressed as the sodium oxide (Na2O)
equivalent which the constituent material supplier guarantees will not be exceeded by
any test result on any spot sample.
Cementitious Materials: cement, cement plus GGBS, or cement plus GGBS plus
Microsilica or cement plus water proof powder.
Admixtures: a material other than water, aggregate, cementitious materials or fibre

reinforcement, used as an ingredient of concrete or mortar.
Hot weather: when the shade temperature is above 40°C on a rising thermometer or
43°C on a falling thermometer.
Coarse Aggregate: considered as that size predominately passing a 28mm sieve

and predominately retained on a 5mm sieve.

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Fine Aggregate: considered as that size predominately passing a 5mm sieve and
predominately retained on a 0.075mm size.
OPC: ordinary Portland cement.
SRPC: sulphate-resisting Portland Cement
MSRPC: moderate sulphate-resisting Portland cement.
GGBS: ground granulated blast furnace slag.
MS: Microsilica.
Gap-graded aggregate: graded aggregates without one or more of the intermediate

sizes.
Single-sized Aggregates: aggregates containing a major proportion of particles of

one size.
Target Mean Strength: the specified strength plus the margin.
Acceptable or Accepted: acceptable or accepted by the Engineer.
Approval or approved: approval from the Engineer or approved by the Engineer.
All-in aggregate: the materials composed of a mixture of coarse aggregate and fine
aggregate.
Glossary
Air entrainment : The intentional incorporation into a concrete mix by means of an

admixture, of minute discrete bubbles of air typically less than
0.3mm (300 microns).
Autogeneous : The natural sealing of a crack in concrete by siltation together

healing with further hydration of cement or by the deposition of calcium
hydroxide with consequent conversion to calcium carbonate.
Bleeding : The phenomenon of water migrating to the surface of fresh

concrete due to settlement of particulate materials.
Blended cement : See Composite cement.
Cohesiveness : The degree to which fresh concrete resists segregation.
Cold joint Plane of weakness caused by interruptions to placing which

results from new concrete being cast against unprepared stiffened
concrete.

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Cold weather : Cold weather placing and finishing concrete when air
concreting temperatures are below 5°C or when freezing is likely to occur
soon after concreting
Compressive : Classification comprising the type of concrete, the minimum

Strength Class characteristic 150mm cube strength and the 150mm dia x 300
mm cylinder strength.
Comp actability : The ease with which the entrapped air in concrete can be
expelled.
Cement content : Mass of cement contained in a cubic metre of fresh, fully

compacted concrete expressed in kg/m³.
Composite : A cement or combination containing two or more main

cement constituents, one of which is Portland cement, mixed at a cement
works or at a ready-mix plant or on site.
Combination : Restricted range of Portland cement and additions which having

been combined in the concrete mix.
Consistence The resistance to flow of fresh concrete
Core : The innermost part of a (thick) concrete section which is generally

unaffected by external ambient temperatures.
Creep : The continuing deformation of concrete under sustained stress.
Curing : The action of preventing or minimizing the loss of moisture from

fresh concrete and maintaining a satisfactory temperature so that
desired properties may develop.
Curing Initial : Deliberate action taken between placement and final finishing of
concrete to reduce the loss of moisture from the surface of the
concrete.
Curing final : Deliberate action taken between the final finishing and termination
of curing.
Evaporation : A material that generates a continuous thin film when spread over
Reducer water on the surface of fresh concrete and thus retards the
evaporation of bleed water.
Design Chemical : Designations used to describe a concrete quality capable of

resisting the selected aggressive chemical environment for the
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Class (D,C Class) concrete
Drying shrinkage : The long-term reduction in size of a concrete element caused by

the loss of water upon drying.
Early age thermal : The reduction in length of a concrete element caused by its
contraction cooling from the elevated temperatures developed during
hydration of the cement.
Finishing : Mechanical operations carried out on the surface of placed

concrete to achieve the required texture, appearance and
serviceability.
Fresh concrete : Concrete which has insufficient reaction between the cement and
water to exhibit significant mechanical properties.
Hardened : Concrete which exhibits mechanical properties as a result of the

concrete reaction of cement and water
Heat of hydration Heat generated by the chemical reaction of cement and water.
Hot weather : Placing and finishing concrete when air temperatures are above
concreting 25°C and the combination of temperature and humidity is such
that the quality of fresh or hardened concrete may be impaired
unless preventive measures are taken.
Joint construction : A monolithic joint with no provision for movement.
Joint movement : A joint formed or induced to allow movement to occur with one or
more degrees of freedom
Laitance : A layer of cement and fine sand with excess water content on top
of concrete
Matrix : The part of concrete which is composed of cement paste and

sand.
Minimum cover : Cover to reinforcement assumed for the purpose of durability
Mobility : The ease with which fresh concrete can be made to flow.
Nominal cover : Cover to reinforcement shown on the drawings comprising the

minimum cover plus a tolerance c to accommodate fixing
precision.

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Placing : All operations necessary for introducing the fresh concrete into
form work or other enclosures.
Plastic concrete : See fresh concrete
Plastic settlement : Cracks which form due to differential settlement of concrete while
cracks still in a fresh (plastic) state.
Plastic shrinkage : Cracks which form because of excessive loss of moisture from
cracks concrete while still in a fresh (plastic) state
Restraint : Anything (internal or external) which prevents the free movement

of concrete
Re-tempering : Addition of water and remixing of concrete to increase its

workability
Rheological : Pertaining to the flow of concrete
Segregation : Loss of uniformity of fresh concrete mix due to separation of one

or more of the constituents of the mix.
Settlement : Sedimentation or the act of the heavy solid particles settling in

fresh concrete.
Stability : See Cohesiveness.
Stiffening time : Time beyond which reworking of concrete would be detrimental.
Tensile strain : The tensile strain at which a concrete will crack.

capacity
Transporting : The conveying of fresh concrete from the point of discharge from
the mixer to the point of discharge into the form work or other
enclosure
Warping : The distortion of a slab caused by temperature or moisture

gradients across the depth of section.
Consistency : The rheological properties of fresh concrete influencing the ease

with which it can be placed, compacted and finished

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3.2.4.2 Concrete with Special Requirements
Except where otherwise required by another approved standard specified herein,

concrete shall comply with the recommendations contained in the approved standard
or such modifications as may be agreed with the Engineer.
All below ground concrete structures are to be tanked as a protection from the
aggressive groundwater both below the ground water table and in the capillary zone
above.
a) The concrete mix for water retaining structures shall be designed to achieve the
structural performance level to “HIGH” as given in the table ‘5’ of BRE Special
Digest No.1 part 3: 2003 and as per BS8500-1:2006.It shall also be watertight as
described in BS EN 1992-3:2006. Concrete to be used in aggressive ground shall
be designed as recommended in Part 2 of BRE Digest No.1Part 2 and 3 and for
precast products it shall be as specified in Part 4 of BRE Digest No.1.
b) The choice of cement to be used for underground structures shall depend on the
sulphate and chloride concentrations in ground water and the soil. The tenderer
shall consider in his offer the sampling and testing of soil and ground water in
accordance with BS 5930 :1990+A2:2010. The concrete mix is to be designed
after assessing the classification of aggressive ground conditions at site. (Refer
BRE special DigestNo.1and CIRIA guide recommendation). The chemical
classification of the site is to be decided after considering step No.1 to 5 specified
in BRE Digest No.1:2003 Part I cl:6.
c) The choice of constituent materials of concrete and its limitations given in BS EN

1992-3:2006 , BRE Digest No.1 and BS 8500:2002 are to be taken into
consideration to satisfy the structural performance level of buried concrete (Ref.
Section ‘3’ of BS EN 1992-3:2006 and BRE Digest No.1:2003 part 1-4).
d) The qualities of concrete that are required to resist chemical attack shall be as
recommended in CL 4 to 6 of BRE Digest No.1:2003 Part 2.
e) Usage of fibrillated polypropylene fibres in concrete may reduce the rate and
amount of bleeding as well as the effect of plastic settlement cracks in concrete.
Therefore where approved/ or use by the Engineer fibrous concrete shall be
designed as stated in the mix design specification.
f) Controlled Permeability formwork(CPF) on structural concrete shall be used
(i) To prevent loss of fines from concrete during Vibration.
(ii) To evacuate the excessive air from concrete, avoid air voids on concrete
surface and improve the surface quality (Ref. CIRIA guide CL 15.5.4 and
17.6.3)
(iii) To substitute an insulation layer on external concrete surface to control the

in situ concrete temperature gradient and concrete surface temperature.
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(iv) To increase the concrete surface and wear resistance.
(v) To decrease the ratio of chloride penetration, water penetration and

carbonation effect.
(vi) For textured surface finish to avoid sand blasting before painting and to
acquire an ideal substrate base.
(vii) To reduce bacterial and algae growth due to dense surface without cracks
and blow holes.
3.2.4.3 Ready Mixed Concrete
The contractor may use ready –mixed concrete from an approved source with the
written authorization of the Engineer. Ready-mixed concrete and all constituent
materials shall conform to this specification.
3.2.4.4 Mix Design Constraints
All design mixes shall comply with the following constraints:
a) The structural design of the concrete elements shall be in accordance with BS EN

1992-1-1:2004.
b) Concrete for water retaining structures and below ground structures in this
Contract shall be water tight and shall comply with the requirements and
recommendations of BS EN 1992-3:2006 : and BRE Digest No.1: 2003 and CIRIA
Guide Publications. Classification of sites, choice of cement and aggregates,
concrete in aggressive grounds and the additional protective measures as
recommended in BRE Digest No.1 also to be taken into consideration.
c) Characteristic strength are basic mix strengths and do not allow for any reduction
in strength due to the use of air entrainment agents. Air entrainment agents will
be used only where specified.
d) Only air entrainment agents based on vinsol resins will be approved. Where air
entrainment is specified, the average air content by volume of fresh concrete
(measured in accordance with the approved standard BS12350 P7:2009) shall be
5% for 20 mm nominal maximum aggregate size. This will produce concrete
having strength approximately 70% that of non-air entrained concrete.
e) If bleeding occurs in any trial mix it shall be assessed in accordance with the
approved standard ASTM C230:1999 (non-vibrating) and where necessary the
mix design or sand grading shall be adjusted to prevent recurrence.
f) The mix proportions shall be adjusted to achieve the maximum density from the
available materials. Unless otherwise agreed by the Engineer, the saturated
surface dry density of fully compacted cubes shall be not less than 2500 kg/m³ for
those concretes for which air entrainment has not been specified. As a guide the

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Contractor should note that for non-air entrained concrete, United Arab Emirates
aggregates dredged sand normally achieve densities greater than 2450 kg/m³.
g) In general the actual cement content will need to be higher than the minimum
value specified to ensure adequate workability and compliance with the maximum
water/cement ratio. Approved plasticiser may be used to maintain workability.
h) Mean strengths may exceed those required to achieve the characteristic strength
in order to comply with the maximum water/cement ratio.
i) The initial drying shrinkage of all the proposed concrete mixes, prepared and
tested in an approved laboratory shall not exceed 0.05%. It should be noted that
the above involves a testing period of about eight weeks.
j) The basic requirements as specified in BS 8500 – 1:2006 Cl. 4.3.2 and the
additional requirements where required as specified in Cl. 4.3.3 shall strictly be
followed for designed concrete and a compliance statement is to be provided to
the Engineer by the concrete mix designer.
3.2.4.5 Concrete Mix Specification
Concrete mix shall be as shown in Table 3.8. The number of mixes may require to be
increased. The criteria given in the Table are designed to produce concrete of the
required strength durability and the area of use. If the maximum aggregate size is
10mm then the cement content stipulated for the class of concrete given in Table 3.8
shall be increased by 40kg per m³. All structural concrete mixes shall be verified by
Dubai Central Laboratory.

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Table 3.8 - Concrete Classification, Mixes and Area of Use
Sr. Classification Concret Type of Strength Min Free Max size Characteristi Governing Other Area of use
e Grade Cement as per Class of Cement WCR of c strength mean Cube Compliance
ASTM/BS Cement Content (Max) Aggregate @28 days Strength @28 requirements
Standards N/m m² (kg/m³) (mm) days
1. PC – BL ** C25 SRC to BS 42.5 340 0.50 20 As As derived Basic Plain concrete
4027 or calculated from the requirement blinding under
ASTM from the concrete trial s as per Cl structural concrete
concrete batch 4.3.2 of
Type V production BS8500:P1
& as per BS
EN 1992-
3:2006
2. PC – UR** C30 Ditto ,, 380 0.45 20 Ditto Ditto Ditto Plain unreinforced
mass fill concrete
and reinforced
concrete for minor
structures similar
to Manholes,
chambers, pipe
surround,
protection slab,
anchor blocks etc.
3. PC-GR** C35 Ditto ,, 400 0.42 10 Ditto Ditto Ditto Benching grano
concrete

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4. RCC/WS/ C40 Ditto ,, 400 0.35 20 Ditto Ditto Ditto RCC for water
F** retaining
structures and the
related adjoining
chambers similar
to Air valve
washout chambers
, Access Shafts
etc.
5. RCC/PU/F C50 Ditto ,, 400 0.35 20 Ditto Ditto Ditto RCC Precast units
**
6. SCC ** C60 OPC/SRC ,, 400 0.35 20 Ditto Ditto Ditto In situ piling works
7. UWC** C40 OPC/SRC ,, 400 0.40 20 Ditto Ditto Ditto Under water
concrete
8. Pc – BR ** C40 OPC ,, 400 0.40 10 Ditto Ditto Ditto Precast Bricks
9. RCC/AG/F C40 OPC /SRC ,, 400 0.38 20 Ditto Ditto Ditto RCC for Building
** structures above
BSEN 197- ground with OPC
1:2000 and below ground
foundation with

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/Type 1. SRC
BS4027
Type V
NOTES:
1. PC-BL plain reinforced concrete with protective measures as specified for blinding
2. PC-UR - plain unreinforced mass fill concrete and reinforced concrete for minor structures with protective measures as specified
3. PC-GR - Granolithic concrete for benching / haunching works with protective measures as specified.
4. RCC/WS/F - structural reinforced water proof concrete contains polypropylene fibres with protective measures as specified for water retaining structures.
5. RCC-PU/F RCC - Precast units including surround concrete for Micro tunnelling pipes.
6. SCC - self compacting concrete for insitu piling works and concrete having congested reinforcement
7. UWC - underwater concrete
8. PCBR - concrete for precast corbel bricks/blocks/surround to gully pot etc.
9. RCC/AG/F RCC - structural concrete for the above ground structures with polypropylene fibres for building and similar other above ground structures and its foundation below
ground.
** Double starred concrete requires to have aggregate carbonate range ‘C’ (lowest carbonate content).

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3.2.4.6 Chloride and Sulphate Levels in Concrete
The chloride and sulphate levels in the concrete mix shall comply with the
requirements of Table 3.9.
Maximum limits of chloride and sulphate content as a percentage by weight of

cement in the mix.
Table 3.9 – Maximum Limits of Chloride and Sulphate Content in Concrete Mix
Type of Concrete Chloride as Cl% Sulphates as SO3 %

according to BS 1881:
BS 1881:1988
Part 124 Addendum
01:1988 Addendum 06:2002
For reinforced
concrete
if made with
0.30 3.70
OPC/MSRPC
0.06 3.70
if made with SRPC
For mass concrete
if made with
OPC/MSRPC 0.60 3.70
if made with SRPC 0.12 3.70
For Pre-stressed
concrete and heat-
cured reinforced
concrete 0.10 3.70
Note: The OPC and MSRPC cements can also contain chlorides, the relevant standard BS EN 197-
1:2000 latest edition allows up to 0.1% Cl. Therefore any chloride content present in the cement
as determined by BS EN 196 Part 2:2005 has to be taken into account while computing total CI in
the mix. In case the cement contains the maximum limit of 0.1% Cl, then the aggregates, water
and admixtures used for pre-stressed concrete or heat-cured reinforced concrete should be
absolutely free of chlorides

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3.3 CONCRETE MIX DESIGN
3.3.1 General – Samples of Aggregate
Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the necessary
tests and analysis to show that the samples comply with the Specification. During the
progress of the Works, the grading and chemical characteristics may be checked at
frequent intervals. Sampling of aggregates shall be carried out in accordance with BS
812: Part 101 and Part 102.
The results of these tests shall be submitted to the Engineer and his approval shall
be obtained before any of the material is used in the Works. Part of each sample will
be required for concrete trial mixes and part shall be retained for comparison with
subsequent deliveries.
No deliveries in bulk are to be commenced until such samples are approved by the
Engineer as complying with this Specification.
3.3.2 Concrete Mix Design Submittal and Method Statement
The concrete mix design submittals shall have:-
a) Manufacturer’s Data: Submit manufacturer’s product data, specifications with

application and installation instructions for proprietary materials and items,
including admixtures, polypropylene fibre, waterproofing powder etc.
b) Product Data, test results and other information as required to prove compliance
with the specification shall be submitted for approval according to Section on at
least the following products.
(i) Cement
1. Recent independent tests results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards.
2. Manufacturer’s certificates shall also be supplied with each consignment

of cement certifying compliance with the relevant standard for each type
of cement.
(ii) GGBS
1. Recent independent test results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards
2. Manufacturer’s certificates with all information necessary to verify

compliance with BS 6699 shall also be supplied with each consignment
of GGBS.

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(iii) Microsilica & Water Proof Powder

2. Manufacturer’s certificates with all information necessary to verify

compliance to an internationally recognized standard shall also be
supplied with each consignment with microsilica and water proof
powder.
(iv) Aggregates

2. Full details of the proposed sources of aggregates.
(v) Water
Recent independent test results acceptable to the Engineer confirming

(vi) Admixtures
1. Manufacturer’s technical specifications and recommendations.
2. Recent trial results acceptable to the Engineer illustrating the efficiency

of the product for its particular application
(vii) Polypropylene fibre:
Manufacturer’s technical specifications and recommendations.
c) Concrete Mix design for each class of mix with at least the following information:
(i) Type of cement
(ii) Cement content
(iii) GGBS content
(iv) Microsilica content
(v) Water proofing powder content
(vi) Polypropylene fibre content, the source and properties
(vii) Max. aggregate size, type and source
(viii) Combined grading curve
(ix) Quantities of all individual materials

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(x) Name of admixture, type and source
(xi) Target slump (at discharge)
(xii) Details to calculate W/C ratio
(xiii) Compressive strength
(xiv) Hardened density
(xv) Water permeability & water absorption
(xvi) RCP
(xvii) Bleeding
(xviii) SO3 and Cl contents in the mix
(xix) Slump profile
(xx) Target unit weight
(xxi) Target temperature
(xxii) Structural performance level of the designed mix
(xxiii) Aggregate carbonate range limit in the aggregate mass
(xxiv) Temperature gradient anticipated in the concrete
(xxv) Compliance statement in accordance with BS8500-1: 2006 Cl. 4.3.2 &
4.3.6.
d) Method statements
The Contractor shall submit a method statement for concrete batching and
delivery which shall include at least the following details:
(i) Type of plant proposed
(ii) Layout of concrete production facility
(iii) Proposed method of organization of the concrete production facility.
(iv) Quality control procedures for concrete and concrete materials
(v) Batching and transport of concrete.
e) Purchase orders: Copies of all purchase orders shall be certified by the

Engineer’s Representative before being issued for procurement.
f) Delivery Tickets: With each load of concrete delivered to the job, duplicate tickets
shall be furnished by the ready-mix concrete producer. Furnish one (1) to the
Engineer’s Representative.
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g) Samples
(i) Provide samples of all materials and concrete accessories of every type
proposed for use including component parts of prefabricated formwork
systems and manufacturer's technical literature relating thereto. Prepare
mock-ups and carry out such tests on the proposed prefabricated formwork
systems as may be required by the Engineer in order that he may be
satisfied as to the system's suitability.
(ii) Furnish reinforcement and accessories for sample panels and mocked-up
portions of the structure as required using all materials and techniques as
they will be used in actual construction.
h) Samples of the following concrete mix material shall be submitted.
(i) Cement
1. Provide cement samples from each consignment delivered to the site as

required by the Engineer for testing.
2. Samples shall be taken in the presence of the Engineer’s

Representative
(ii) GGBS
1. As requested by the Engineer for independent testing.

Representative
(iii) Microsilica & Water Proof Powder
1. As requested by the Engineer for independent testing.

Representative
(iv) Aggregates
1. Provide samples of both fine and coarse aggregates for testing at least
three weeks prior to beginning deliveries to the site and at regular
intervals as required by the Engineer.

Representative
(v) Polypropylene Fibre
1. Provide samples with test report.

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Representative
(vi) Water
1. Provide samples of water proposed for concreting works.

Representative
(vii) Admixture: as requested by the Engineer.
i) Mill Tests:
Furnish the Engineer with certified mill test reports for cement.
j) Test Reports:
Submit preliminary test results for the Engineer’s approval at least three weeks
prior to the beginning of the work. In addition to the test reports specified under
“Quality Control”, submit the following directed to the Engineer:
(i) Preliminary Design Mix Reports
(ii) All related test reports to Aggregate and Cement outlined here in this
Section.
3.3.3 Design Mixes for New Batching Installations
3.3.3.1 General Requirements
a) Concrete shall be batched only with approved materials, approved mix designs,
and at approved facilities.
b) The Contractor shall define the method of design of the mix, by reference to a
recognised published design method. The design method shall be approved by
the Engineer.
c) Plant trials shall be carried out for each grade and type of concrete in the
contract, unless approved otherwise by the Engineer.
d) Aggregate proportions shall be based on measured and not assumed relative

densities.
e) If requested by the Engineer, concrete mix designs which include an admixture

shall be prepared and tested both with and without the admixture to give a clear
indication of its effects on the physical characteristics of the mix.
f) Results of the trial mixes must demonstrate that the proposed mix complies with
the strength, workability and durability requirements of this specification.
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3.3.4 Trial Mixes for Concrete
a) Following the Engineer’s approval of the materials for each class of concrete, the
Contractor shall prepare laboratory trial mix on one batch for each grade of
concrete in the presence of the Engineer’s Representative. Each trial mix shall
comprise not less than 1/3 of a cubic metre of concrete and shall be mixed in an
approved type of concrete mixer similar to that which the Contractor propose to
employ on the Works. The quantities of all ingredients of trial mix including water
shall be carefully determined by weight according to the approved mix design.
Each trial mix shall show no tendency to segregate when handled and compacted
by the methods by which the Contractor proposes to handle and compact the
grade of concrete in the Works and it shall be capable of adequate compaction by
such methods.
b) Preliminary laboratory tests on lab trial mixes shall be carried out to determine the
mixes to satisfy the specification with the approved materials. Approval of the
laboratory mix proportions shall in no way relieve the Contractor of his
responsibility to produce concrete which meets the requirements of these
Specifications. All costs connected with the laboratory trials and the design of the
proposed mixes shall be borne by the Contractor. Whenever a change of brand or
source for any of the concrete ingredients occurs, additional laboratory mixes may
be required and the cost of these trials shall also be borne by the Contractor. The
suitable and economical mix designs selected from the lab trials shall be
subjected to plant trial.
c) The mean strength of concrete at 28 days from each batch shall exceed the
characteristic cube strength (CCS) by a margin of 1.64 times the standard
deviation expected from the concreting plant, except that no standard deviation
less than 3.5 N/m m² shall be used as a basis for designing a mix. Unless
otherwise approved a standard deviation of 7 N/m m² and the working margin of
minimum 11.5 N/m m² shall be used to work out the target mean strength for
design mixes for new batching installations.
d) All the trial mixes for each class of concrete shall be tested to determine the
following properties of mixes proposed for initial field tests:
Table 3.10 Lab Trial Testing of Concrete
Properties Test Method Specification Limit
Fresh and hardened BSEN 12350:P6 & BSEN 12390:  2500 kg/m³
densities of Concrete P7 or BS EN 12350-6:2000
Bleeding of wet fresh ASTM C232 Non vibrating  0.50%

concrete method and vibrating method

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Air content in concrete if BS12350: P7:2009 / ASTM C173  2%

applicable
for air entrained
concrete
 5%
Fresh and fully compacted ASTM C 138: 1992 N/A

wet concrete yield
Cement content and free BS 1881  Mix design

water cement ratio of requirement
concrete
Concrete temperature, flow BSEN 12350 Part 1, 2 & 5  Specification

and consistency of concrete requirement
(slump)
Initial, 30 min, 60 min and

90 min
Total chloride & sulphate BS 1881: P124 or BSEN 196-2  0.3% by weight of
content in the concrete mix :2005, cement
BSEN 1744-1 & BSEN 480-10  3.7% by weight of

cement
Total alkali content in the BSEN 196-1 and BS 8500:1 & 2  3.5 kg /m³ concrete
mix Na2O Eq:
Permeable pores in ASTM C642 or BSEN 480-11  7% at 7days

concrete
Mortar fraction of concrete By calculation 55-67%
Overall grading of BS EN 12620 : 2002+A1:2008 As per clause 3.2.1.8

aggregate (Wet analysis of
concrete)
Initial setting time of ASTM C403, C494 As per standard

concrete
Compressive strength of BS EN 12390-1:2000 & BS1881: Spec requirement

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hardened concrete P116
Flexural strength of BSEN 12390: P5 Concrete grade upto

concrete prism C40 3.5 N/m m²
For C40-C50 grade

concrete 4N/m m²
For concrete C50 and

above 5N/m m²
Tensile splitting strength of ASTM C 496: 1996 or BSEN  4N / m m²

concrete cylinder 12390-2
Surface tensile strength of BS 1881: P207: 1992  3 Mpa

concrete
Initial surface absorption of BS 1881: Part 122 or  0.03ml/ m²/sec

concrete @7days
BS 1881: P208: 1996
 0.02 ml/ m²/sec@28
days
Capillary absorption of BSEN 480-5 7 days cure @7 days

concrete absorption 0.6% (90
days cure) @ 28 days
absorption 2.5%
Water absorption of BS 1881: P122:2011 As specified in Table

concrete 3.13
Chloride permeability (RCP) ASTM C 1202: 1999 As specified in Table

3.13
Depth of water permeability BSEN 12390: P8:2009 -ditto-

(RCP)
Drying shrinkage of BS EN 12390-7:2000 , BS 1881- Drying shrinkage

concrete 121:1983, BS 1881-122:2011, BS 0.05%
1881-209:1990 , BS 1881-
208:1996 or BS EN 772-2:1998 ,
BS EN 771-3:2003

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Wetting expansion of -Ditto- Max. 0.03%

concrete
Temperature gradient of the Mock up sample  15oC.

concrete
Note:
1. Durability test is required only for RCC structural concrete.
2. The most suitable mix shall be selected after the full properties are verified and shall be subjected to
plant trial as specified.
3.3.5 Design Mixes from a Continuing Source
For mixes proposed from a continuing source for which the necessary test results of
concrete materials and concrete are available and for a batching installation which
has been operated for a sufficient period to produce the required cube results the
following procedure shall be adopted.
The mean 28 days compressive strength calculated from 'n' cube results, from
separate batches of concrete shall exceed the specified characteristic strength by a
margin equal to:
1.64 × SD {(0.86 + ( 2 / n) }
where:
'SD' is the standard deviation from 'n' results but not less than 3 N/sq.mm.
'n' is the number of results not less than 10 and not greater than 100
When 'n' exceeds 100, the margin shall be calculated as:
1.64 × SD
where 'SD' is as defined above.
Previous production data for use in the above criteria shall be 28 day cube test
results from separate batches of concrete sampled at random over an immediately
prior period exceeding one month and not exceeding one year using materials and
plant which are proposed for the Works.
3.3.6 Slump, Flow, Temperature and Air Content Testing of Fresh Concrete at Site
3.3.6.1 Sampling
The sampling shall utilise a spot sample obtained from the initial discharge, if
concrete is delivered in a truck mixer or agitating equipment. The spot sample shall
be taken after a discharge of approximately 0.3 m³ by taking six increments from the
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moving stream of the concrete in accordance with BS EN 12350-1. The sample shall
be remixed on a non-absorbent surface and tested for slump or flow.
Table 3.11 Identity Criteria and General Guidance for Slump & Flow of In-situ
Concrete at Site
Use of concrete Form of (Dimensions in mm)

compaction
Spot sample taken from initial discharge
Slump Not less Not greater Flow Flow

Class than than Class Range
Kerb bedding and Tamping S1 25 70 N/A

backing
Floors and hand placed Poker or S2 30 120 N/A

pavements beam
vibration
Strip footings Poker or S3 80 120 N/A

beam
vibration
Mass concrete And/or S3 80 120 N/A

foundations tamping
Blinding S3 80 120 N/A
Normal reinforced S3 80 120 N/A

concrete in slabs,
beams, walls and
columns
Sliding formwork S2 30 120 N/A

construction
Pumped concrete S4 100 150
Vacuum processed S4 100 150

concrete
Trench fill Self-weight S5 140 240 F1 53070

compaction mm
In-situ piling -ditto- S5 140 240 F1 53070

mm

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Use of concrete Form of (Dimensions in mm)

compaction
Spot sample taken from initial discharge
Slump Not less Not greater Flow Flow

Class than than Class Range
Underwater Concrete S5 140 240 F1 53070

mm
Under no circumstances shall a slump and flow test be used as a means of

monitoring water content and it shall be noted that for any concrete mix the slump will
reduce with increasing temperature.
Concrete mixes shall be designed such that the minimum consistence at the time of
placing is adequate to allow the concrete to be placed and compacted as specified.
3.3.6.2 Temperature Records
a) The Contractor shall supply suitable maximum / minimum thermometers and

record the shade and sun temperatures adjacent to all parts of the works concrete
is being placed.
b) Procedure to measure the temperature of fresh concrete at site:
(i) Sampling shall be as given in Cl. 3.3.6.1
(ii) Within 2 minutes of taking sample at delivery, insert a type A100 mm

immersion thermometer (having a range of –5oC + 110oC, graduated in
intervals of 1oC (calibrated and conforming to BS 1704) in the concrete
sample to a depth not less than 100 mm.
(iii) When steady condition have been maintained for 1 minute record the
temperature to the nearest 1oC.
Use an alternative form of temperature measurement device with a precision at

least that of a thermometer conforming to BS 1704, to record the steady-state
temperature to the nearest 1oC.
c) Method of Taking Air Content in Fresh Concrete
(i) Sample shall be a composite sample taken in accordance with BSEN

12350-1.
(ii) Air content shall be a measured in accordance with BS EN 12350-7
(iii) The identity criteria for air content shall be as specified.
d) Method of Making Test Cubes from fresh concrete shall be as follows:

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(i) Fresh concrete sample shall be emptied into a metal tray 1.2m x 1.2m x 50
mm deep and thoroughly mix by square mouthed shovel to turn the
concrete from outside toward the centre.
(ii) Place the cube mould on a rigid horizontal surface or vibrating table. By
means of 100 mm wide scoop place the concrete in the cube mould in
layers approximately 50mm and compact each layer by using either the
steel compacting bar having 25mm square ramming face, 300 mm long and
1.8 kg weight or the vibrator. The number of strokes per layer required to
produce full compaction will depend on the workability of the concrete but in
no case shall the concrete to be subjected to less than 35 strokes per layer
for 150 mm cubes or 25 strokes per layer for 100 mm cubes, except in case
of high workability concrete. The concreted mould shall be covered with
plastic sheets and keep under the shade and be protected from harmful
effects of sunshine, drying winds, rain or running water. The concrete cube
specimen shall be removed from the mould after 24 hours, transported
carefully without damage and is to be immersed in water in a curing tank of
specified temperature.
3.3.7 Consistency Testing (Slump & Flow)
The Contractor shall carry out slump test in accordance with BSEN 12350-2, Vebe
time shall be performed in accordance with BSEN 12350-3 and flow test shall be
performed in accordance with BSEN 12350-5 and degree of compactibility shall be in
accordance with BSEN 12350-4 at such frequency as the Engineer’s Representative
considers necessary to ensure that the workability and consistency of the concrete is
maintained in accordance with the specified mix or accepted mix design and the trial
mix.
3.3.8 Durability Tests
Concrete shall be tested for durability properties by undertaking all the tests where
appropriate, or directed by the Engineer, as given in Table 3.13.
Water absorption tests shall be carried out in the laboratory on 75 mm diameter cores
cut at an age of 24 to 28 days to enable the tests to be carried out between 28 and
32 days in accordance with BS 1881 Part 122.
Depth of water penetration test as described in (BS EN 12390: Part 8) shall be

carried out.
Durability tests for concrete are applicable on reinforced concrete.
3.3.9 Other Tests
a) Concrete shall be tested for Tensile Strength as per ASTM C496 and BSEN
12350-5: 2009 for flexure strength. When instructed by the Engineer, concrete
shall be tested for drying shrinkage and wetting expansion, for which 75 x 75 mm
prisms shall be prepared and tested in accordance with BS EN 12390-7-2000 ,
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BS 1881-121 :1983 , BS 1881-122 : 1983, BS 1881-209 : 1990 , BS 1881-2008 or

BS EN 772-2: 1998, BS EN 771-3:2003 . The maximum acceptable limits shall
be: as given in table 3.10
b) Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.
c) The air content of the concrete shall be determined (BS EN 12350-7:2000) for
each batch produced until consistency has been achieved, when batches may be
tested. The maximum value shall not exceed 2%.
d) Compaction factor, slump, Vebe or other workability tests shall be carried out as
required during concreting or permanent works to control workability at the
batching plant and at the site of the pour. The degree of workability shall be as for
trial mixes; permitted tolerances shall be in accordance with BS 8500 – 1 & 2.
e) For new proposals to use a continuing source, such as a ready mix concrete
supplier, the suitability of the proposed mix shall be tested by preparing 2
separate batches on each of two days from the Plant with cement and aggregates
known from past records of the suppliers of the materials to be typical of those
specified and tested to demonstrate compliance with the strength, durability and
workability requirements of this Specification. The specified water cement ratio of
the both trial batches shall not exceed when their workability is the same as that
which is proposed to be used in the work.
3.3.10 Method Statements
Method statements shall be prepared for each grade and type of concrete in the
contract and shall include: -
a) Definition of the method of design of the mix, by reference to a recognized

documented design method. Designed aggregate proportions shall be based on
measured and not assumed relative densities.
b) Proposed mix proportions including any proposed admixtures and, for new
batching installations, results of preliminary batch testing.
c) Results of testing of trial mixes to demonstrate that the proposed mix complies
with the strength and workability requirements of this Specification.
Method statements shall be approved before any concrete is placed and any
alteration in the source or quality or proportioning of any of the materials in the mix
will necessitate a new method statement.
3.3.11 Prescribed Mixes for Minor Works
Prescribed mixes shall only be used with the Engineer’s agreement and where
isolated quantities of less than one cubic metre are required. They shall comply with

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Table 3.12 and be either site batched or supplied dry in bags ready for mixing with a
set volume of water. Concrete shall not be hand mixed.
Table 3.12 Prescribed Concrete Mixes
Grade Nominal Fine Coarse Cement

Maximum Aggregate Aggregate Content
Aggregate Size Content Content
kg/m³
mm kg/m³ kg/m³
C30/20 20 650 1150 450

P
Weight requirements given are per cubic metre of compacted concrete. Aggregate
grading shall comply with clause 3.2.1.8 .
3.4 PLANT TRIALS WITH APPROVED CONCRETE MIX DESIGN
General
At least 35 days before commencement of concreting trial mixes shall be prepared

under full-scale site conditions or in batching plant and tested in accordance with BS
1881: 1983.
a) Samples of concrete incorporating the reinforcing details and formwork similar to

be used at site shall be cast and examine the peak temperature and the
temperature gradient during hardening, and after hardening by coring to assess
the quality of the mixes. Cores shall be taken in accordance with BS EN 12504-
1:2000.
b) The Plant trials must prove compliance of all criteria set forth, unless otherwise
accepted by the Engineer.
c) Plant Trials shall be mixed for the same time, by the same means and with the
same equipment which the Contractor proposes to use in the Works.
d) The proportions of cement, GGBS, Microsilica, aggregate, admixtures, P.P. fibre

and water shall be carefully determined by weight to correspond with the
Contractor’s approved mix proportions.
e) Contractor shall make three separate batches in three different days for each
class of concrete mix, unless otherwise approved by the Engineer.
(i) Each batch on each day shall be not less than 3.0m³ of concrete, unless
otherwise accepted by the Engineer.
(ii) Required no. of test cubes shall be made from each batch for conducting
the relevant strength and durability tests.

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(iii) Methods of making and curing cubes shall be in accordance with BS EN

12390-1 & 2 :2000 respectively and as follows:
 Cubes shall be stored in insulated boxes with identification marks until

removed from the moulds.
f) The slump and temperature of each batch during each plant trial shall be
measured and recorded, by the method described in relevant BS standards.
g) Further trial mixes shall be made if the range (the maximum minus the minimum
of the three cube strength results in any batch) exceeds 15% of the average of
that batch, or if the range of the three batch averages exceeds 20% of the overall
average of the batches.
h) The mixes of each batch shall be tested to determine the following properties:
(i) Bleeding in accordance with ASTM C232 : 1999
(ii) Air content if applicable BS 12350 : P7 : 2000
(iii) Free water/cement ratio BS 1881
(iv) Compressive strength of concrete: BS EN 12390-3:2002
(v) Tensile strength in accordance with BS EN 12390-6:2006 and BS EN

12390-5 :2000. Splitting tensile strength of concrete cylinder shall be in
accordance with ASTM C 496: 1996. Flexural strength of concrete prism in
accordance with BS EN 12390 : P5
(vi) Total sulphate & Chloride content in the mix as specified in Table 3.3 &
Table 3-9
(vii) Water absorption of concrete: BS 1881: P122.
(viii) Durability tests as specified.
(ix) Initial setting time of concrete.
The average 28-days Governing Compressive Strength of Concrete Cubes

of the three trial mixes shall not be less than the target designed mean
strength, and the results of the above tests shall be acceptable before the
mix is approved. Otherwise the mix shall be re-designed.
i) The engineer will review the Contractor’s trial-mixes, verify the test cubes strength
results at seven (7) and twenty-eight (28) days and the durability test results. The
Engineer will then determine which of the most suitable trial mixes shall be used
for the work. If none of the trial mixes for a class of concrete meets the
Specification, the Engineer will direct the Contractor to prepare additional trial-

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mixes. No class of concrete shall be prepared or placed until its job-mix

proportions have been approved by the Engineer.
j) The approval of the job-mix proportions by the Engineer of his assistance to the
Contractor in establishing those proportion, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements of these
Specifications.
k) The Engineer may also require practical tests to be made on the Site by filling trial
moulds to confirm the suitability of the mix for the works, the type of plant used for
mixing, the method of compaction used, and the formwork face intended for use
in the works and the temperature gradient of the mix.
l) All costs connected with the preparations of trial-mixes tests and the design of the
job-mixes shall be borne by the Contractor.
Trial Slabs
m) For grades C40, C50 and C60 at least one reinforced horizontal slab measuring
1.0m x 1.0m x 0.2m and one reinforced wall section measuring 1.0m x 1.0m x
0.2m shall be cast utilizing the same placement and curing methods as proposed
for the works.
n) Each slab shall be sampled and tested for RCP values.
o) Each sampling shall consist of three 100mm dia. Cores of suitable length for RCP
testing.
(i) A cover meter shall be utilised to locate the rebars to avoid rebar in the
core.
(ii) The cores will be given to the Engineer for delivery to an independent
laboratory of the Engineer’s choice.
p) The cores shall be promptly tested for RCP values and the results promptly given
to the Engineer.
q) The average RCP value from the cores taken from trial slabs shall not exceed the
specified value given in Table 3.13.
r) All associated costs for coring and testing shall also be borne by the Contractor.
s) Contractor shall only use the approved mix of each grade of concrete in the
Works.
t) If at any time during the construction of the Works, the source of cement, GGBS,
Microsilica, aggregate, admixture or mix proportions are changed, the concrete
shall be rejected /or new trial mixes shall be made, tested and approved for use.

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3.4.1 Quality Control
3.4.1.1 General
a) The Contractor is to employ a laboratory technician at batching plant and at site

and install on site a testing laboratory approved by the Engineer to perform the
workability tests, making concrete cubes and cylinders for the testing described in
this specification.
b) Sampling and testing for quality control of the placement of concrete shall include
the following as directed by the Engineer.
3.4.1.2 Test Cubes
Cubes shall be manufactured in an on-site laboratory, specially equipped for the

purpose, in controlled conditions. They shall be made, cures, stored, transported and
tested to BS EN 12390-1, 2 & 3: 2000, BSEN 12390-7. The method of compacting
cubes shall be an approved method of hand compaction or either using a vibrating
table in the laboratory or 25 mm vibrating poker on site.
3.4.1.3 Sampling Cubes
a) A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each day.
The standard deviation shall be calculated from at least 40 individual cube results
each representing separate batches of similar concrete produced by the same
plant under the same supervision. The current margin for the plant shall be thus
established as 1.64 times the standard deviation.
b) Thereafter one sample shall be taken at random for each class of concrete in
accordance with Table 3.15 of the Specification. A quality analysis of concrete
cubes of minimum 100 batch results shall be used in assessing whether the
moving strength of concrete is being maintained at a sufficient level to comply
with specification requirements.
c) It is then possible to form an estimate of the future distribution of results. Should

these show greater variability as time goes on, due to various factors then the
increased variability shall be investigated.
d) In addition to the above requirement, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of a
single pour.
e) From each sample three cubes shall be made for testing at 28 days and three for
testing at 7 days for control purposes.
f) Six cylinder samples shall also be taken to determine the spilt tensile strength of
the concrete 3 at 7 days and 3 at 28 days, as specified in ASTM C496: 1996.
These samples shall be taken from every 100 batches, but at least once a week

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during concreting operations, and shall coincide with samples taken for test
cubes.
g) The frequency of sampling may require to be varied as directed by the Engineer.
h) The procedures shall be repeated when materials or design mixes are changed.
3.4.1.4 Cube Strength Results
a) Concrete production results will be acceptable if:
(i) The average strength determined at the age of 28 days from a sample of
three or more cube test results exceed the specified CCS by 0.5 times the
current margin,
(ii) No individual result of the sample is less than that specified CCS minus 4
N/m m²),
(iii) Number of individual results in the sample below the specified CCS is not
more than one.
b) If the above criteria are not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate:
(i) Cutting and testing cores from placed concrete.
(ii) Non-destructive testing of placed concrete
(iii) Load-testing relevant structural units.
(iv) Cutting out and replacing defective concrete.
c) If the range of individual cube strengths made from the same sample exceeds
15% of the mean, then the method of making, curing and testing cubes shall be
checked. In the event of a sample having a range exceeding 20%, then the result
shall be unacceptable and the Engineer may order any of the following actions:
(i) Changing the mix.
(ii) Improving quality control
(iii) Cutting and testing cores from placed concrete.
(iv) Non-destructive testing of placed concrete.
d) In the event of cutting and testing of cores are required, the Contractor shall cut
cores from approved locations and test them to BS 1881 or by BS 6089. The
acceptance criteria shall be as specified in BS 6089.

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3.4.1.5 Durability Tests
a) Concrete shall be tested for durability properties by undertaking absorption and

permeability tests where appropriate, or directed by the Engineer, as directed
below:
b) Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out between
28 and 32 days in accordance with BS 1881 Part 122: 2011.
c) Effective permeability tests in accordance with the method described in BS EN

12390 Part 8: 2009 shall be carried out. The maximum acceptable penetration at
seven days and the maximum acceptable penetration at 28 days shall be as
given in Table 3-13.
d) Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried out.
3.4.1.6 Other Tests
a) When instructed by the Engineer concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and tested
in accordance with BS EN 12390-7-2000 , BS 1881-121 :1983 , BS 1881-122 :
1983, BS 1881-209 : 1990 , BS 1881-2008 or BS EN 772-2: 1998, BS EN 771-
3:2003. The maximum acceptable limits shall be as given in Table 3-13.
b) Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to curing and to check testing and sampling
errors.
c) The air content of air-entrained concrete shall be determined (ASTM C231) for
d) Compaction factor, slump, vebe or other workability tests shall be carried out as
required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree for workability shall be as for the
trial mixes; or as given in Table 3.12.
3.4.1.7 Documentation
a) A summary of all concrete cube results at 7 days and 28 days, histogram and
quality analysis chart showing the moving average, mean strength distribution
and the standard deviation of concrete strength shall be submitted on a monthly
basis.
b) The temperature differential chart of each concrete pour.

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Table 3.13 Concrete - Durability and other Performance Requirements
Sr. Specified Concrete Area of Use Exposure Method CCS at Chloride Water Initial surface 30 min Max Max Surface
Concrete Grade Classes of 28 days permeabili permeability absorption to water drying wetting Tensile
Class to BS placing (Mpa) ty to ASTM to BSEN BS1881 absorpti shrinkag Expansion Strengt
8500-1 12390:P8:200 (Part5) / Part on to BS e to BS to BS h
2002 & C-1202 9 208 (m1/ 1882 1881 : 1881: BS1881
Table A-1 (Coulombs m²/Sec@30 Part 122 P5 1970 1970: P5 : Part
to A-5 of ) min. (%) Test (5) Test: (5) or 207:
BSEN or BS BS 6073
206-1 6073: P1 Part 1 1992
App: D App: D
1. PC-BL C25/20 Blinding Crane N/A N/A N/A N/A N/A N/A N/A
SRC or Pump
2. PC-UR C30/20 Mass Crane N/A N/A N/A N/A N/A N/A N/A
SRC Concrete or Pump
including
minor RCC
structures
3. PC-GR C35/10 Granolithic Crane N/A N/A N/A N/A N/A N/A N/A
SRC concrete or Pump
4. * RC-S/F C40/20 Water Crane 1000 12mm; 8mm @7days=0.03 1% 0.05 0.03 3.0 MPa
SRC retaining or Pump
RCC/WS/F structures @7days @28
@28days days=0.02

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Sr. Specified Concrete Area of Use Exposure Method CCS at Chloride Water Initial surface 30 min Max Max Surface
Concrete Grade Classes of 28 days permeabili permeability absorption to water drying wetting Tensile
Class to BS placing (Mpa) ty to ASTM to BSEN BS1881 absorpti shrinkag Expansion Strengt
8500-1 12390:P8:200 (Part5) / Part on to BS e to BS to BS h
2002 & C-1202 9 208 (m1/ 1882 1881 : 1881: BS1881
Table A-1 (Coulombs m²/Sec@30 Part 122 P5 1970 1970: P5 : Part
to A-5 of ) min. (%) Test (5) Test: (5) or 207:
BSEN or BS BS 6073
206-1 6073: P1 Part 1 1992
App: D App: D
5. * RCC/PU/F C50/20 Pre-cast units Crane 1200 15mm; @7days=0.03 1.5% 0.05 0.03 3.0 Mpa
SRC , or Pump 10mm
@28
@7days days=0.02
@28days
6. * S.C.C C60/20 In-situ piling Crane 1500 15mm; @7days=0.03 1.5% N/A N/A N/A
OPC / SRC works or Pump 10mm
@28
@7days days=0.02
@28days
7. U.W.C C40/20 Under-water Crane N/A N/A N/A 1.5% N/A N/A N/A
OPC/ SRC concrete or Pump
8. PC - BR C40/10 Precast bricks Crane N/A N/A N/A 2.0% N/A N/A N/A
OPC or Pump
9. * RCC/AG/F C40/20 Building Crane 1200 15mm; @7days=0.03 1.5% 0.05 0.03 3.0 MPa
OPC structures or Pump 10mm
@28
days=0.02

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* Note: Durability tests for concrete are applicable only to reinforced concrete.

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3.4.2 Minimum Routine Concrete Testing
3.4.2.1 General
Under the supervision and direction of the Engineer, the Contractor shall perform all
tests as shown in Table 3.14 unless otherwise instructed by the Engineer.
Table 3.14 - Frequency of Testing for Fresh and Hardened Concrete Sampled
from Site
Minimum Frequency
Test
C25 C 40 and Above
Temperature As directed by the Each load

Engineer
Concrete Slump and Every 25m³ Each load (flow test applicable
flow only for self compacting
concrete)
Visual Examination of As directed by the Each load

Aggregates (after Engineer
washing)
Concrete density & 6 cubes, minimum once As given in Table 3.15

Compressive Strength per day
Concrete unit weight – Every 100m³

(wet) & WCR
Split tensile strength – From every 100 batches
Flexural Strength – From every 100 batches
Concrete bleeding – From every 100 batches
Water permeability – Every 500m³/ As directed by the

Engineer
ISAT – Every 300m³ or as directed by

the Engineer
Rapid chloride – Every 250m³ or as directed by

penetration (RCP) the Engineer

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Minimum Frequency
Test
C25 C 40 and Above
SO3 and Cl contents – Every 250m³ or as directed by

the Engineer
Concrete temperature – For each concrete pour of all

difference between water retaining structures
core & the surface
3.4.2.2 Minimum Test Requirements for Concrete
One set of 6 cubes for each class of concrete and for each particular application
represent a maximum quantity of concrete as shown in Table 3-15. The point of
sampling of fresh concrete shall be at delivery into the construction unless otherwise
directed by the Engineer. Each set of cubes shall be made from a separate batch.
Table 3.15 Sampling Rates for making Cubes
Sr. Type of Structure Sampling to Represent a

Volume of m³ up to
1 Critical structures e.g. masts, cantilevers, 10

columns
2 Intermediate structures e.g. beams, slabs & 20

walls
3 Heavy concrete construction e.g. solid rafts 50 or as agreed on site

& mass fill concrete
3.4.2.3 Routine Test Cubes & Cylinders
a) Test cubes shall be randomly taken from the concrete which is being used in the
work and prepared in accordance to the relevant standard and the following
provisions, unless otherwise approved by the Engineer.
(i) All cubes shall be made at the point of delivery and all cubes for each set
must be from the same load (transit mixer truck)
(ii) Use approved cube moulds of the same type and manufacture for making
all test specimens.

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(iii) All cubes shall be kept in closed insulated boxes for initial curing until
removed from the mould and placed directly in a suitable curing tank.
(iv) Six cubes (150 mm) shall be made for density and compressive strength
testing.
(v) Six cubes (150mm) shall be made for water permeability testing.
(vi) Six cubes (150mm) shall be made for RCP testing.
(vii) Each grade of cubes shall be numbered consecutively throughout the work
and marked with the date.
(viii) Six cylinders 150mm dia & 300 mm long shall be made for tensile splitting
strength.
b) For compressive strength and density, test 3 cubes at 7 days and 3 at 28 days.
c) The Mean of 3 cube strength results shall be taken as the test result.
d) For Water Permeability, test 3 cubes at 7 days and 3 cubes at 28 days.
e) For Rapid Chloride Penetration, test 3 cubes at 7 days and 3 cubes at 28 days.
f) For Tensile Splitting strength, 3 cylinders at 7 days & 3 cylinders at 28 days.
g) If the test cubes fail to meet the requirements of Spec Cl. 3.4.1.4 & Table 3.13
then the following action shall be taken by the Contractor.
(i) Suspend concreting operation and do not proceed further without

Engineer’s approval.
(ii) Take test cores in accordance with BS EN 12504-1:2000, from the suspect
concrete and test as directed by the Engineer. Cylindrical core specimens of
150 mm nominal diameter shall be cut perpendicular to the face of the
hardened concrete in the Works for the purpose of examination and testing.
(iii) Prior to preparation for testing, specimen shall be made available for
examination by the Engineer
(iv) If the crushing strength of the specimen tested in accordance with BS EN

12504-1:2000 is less than the minimum crushing strength specified or if , in
the opinion of the Engineer, the concrete fails to meet the specified
requirements in other respects, the concrete in that part of the Work will be
considered not to comply with the specified requirements.
3.4.3 Routine concrete coring and testing
a) From every 500 cubic meters of concrete cast in water retaining structures the
Engineer shall designate a structure (or portions of a structure) to be core
sampled and tested for RCP values.
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b) Each sampling shall consist of three 100mm dia. Cores of suitable length for RCP
testing. Extreme care shall be taken while coring and be taken without cutting the
reinforcement.
(i) The Contractor shall provide a cover meter to locate the rebars.
(ii) Core locations shall be marked by the Engineer.
(iii) The cores will be given to the Engineer for delivery to an independent
laboratory of the Engineer’s choice.
c) The cores shall be promptly tested for RCP values and the results promptly given
to the Engineer.
d) The average value shall not be more than that given in Table 3.13
e) All associated costs for coring and testing, refilling core holes shall be borne by
the Contractor.
3.4.4 Test on Hardened Concrete
The following tests are to be conducted on hardened concrete as directed by the

Engineer.
a) Analysis of hardened concrete in accordance with BS 1881: P 124 to determine

the cement content, aggregate grading, aggregate content, water content, water
cement ratio, type of cement, sulphate and chloride content and alkali content in
the concrete.
b) Non- destructive tests as referred in BS 1881: Part 201.
c) Core test in accordance with BS 6089.
3.4.5 Non – Compliant Concrete
a) Concrete shall be considered to be non-complaint if any of the following

conditions are found to exist.
(i) Compressive strength results less than those specified value.
(ii) Unapproved mix is utilised.
(iii) Approved mix proportions or materials have been changed.
(iv) Sulphate and chloride content in excess of those specified values.
(v) Water/cement ratio in excess of those specified.
(vi) Cementitious material contents and the proportion less than those specified.
(vii) GGBS content in excess those specified.

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(viii) Microsilica content in excess those specified.
(ix) Cube results for, water permeability or RCP in excess of those specified.
(x) Mean core results for RCP values taken from water retaining & other
structures in excess of that specified in Table 3.13.
(xi) Concrete that fails to meet one or more requirements of the specification.
b) Any part of structures containing non-complaint concrete shall be completely

broken out and removed, unless otherwise accepted by the Engineer.
c) The Engineer’s decision shall be final in all aspects related to non-complaint

concrete.
d) Any additional costs associated with non-complaint concrete shall be at

Contractor’s expense.
3.5 CONCRETE DESIGN LIMITS
3.5.1 Limits of Specifications
The following will be designated by the Engineer within the limits of the
Specifications:
a) Limiting composition and properties of concrete as specified in Table A11 to A20

of BS 8500-1:2006.
b) The minimum cement content in kg per cubic metre of concrete
c) The alkali content in the concrete mix
d) The fineness of cement in m²/kg
e) The maximum allowable water/cement ratio including surface moisture, but

excluding water absorbed by the aggregates.
f) Type of aggregate and cement
g) Slump or slumps and the concrete temperature designated at the point of delivery
h) The peak temperature of concrete within the pour
i) Changes requested by the Contractor in mix proportioning previously approved

shall be made only with the agreement of the Engineer.
j) The maximum temperature differential within a single concrete pour
k) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as directed by
the Engineer. No additional payment shall be made for the added cement.

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l) Initial surface absorption of concrete
m) Failure of the mixed concrete to meet specifications as determined by the

Engineer will be grounds for the Engineer to reject the concrete.
n) Surface hardness and tensile strength of hardened concrete.
o) Bleeding limitations when tested in accordance with ASTM C 232.
3.5.2 Measurement of Ingredients
a) The aggregates for the concrete shall be measured by weight but measurement
by volume may be allowed in special circumstances with the approval of the
Engineer.
b) When the aggregates are to be measured by volume, the proportions of fine and
coarse aggregates shall be measured in well-constructed gauge boxes of
dimensions approved by the Engineer’s Representative to guarantee that whole
multiples of such gauge boxes will ensure the use of one more whole bags or
containers of cement and the capacity of the concrete mixer shall be such as to
ensure that no splitting of cement bags or containers is required. Gauge boxes
shall be properly filled and struck off level, addition of fine aggregates to allow for
bulking due to moisture content being made as required.
c) An efficient water measuring device shall be fitted to each concrete mixer
d) Any cement container shall be such as to contain an accurately weighed amount

of cement.
3.5.3 Making Concrete
3.5.3.1 General
a) The weighting and water dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in BS
1305 and checked against accurate weights when required by the Engineer.
b) The mass of the fine and coarse aggregates shall be adjusted to allow for the free
water contained in them. The water to be added to the mix shall be reduced by
the quantity of free water contained in the fine and coarse aggregates.
Table 3.16 - Batching Accuracy
Material Accuracy
Cement
a. Above 30% scale capacity 1%

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Material Accuracy
b. Below 30% scale capacity -0- +4%
Aggregates
a. Individual batches 2%
b. Cumulative weight, % of the required cumulative 1%

weight
3%
1. Above 30% capacity
2. Below 30% scale capacity
Water
a. Added by weight or volume 1%
b. Total water (including any wash water) 3%
Admixtures
a. By weight or volume 3%
c) Any admixture which may be used shall be measured separately in calibrated and
transparent dispensers which are easily visible to the operator, unless otherwise
d) Admixture shall be added to the mixture with the water preferably in a single shot.
e) Dispenser shall be capable of dispensing the agent in quantities varying by not

more than 3% from the quantities required and in such manner to ensure
uniform distribution of the agent throughout the batch during the time of mixing.
(i) Capability of the dispenser to achieve the required dosing and delivery
requirements shall be demonstrated to the Engineer.
(ii) Shall be checked each day before concrete mixing commences.
f) Contractor shall provide weights, containers and equipment necessary for testing
the accuracy of the weighing system, water-measuring system and admixture
dispenser.

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3.5.4 Mixing Concrete at Batching Plant and the Procedure to deliver the Concrete to
Site
a) All concrete batching shall comply with the following requirements, unless
otherwise approved by the Engineer.
b) All concrete shall be manufactured in a fully automated, computer controlled

batching plant.
c) The plant shall be equipped with a suitable water chiller along with sufficient
insulated storage and flake ice making facility with automatic feed to ensure
concrete temperatures are maintained within specified limits.
d) Dry mixing or mixing in the truck drum is not allowed.
e) Automatic moisture control probes set in the hoppers shall be used to

continuously determine the moisture content of any washed or sprinkled
aggregates.
f) Mixing and transporting of concrete shall be in accordance with the requirements

for ready mixed concrete specified in BS 8500 or ASTM C94 except as modified
hereunder or as directed by the Engineer.
g) Concrete shall be transported from the mixer to the point of placing as rapidly as
practicable in approved agitators.
h) Concrete shall be mixed in batches with suitable equipment capable of combining

the aggregates, cement, GGBS, Microsilica, water proof powder and water
(including admixtures, if any) into a mixture of uniform colour and consistency and
of discharging the mixture without segregation.
i) Amount of concrete mixed in anyone batch shall not exceed the rated capacity of
the mixer.
j) Manufacturer's rated capacity shall be displayed on the mixer in terms of the

volume of mixed concrete.
k) The mixing time shall not be less than that used by the mixer manufacturer in
assessing its performance or as determined by trials carried out in the presence
of Engineer.
l) All materials from the previous batch shall be removed before materials for a
fresh batch enter the drum.
m) If work is suspended, including any periods exceeding twenty minutes, the mixers
and all handling plant shall be washed with clean water.
n) All mixing and batching equipment shall be maintained free of set concrete or
cement and shall be clean before commencing mixing.

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o) The natural 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.
p) The amount of water added to each mix shall be adjusted to maintain the
approved free water/cementitious ratio of the mixed concrete.
q) Limitation of water/cementitious ratio - No concrete shall exceed the

water/cementitious ratios as given in the approved mix design.
r) Whenever required by the Engineer free water/cement ratio shall be determined

in an approved independent laboratory on concrete samples cored from locations
selected by Engineer. The Contractor shall bear all the costs.
s) In no circumstances shall the consistency of the concrete be such as to permit a

separation of the aggregate from the mortar during handling.
t) Excess water shall not be permitted and any batch containing such excess will be
rejected.
u) Manufacturing and delivery resources of the proposed supplier shall be adequate

to ensure proper and timely placement and shall be subject to the approval of the
Engineer.
v) Each load shall be accompanied by a batch ticket containing at least the following
information:
(i) Name of Ready Mix Co.
(ii) Batch Ticket No. and serial No. of computer printout.
(iii) Location of Plant
(iv) Name of Customer
(v) Date
(vi) Concrete Grade
(vii) Type and Manufacturer of Cement, GGBS and Microsilica
(viii) Quantity of Concrete in the Transit Mixer (m³)
(ix) Total Quantity Ordered (m³)
(x) Truck Identification Number
(xi) Signature of Ready Mix Representative
(xii) Tel. No. of Technical Manager
(xiii) Type and Brand of each Admixture per batch (litres)

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(xiv) Type of all Aggregates
(xv) Enough space to write comments by the Site Staff
w) Each load shall be accompanied by a computer controlled non-simulated printout

listing at least the following:
(i) Name of Ready Mix Co.
(ii) Serial No. of computer printout.
(iii) Concrete Grade
(iv) Mix Identification Name or Number
(v) Confirmation of non-simulated print out
(vi) Time (hr: min.) when water is first added to the mix
(vii) Mixing Time (sec.)
(viii) Target Quantities
(ix) Individual Weight of Aggregates (per batch) in kg.
(x) Cumulative quantity of each ingredient per truck (or load)
(xi) Weight of Cement per Batch (kg)
(xii) Weight of GGBS per Batch (kg)
(xiii) Weight of Microsilica per Batch (kg)
(xiv) Weight of Pozzolanic Materials per Batch (kg)
(xv) Quantity of each admixtures (per batch) in litres
(xvi) Quantity of Flake Ice per Batch (kg)
(xvii) Moisture content of each Aggregate (%)
(xviii) Water Absorption of each Aggregate (%)
(xix) Total Quantity of Water, added per Batch (kg)
(xx) Total Quantity of Moisture in each Batch
(xxi) Variation of individual Batch Quantities, of all Materials per Batch (% errors)
(xxii) Total Quantity of Water absorbed by each aggregate in a Batch
(xxiii) Actual free Water / Cementitious ratio total variation of
(xxiv) accumulated individual Ingredients per Batch (% error)

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(xxv) Concrete slump at plant
(xxvi) Concrete temperature at plant
x) A copy of the batch ticket and computer printout shall be given to the Engineer's
site representative upon delivery for each and every truck.
y) The print out and batch ticket may be combined provided the minimum
information is included. Loads may be rejected for insufficient information at the
Engineer's discretion.
z) Unless approved otherwise in advance of batching, all concrete of a particular mix

for any one day's pour, or for each structure shall be from the same batching plant
with the same type of materials.
aa) Concrete mixes containing aggregate and cement from different sources shall not
be permitted in a single structure, unless otherwise approved by the Engineer.
bb) No water shall be added into the transit mixer during transport of concrete to the
site or at the site.
cc) Each mixer truck shall arrive at the job site with its water container full.
dd) In the event that water container is not full or field test results are outside the
acceptable limit, the load shall be rejected.
ee) Except for grade C25 concrete temperature in each load shall be recorded at the
point of discharge.
ff) Perform slump tests in accordance with BS 1881 at plant and at site for each load
delivered to site, except of grade C25 which shall be at the Engineer's decision.
gg) Concrete placement shall proceed only following satisfactory verification of slump
and concrete temperature or other specified field test results.
hh) The Contractor shall provide at no extra cost, all facilities and services of
technician, including suitable transport, acceptable to the Engineer, for the sole
use of Engineers staff or persons authorised by him to monitor the concrete
batching, mixing, sampling and testing.
3.5.5 Waterproof Concrete
Concrete for all water retaining structures shall be of water proof concrete as
described below.
a) Waterproof concrete shall consist of structural concrete as specified herein and

with the addition of an approved waterproofing additive. This shall be mixed in
accordance with the manufacturer’s instructions. Supervision from manufacturer’s
technical representative or approved applicator shall also be provided.

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b) Contractor’s attention is drawn to the special care required for casting water
retaining structures. These are all designed to BS EN 1992-3:2006 and the
contractor’s attention is to ensure that the workmanship and curing are as per BS
EN 1992-3:2006.
c) All water retaining concrete structures will be water tested in accordance with BS
EN 1992-3:2006 and should comply the requirements specified therein.
d) The contractor shall take full responsibility for ensuring that the resulting
construction is completely watertight and free from penetration of moisture without
the application of membrane. Should there be any leakage or damp patches in
the finished work after water test, the affected works shall be rectified to the
Engineer’s approval at the Contractor’s cost.
e) Water bars shall be provided in all construction joints and the type of water bar
will be as specified or to the approval of the Engineer. All water bars will be joined
by welding strictly in accordance with the manufacturer’s recommendations and
all multiple joints and special intersections shall be manufactured by the supplier.
f) All services holes cast in shall incorporate sleeves with puddle flanges, and
temporary openings for services should incorporate water bars.
g) The maximum allowable drying shrinkage of aggregate shall be 0.045%
h) Care shall be taken at all times to ensure that water bars are not perforated or
damaged in any way and the concrete shall be carefully placed and compacted
around the water bars to ensure void free impervious concrete.
i) All kickers or starter plinths to walls (if used) on the periphery of the water tight
construction shall be cast monolithically with the base and shall be minimum
height as shown in the approved drawing.
j) The formwork shall comply with this Specification and in addition any bolt or
fastening embedded in or passing through the concrete shall be to the water
tightness of the structure. Ties passing through liquid retaining structure shall be
approved by the Engineer and shall be of a type that will not form a potential
drainage path through the concrete and will permit their removal or partial
removal without damage to the concrete. All ties shall incorporate an anti-torsion
bar or other device to ensure that they do not twist on striking. They shall be
degreased before being placed in position and the use of grease on the outside of
any end-former, later removed from the concrete, will not be allowed. The ties
shall not foul or touch the reinforcement. The use of through bolts will not be
permitted. The surface of the concrete in all tie bolts holes shall be roughened by
mechanical wire brushing or similar means after which the hole shall be sealed in
an agreed manner with an approved patent expanding mortar or filling compound.
k) Special attention shall be given to the elimination of shrinkage or thermal

cracking. The size of any bay or slab or wall and sequence of pouring shall be
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such as to minimise cracking. Where box-outs are permitted to take the passage
of pipes or ducts through concrete structures, the opening so formed shall be
grouted up using the same concrete mix as in the main structure after fixing of the
pipework. Where directed by the Engineer the sides of the opening formed shall
be scabbled prior to fixing of the equipment. Shuttering shall be provided as
required.
l) Slotted inserts or sockets cast into the structural concrete shall be provided for all
fixing including services. The cutting of holes in watertight concrete is strictly
prohibited. Where box-outs are permitted below water level, the shuttering shall
be provided with joggle joints and the sides of the opening formed shall be
scabbled prior to fixing of the equipment. Where ordered by the Engineer, the
box-out shuttering shall include a water bar and the concrete joint at the water
face shall be provided with an approved sealer in a pre-formed sealing chase.
m) For structural design purposes the horizontal reinforcement should be completely

continuous at vertical joints.
n) A central water stop shall be used together with sealing compounds on both faces
and a sealing strip as specified in Clause 3.13.
o) Where roofs and walls are monolithic, movement joints in roofs shall correspond
with those in walls are to be provided to avoid possibility of cracking.
3.5.6 Self-Compacting Concrete
3.5.6.1 General
The concrete used for piling works or having congested reinforcement shall generally
be with self-compacting concrete which is able to flow under its own weight, even in
the presence of dense reinforcement, without the need for any vibration, while
maintaining homogeneity and avoiding segregation.
3.5.6.2 Concrete Mixes
a) Normal Designed Mix for Piling works
(i) To the relevant clauses of BS 5328-2, BS 8500 and BS EN 206-1:2000.
(ii) Grade: C60 Self Compacting concrete
(iii) Nominal maximum size of aggregate : 20mm
(iv) Aggregates(s):
1. Coarse: Coarse aggregate content shall be between 28 to 35% of the

mix volume to BS EN 12620:2002 + A1:2008 .
2. Sand: The sand content shall be minimum 38% of the mix, to BS EN

12620:2002 + A1:2008.
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3. Special requirements: maximum dry shrinkage when tested to BS EN

1367-4:1998 0.05%
(v) Cement: (OPC)
(vi) Minimum cement content : 400kg/m³
(vii) Maximum free water cement ratio: 0.35
(viii) Maximum cement content: 450 kg/m³
(ix) Admixtures: Refers to clause 3.2.2.3 (c&g)
(x) Cement replacement: condensed silica fume conforming to ASTM C 1240,

maximum weight 7% of the total cementitious materials.
(xi) For concrete containing Portland cement the maximum total percentage of
chloride ion by mass of cement: 0.2%
(xii) The total content of acid soluble sulphate shall not exceed 3% by weight of
cement
(xiii) Rate of sampling for compressive strength testing: one sample per 10 m³ or
10 batches whichever represents the lesser volume, but not less than one
for each day of use.
(xiv) The alkali content (Na2O and K2O) of the concrete shall not exceed 3 kg/m³
(xv) Information to be provided by the producer: As BS 8500-1/2, BS EN 206-

1:2000 Clause 6.
3.5.6.3 Trial mixes:
a) The Contractor’s mix proposals for each mix require the Engineer’s approval.
Existing data provided as evidence of satisfactory previous performance shall
include the workability and water/cement ratio.
b) During production the Contractor shall inform the Engineer of all changes in
sources of materials or cement content.
c) Trial mixes shall be made initially as well as before any substantial change is
made. No changes shall be made without the Engineer’s approval.
3.5.6.4 Performance Testing of Trial Mixes:
The following testing shall be carried out at the trial mix design stage and periodically
during production to verify the mix design.
a) Consistency and segregation of self-compacting concrete

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(i) The consistency shall be verified by slump flow using Abrams cone. The
acceptable range for this test is between 530 mm – 600 mm.
(ii) The proportions of the ingredients of the concrete, including the water, shall
be so chosen that the concrete will be workable enough to be fully
compacted and not be prone to segregation or bleeding.
(iii) Segregation of aggregates in self-compacting concrete shall be verified

using the V-funnel test. The acceptable range for results is 6 to 10 seconds.
b) Bleeding
The bleeding test for self compacting concrete shall be performed in accordance
with ASTM C232-90 and shall indicate no bleeding of the concrete. Testing shall
be carried out on all trial mixes and on every 500m³ of concrete produced.
c) Durability Tests
The following tests shall be carried out on all trial mixes:
(i) Chloride permeability to ASTM C 1202 Maximum Charge Pass (Coulombs)

age 28 days
Self-compacting concrete 1,500
(ii) Water permeability to BSEN 12390: P8: 2009 Maximum Penetration (mm)
Age 28 days
Self-compacting concrete: 10 mm
(iii) Initial surface absorption to BS 1881 Part 208 Maximum ISAT at 28 days:
30 minute test
Self-compacting concrete: 0.02ml/ m²/sec
(iv) 30-minute absorption to BS 1881 Part 122: Maximum Penetration (mm) Age
28 days
Self-compacting concrete: 2%
d) Strength Tests
(i) For each mix of concrete the Contractor shall prepare three separate
batches of concrete using the materials which, have been approved and the
mixing plant which he proposes to use for the Permanent Works.
(ii) Six test cubes shall be cast from each batch.
(iii) The making, curing and testing of all test cubes shall comply with the
requirements of BS 1881. The consistency test of the concrete carried out in
accordance with BS 1881 shall be recorded for a range of mixing
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temperatures and at various times after mixing. The mixing temperature

shall be temperature after the water has been added. Slump control graphs
shall be prepared for use on site.
(iv) Two cubes from each batch shall be tested for compressive strength at 7
days, three at 28 days and one cube shall be kept as spare.
(v) The density of all cubes shall be determined before the cubes are crushed.
(vi) The strength of the mix shall be approved if the mean strength at 28days of
the set of none cubes from the mix (three cubes from each of the three
separate batches) exceeds the Characteristic Strength plus 11.5 N/m m².
3.5.7 Precast Concrete
3.5.7.1 General
The work included in this Section comprises furnishing all labour, equipment,
appliances and materials and performing all operations in connection with structural
precast concrete Work.
3.5.7.2 Quality Assurance
a) This Specification Section shall govern all structural precast concrete work for the
project except where more stringent or specialised requirements are indicated.
b) Precast concrete pipes are generally made with concrete surrounded GRP pipes
for micro-tunnelling. Pipe line systems shall be as conforming to design chemical
class DC-4 specified in CL 3.2 & Table ‘4a’ of BRE Digest No.01 Part 4: 2003.
Design guides shall be as specified in CL 3 of BRE Digest No.1, Part 4: 2003.
c) All work shall be performed to secure for the project homogeneous concrete
having the required strength, surface finish, materials, durability, and weathering
resistance, without planes of weakness or other structural defects, and free of
honeycombs, air pockets, voids, projections, offset of plane and other
defacements of concrete.
d) Be fully responsible for any defects or damage in the structure or building arising
from faulty materials or workmanship and the costs of remedial measures in order
to ensure that the completed work complies with the Contract Documents.
e) Base construction methodology on the construction indicated in the Contract

Documents.
f) No alternations or substitutions of the structural systems shown on the Drawings

are permitted unless otherwise specified.
g) Supervise and co-ordinate all phases of the structural precast concrete

construction process and be responsible for the complete manufacturing process.

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(i) 1. All methods of manufacture and practices of handling raw materials and
manufactured concrete shall be reviewed by the Engineer prior to execution
of the structural precast concrete work.
h) Only materials of known quality shall be incorporated in the work.
(i) 1. All materials shall be properly selected, reviewed and approved by the
Engineer before use and maintained during shipment, storage and use.
(ii) Construction systems and techniques shall be properly selected, reviewed

and approved by the Engineer before use and maintained throughout the
complete structural precast concrete construction phase.
(iii) Adequate spare equipment, parts, additional components and repair

facilities shall be available for all tools and equipment.
i) Regardless of approvals by the Engineer, the Contractor shall be responsible for

all materials and methods of structural precast concrete work.
If any work does not satisfy the Contract Documents the Contractor shall at no
additional cost to the Employer:
(i) implement removal, replacement or remedial work.
(ii) revise procedures or materials to prevent recurrence of unacceptable work.
3.5.7.3 Qualifications
a) Structural precast work shall be executed by an approved specialist Sub-

Contractor.
b) Contractor may execute this work himself if he can satisfy the Engineer that he
has sufficient experience and expertise in this field.
(i) Provide satisfactory evidence that his tradesmen and their supervisory
personnel engaged in such work have successful experience with work
comparable to that shown and specified.
(ii) Provide details of organised quality control and testing procedures.
3.5.7.4 Testing
a) Concrete shall be tested as specified in relevant sections.
b) Conduct load tests in accordance with BS EN 1992-1-1:2004 or as specified

separately before erection and also after erection.
(i) Casting of topping slab to substantiate the performance characteristics of

structural precast element so designated by the Engineer.
(ii) Review itinerary with the Engineer prior to testing.

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(iii) Provide calibrated instrumentation for measuring and recording load,

deflection, stresses and strains.
c) The Engineer will evaluate the adequacy of the Contractor’s quality control.
In addition to the requirements hereinafter specified under Paragraph “MIX

DESIGN”, the Contractor shall:
(i) Furnish labour required to facilitate testing.
(ii) Inform the Engineer with at least one day’s advance notice when concrete is
to be placed.
(iii) Provide storage facilities for concrete test cubes
(iv) Provide materials samples and access to materials as required for testing.
d) Be responsible for the expenses of testing or inspection resulting as a

consequence to the following:
(i) Work not evidencing compliance with this Specification.
(ii) Additional testing such as additional cubes for early breaks etc., for
construction purposes.
(iii) Testing to verify the adequacy of work done without prior notice, without
proper supervision, or contrary to standard construction practice.
(iv) Providing additional tests as requested by the Engineer.
e) Contractor shall station a qualified technician at the batching plant during the
entire time of batching and shall continuously test, inspect and report on the
following:
(i) The batching equipment and procedures.
(ii) The conformance of the materials (cement, aggregates, water and

admixtures) to the approved materials.
(iii) Correct dosage of admixtures as prescribed by the manufacturer are used.
(iv) The proportioning of the concrete.
(v) Mix transport equipment.
f) Should the batching plant be located more than 500 meters away from the site
offices, the Contractor shall provide suitable transport acceptable to the Engineer,
for the sole use of the Engineer’s staff.
g) Contractor shall station a qualified technician at the casting site to continuously

witness the test, inspect and report on the following:

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(i) For each forty cubic meters of each different concrete type or portion
thereof cast per day, the following tests will be performed in accordance
with the applicable standards.
1. Six strength tests using 150 x 150 x 150 mm cubes per BS 1881, made
from a mix selected at random.
a. Break three cubes at age 7 days and three cubes at age 28 days.
b. Additional test specimens may be cast for construction progress

control purposes.
2. Slump Tests :One per each batch of concrete as per BSEN 12350 –2.
3. Temperature Tests: Use thermometer calibrated to +/- 0.5% accuracy.
a. Immerse the thermometer probe into each concrete batch at the

time of placement.
b. Stabilized temperature of concrete shall be less than the specified

30C.
(ii) Check and verify conformance with Contract Documents and approved
shop drawings the following:
1. Reinforcing bars
2. Embedded items
3. Formwork
(iii) Check all openings and provisions for full co-ordination with all trades in the
Contracts as shown on approved shop drawings.
h) Contractor shall provide facilities and equipment for conducting of all tests
specified herein except for the strength test which should be carried out by an
approved independent testing agency.
i) Test specimens may be cured by immersion.
j) All welding of steel supports, anchorages, connections and attachment will be

visually inspected by the Engineer.
3.5.7.5 Quality Control
a) Contractor shall prepare and provide his quality control programme for structural
precast concrete work with particular attention to details, pre-checking processes,
procedures and close supervision.

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(i) In order to assure that proper work is performed to prevent later corrective
actions, the Contractor shall provide at least one experienced supervisor full
time to provide quality control for structural precast concrete work.
(ii) The assignment will not relieve the Contractor’s other quality control
personnel of their duties relative to the quality control of the structural
requirements and surface finish of the structural precast concrete work.
b) Contractor shall arrange for the training of his quality control personnel who will
perform quality control of structural precast concrete work. Training shall include
but is not limited to:
(i) Materials evaluation
(ii) Special mix design techniques.
(iii) Mix placement
(iv) Vibrator selection and use.
(v) Formwork details formwork protection.
(vi) Release agent use.
(vii) Reinforcing steel
(viii) Detailing and installation
(ix) Finishing equipment and techniques.
(x) Corrective procedures and protection of completed work
c) Contractor’s quality control personnel shall be responsible for verifying all details
necessary to produce the final structural design objectives.
d) Contractor’s quality control personnel shall also verify the quality of the structural
precast concrete work and guide the production of results which will be within
acceptable physical tolerances.
3.5.7.6 Pre-construction Meeting
a) Within a reasonable time prior to commencement of structural precast concrete

work, the Contractor shall schedule a pre-construction meeting at a mutually
agreeable time with the Engineer and his designated Representative. The
purpose of the meeting is to discuss design, materials, methods of work and
forming systems for structural precast concrete work.
b) Prior to this meeting, the Contractor shall submit to the Engineer the following all
pertinent information.
(i) Written procedural outlines.

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(ii) Description of forming systems.
(iii) Brochures of proposed equipment.
(iv) Sources of all materials.
(v) Characteristics of all materials.
(vi) The above information shall be received by the Engineer at least 30 days
prior to the pre-construction meeting.
c) During the pre-construction meeting the Contractor shall present an outline plan
for all concrete work to be accomplished and indicating special procedures
relative to the structural precast concrete work. The outline shall include:
(i) Reviews of sources of materials with a commentary on source.
(ii) Source variations during the course of the work.
(iii) Storage and use of materials.
(iv) Description of all equipment necessary for batching, mixing, conveying,

placing, forming, reinforcing, and compacting.
(v) Finishing of structural precast concrete.
3.5.7.7 Submittals
a) Manufacture’s Literature
Copies of manufacturer’s specification and installation instructions for each item

of proprietary material used, showing compliance with these Specifications.
b) Mill Certificates
Copies of manufacturer’s certificates of mill tests of all cement and reinforcing

steel.
c) Design Mixes
Copies of mix designs with support materials, as requires by Contract

Documents.
d) Product Design Criteria
Loadings for design:
(i) Initial handling and erection stresses.
(ii) All dead and live loads as specified on the Contract Drawings or as
required.

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(iii) All other loads specified for member where they are applicable.
e) Product Design Calculations
(i) The Design calculation shall be performed by a qualified Structural Engineer

experienced in precast concrete design.
(ii) Calculations for the design of any precast member shall be supported by a
statement explaining the principle of design and type of analysis adopted.
(iii) The influence of any member in achieving the overall stability of the
structure should be considered.
(iv) Any computer programmes used in the designs shall be fully described and
details of input and print out shall be presented in a manner which can be
readily understood.
1. Programme manuals and any instruction to programme users shall be

made available to the Engineer upon request.
2. Where any such programme cannot be demonstrated by the Contractor

to have been fully checked or where the Engineer considers it
necessary, the Contractor shall run such test examples as the Engineer
may choose, in order to verify the completeness and accuracy of the
programme.
(v) Design members exposed to the weather to provide for movement of

components without damage, failure of joint seals, undue stress on
fasteners or other detrimental effects, when subject to seasonal or cyclic
day/night temperature ranges.
(vi) Design system to accommodate construction tolerances, deflection of other

building structural members and clearance of intended openings.
(vii) Calculate structural properties of framing members in accordance with BS

8500 , BS EN 206-1:2000 and BS EN 1992-1-1:2004.
f) Shop Drawings
(i) Layout plans and detailed fabrication and placement drawings for each
structural precast element.
(ii) Shop drawings are to include the following information.
(iii) Size, grade, profile and dimensions of all materials used.
(iv) Connection and anchorage details.
(v) Lifting devices, locations and handling limitations.
(vi) Steel reinforcement details.

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(vii) All openings, sleeves, inserts and other provisions in full co-ordination with
all trades in the Contract.
(viii) Identification marks.
g) Erection Procedures
Detailed outline of sequence and methods of erection.
h) Fabrication Records
A record shall be kept for every piece of precast element produced showing the
following:
(i) Type and Number
(ii) Date of pour
(iii) Concrete test results
(iv) Ref. Shop drawing number
(v) Type and duration of curing
(vi) Date of delivery to site
(vii) Date of fixing in position
i) Test Reports
Copies of all testing and Inspection Reports.
3.5.7.8 Delivery, storage and Handling
a) Remove the structural precast elements from the form without damaging or over
stressing and store or place for transportation on a stable bed that will not allow
further distortion of the member.
b) Separate stacked members with suitable battens and bracing.
c) Mark each member with an identifying reference or piece mark and the date of
casting.
d) Transport the structural precast element with sufficient battens, bracing, and
supports so as not to over-stress by vibration or impact loadings.
e) Transport, store and handle structural precast units in a manner to avoid undue
strains, hair cracks, staining, or other damage.
f) Deliver units from casting site to project site in accordance with schedule and
proper setting sequence.

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g) Store structural precast units free of the ground and protected from wind or rain
splashes.
h) Cover units, secure covers firmly, and protected the units from dust, dirt or other
staining materials.
i) During fabrication, construction and after erection, protect castings to avoid

possibility of any damage.
3.5.7.9 Design Loadings, Actions & Structural Members Selection
Precast elements shall be designed to withstand all loading conditions against which
strength and serviceability must be measured.
a) Vertical loads shall include own weight of precast elements, floor covering and
live loads indicated on the contract drawings.
b) Wind pressure shall be calculated in accordance with the provisions of BS CP3

chapter V Part 2: 1972 “Basic data for the design of buildings – Wind Loads”
using basic wind speed of not less than 160 km/hr.
c) Account must be taken of the loads and deformation caused by temperature and
time dependent deformations. For such purpose 55C temperature variation and
90% relative humidity should be considered for all members, except exterior
elements and façade elements shall consider 85C.
d) Floor systems are assumed to function as rigid diaphragm with respect to in plane
forces. Forces due to lateral loads should be considered to achieve this assumed
condition when designing peripheral beams and continuity ties etc.
e) Precast elements shall be designed in accordance with BS EN 1992-1-1:2004.

Design tensile stresses should not exceed the design flexure tensile stress of
concrete.
f) Nominal cover to steel including links must meet the durability requirement of
severe condition of exposure and to meet requirements for 2 hour period of fire
resistance.
g) Total deflection of any precast element should be limited to 1/350 of the span of
this element.
h) Plan & Design for opening for building services, where required or necessary.
3.5.7.10 Coordination
a) The Work of this Section shall be completely co-ordinated with the work of other
sections.
b) Verify dimensions and Work of other trades which adjoin or pass through
materials of this Section before the installation of items herein.
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3.5.7.11 Precast Concrete Products - Materials
a) General
(i) Obtain cement, aggregates and water from single source, sufficient to
complete the entire structural precast concrete work to assure regularity of
appearance and uniformity of colour.
(ii) Provide all materials in accordance with and meet all applicable
requirements of Section Precast Concrete Production and microtunnelling
pipe system.
b) Manufacturers
(i) The products and manufacturers specified hereinafter are specified for the
purpose of establishing minimum quality.
(ii) Products equivalent to or better than those specified will be considered

acceptable.
(iii) The decision of acceptability will rest with the Engineer.
c) Reinforcing Bars: as specified in Section – “Construction of Reinforcement”.
3.5.7.12 Mix Design
Precast concrete units, unless otherwise specified or ordered shall be constructed

from Grade 50/10 concrete but the coarse aggregate shall be 10 mm to 5 mm.
Precast units shall be either:
a) Cast in vibrated moulds.
b) Formed in hydraulically compressed moulds.
c) Cast in a spun process
d) Cast in open moulds with approved compaction techniques.
In every process, the CPF formwork shall be of adequate quality to produce a

completely smooth finish.
3.5.7.13 Strength Requirements:
Structural Precast Concrete shall be as follows unless otherwise stated:
a) Characteristic cube strength 50 N/m m² at 28 days and 40 N/m m² at the time of

transfer.
b) The Characteristic flexural strength shall be

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(i) For Concrete grade up to C40 shall be 3.5N/mm²
(ii) For Concrete grade C 40 – C 50 shall be 4N/m m²
(iii) For Concrete grade greater than C 50 shall 5N/m m²
(iv) For Precast Paving slabs - 3 N/ m² when tested to BS 12390:P5:2009
(v) The crushing strength of Precast kerb shall be as specified in BS 7263.
3.5.7.14 Formwork
a) As required to constantly maintain dimensional and surface finish controls

specified in BS 5975.
b) Formed surfaces of the structural precast elements are to be at least as smooth,

flat and joint free.
c) Construct forms of non-staining metal, fibre glass reinforced polyester, or other

approved material with ‘CPF’ liner at exposed faces.
(i) Fabricate and reinforce for close control of dimensions, shapes, profiles,
curvatures, smooth and perfect edge and corner finishes and details.
(ii) Make forms sufficiently rigid so that precast units will meet the casting
tolerances.
(iii) Construct forms tightly to prevent leakage of water or mortar.
(iv) Form joints will not be permitted on faces exposed to view in the finished
work.
3.5.7.15 Bearing Pads
a) Elastomeric neoprene pads.
b) Conforming to Standard Specifications for Highway Bridges (Section 25) adopted

by AASHTO.
c) Use un-factored loads for design.
d) Properties
(i) Hardness (Shore A Durometer): 50  5
(ii) Tensile Strength: min. 15.5 N/m m²
(iii) Ultimate Elongation: min. 400%
(iv) Compression set at 100C, 22hrs: 35%

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3.5.7.16 Grout
As specified in Section – “Grout”.
3.5.7.17 Execution – Forming
a) General
(i) Forms and casting beds are to be firmly seated so as not to deflect or be
displaced under concreting or tensioning loads.
(ii) Correct for thermally induced strains or forces.
1. For member penetrations larger than 150 mm, coring or field cutting is
not permitted unless prearranged with the approval of the Engineer.
2. Clean and coat forms with release agent prior to installation or

reinforcing or embedment’s.
b) Refer to Section – “Form Work” for other requirements of formwork.
c) Tolerances: permissible deviations of formed surfaces are not to exceed

tolerance outlined in PCI Manual 116, summarized and / or modified as follows:
(i) Length: +/- 5 mm.
(ii) Width: +/- 3 mm
(iii) Thickness: Stem +/- 3 mm, Flange +/- 2.0 mm
(iv) Embedment or Penetration Location: +/ - 0.2 %
(v) Straightness: +/-3 mm for 3 m
(vi) End Squareness: +/- 3 mm
3.5.7.18 Reinforcing Steel Placement
a) Place reinforcing steel in accordance with properly executed shop drawings.
b) Embedment, inserts and lifting devices are to be firmly anchored to resist

misplacement during concreting.
c) Tolerance: maximum permissible deviation from detailed placement.
(i) In Plane: ±1/200.
(ii) In Position: ±6 mm
3.5.7.19 Concrete Placement and Finishing
a) Batch, transport, deposit, consolidate and strike off the concrete to produce dense
homogeneous concrete elements.
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b) Surface Finishes
Tee Beams
(i) To Receive Bonded Topping: Broomed perpendicular to axis with brush just
sufficient to remove the outer mortar skin and expose the larger aggregate
without disturbing the aggregate.
(ii) Exposed: Hand trowelled
(iii) Concealed: Floated
3.5.7.20 Curing
a) Retain moisture to ensure complete hydration of the cement.
b) Membrane forming curing compounds shall not be used in surfaces to which

topping is eventually to be bonded.
c) Steam curing
(i) Do not apply steam until concrete undergoes initial set (2 to 4 Hours).
(ii) Heat Gain in Enclosure: maximum 4C per hour
(iii) Maximum Heat in Enclosure: 65 C.
3.5.7.21 Surface treatment and Repair
a) Minor cracks and spalls not affecting the structural integrity of the element can be
patched with epoxy type bonding agents and patching compounds.
b) Cracks and honeycombs in anchorages, bearings or otherwise critical zones will

be unacceptable unless repair can be affected and substantiating testing
performed.
c) Do not attempt structural repair without the Engineer’s knowledge and approval.
3.5.7.22 Installation
a) General
Erection responsibilities include the safe and proper placing, aligning and levelling
of the structural precast elements on the accepted bearing surfaces and affecting
their proper securement.
b) Survey
(i) Before placement of structural precast elements, survey and maintain all
temporary supports shown or required to control alignment, deflection.

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(ii) Retain temporary supports until framing elements braced thereby have
attained integral stability in accordance with the design.
c) Guying, Bracing and Shoring
(i) Install in proper sequence and maintain all temporary supports shown or
required to control alignment, deflection and stress levels.
(ii) Retain temporary supports until framing elements braced thereby have
attained integral stability in accordance with the design.
d) Adjustment and Correction
Compensate and correct for misaligning effect of temperature, draw from welding,
bolting or erection sequence or grouting.
e) Erection Tolerance
Comply with the following erection tolerances:
(i) Variations from Plumb: 6 mm in any 6m run; 12 mm total in any

12m or longer run.
(ii) Variation from Level or Elevation: 6 mm in any run; 12 mm in any 12m

run; total 12 mm at any location.
(iii) Variation from Position in Plan: +/-12 mm maximum at any location
(iv) Offsets in Alignment of: 1.5 mm in any 3m run; 6 mm
(v) Adjacent members at Any Joint: maximum
f) Welding
In accordance with AWS recommendations:
(i) Do not weld until all adjacent elements to be connected have been aligned,
firmly seated and braced.
(ii) Control heat build-up by limiting voltage, electrode size and rate.
(iii) Spalled or heat damaged concrete around weldments is not acceptable.
g) Grouting
Complete joints, gaps and connections by filling with grout as shown on the
Drawings and as approved by the Engineer.
3.5.7.23 Field Cutting
Field cutting of holes may be done only with the Engineer’s concurrence and only
with power saws or core drills.

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a) Maximum hole size is 150mm diameter or as limited by member size or strand

location.
b) Cracks, spalls and sharp corners created by field cutting are to be ground, eased
and patched with epoxy type bonding and patching compounds.
3.5.7.24 Precast Concrete Production
a) Precast concrete gullies shall comply with the relevant requirements of the
approved standard.
b) Curing methods shall be as specified. Precast concrete bricks, tiles and similar
small units shall be immersed in water curing tanks.
c) Units shall not be transported until they have matured under suitable conditions
for a period of not less than 14 days.
d) The units shall be so handled, stacked, stored and transported that they are not
subjected to undue stress or damaged in any way and large units shall have
suitable lifting holes or hooks incorporated into their design. No unit shall be built
into the work until it has matured for 28 days.
e) Units may be rejected if they have any of the following defects:
(i) Broken edges.
(ii) Cracks (other than hair cracks)
(iii) Repairs
(iv) Misplaced reinforcement
(v) Honeycombing or air holes
(vi) Finished dimensions different from those specified or shown on the

Drawings.
f) The Engineer may order extra precast units to be manufactured for testing to
destruction. These units will be paid for if the tests show that they comply with the
Specification.
3.5.7.25 Bedding Precast Concrete Units
a) Precast concrete units, except where otherwise specified shall be bedded and
jointed in 1:3 cement/sand mortar true to line and level as shown on the
Drawings, each unit being firmly pressed into position and the joints flush pointed
as the work proceeds.
b) Where units are to be subjected to internal or external water pressure, mortar

joints shall be completely watertight.

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3.5.7.26 Post-Tensioned Wall Panels, Jointing and Post-Tensioning
a) Post-tensioned wall panels for circular tanks shall be reinforced with fabric
reinforcement. The reinforcement shall be cut from flat sheets and not from rolls.
A lifting hole shall be provided in each panel.
b) Joints between precast concrete panels shall be packed with a stiff 1:3
cement/sand mortar. On no account shall liquid grout be used for this purpose.
c) High tensile steel strand shall be cut to length with a high speed disc or other
cutter. Burning is prohibited.
d) For the purpose of attaching the tensioning jacks the length of each cable shall be
1.50 meters longer than the net anchorage length.
e) The top cable shall be tensioned first followed by the third cable from the top, both
sets of anchorages being in the same anchor blocks. The tensioning of the
second and fourth cables shall next be carried out in that sequence, the
anchorages being in the alternative blocks.
f) The Contractor shall secure and maintain the circularity and level of the wall
panels before and during stressing and shall obtain the Engineer’s prior approval
of the methods he proposes to use.
3.5.7.27 Chamber Rings and Cover Slabs
a) Precast concrete chamber and shaft sections and chamber and shaft cover slabs
shall all be to the approved standard and be constructed to the dimensions shown
on the Drawings.
b) Details of the design of all chamber cover slabs shall be submitted to the
Engineer for his approval before manufacture.
c) They shall be suitably protected internally and externally in accordance with this
Specification.
d) Cover slabs shall be arranged so that they are supported on the surround
concrete and not on the chamber or shaft sections.
e) The slabs shall be designed to support their own weight, imposed dead loads
from any shafts, backfill and access covers and live loads based on individual
wheel loads of 112kN.
f) A representative slab of each size shall be tested at the place of manufacture and
test certificates submitted to the Engineer before delivery and/or acceptance.

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3.5.7.28 Precast Concrete Paving Slabs
a) Precast concrete paving slabs shall be to the approved standard and shall be laid
on 1:3 cement mortar. They shall be laid at a level not exceeding 4 mm above the
top of the kerb or concrete edging.
b) The joints shall be thoroughly cleaned out and grouted with cement mortar well
brushed in and flushed off. No cracked or broken slabs shall be used.
3.5.8 Under Water Concrete
3.5.8.1 General
a) Where concrete is to be placed under water the Contractor shall submit his
detailed proposals for the method of working, equipment and personnel for the
approval of the Engineer. No such work shall be undertaken until this approval
has been given.
b) Concrete which is to be placed under water using the Tremie method shall have
the following characteristics: -
(i) The minimum cement content of the concrete shall be 400kg/m³. The
cement shall be ordinary Portland cement or rapid hardening Portland
Cement. Cement containing cement replacement material may be used
subject to the approval of the Engineer.
(ii) The consistency of the concrete shall be increased so that the slump is 185
mm or the flow 530 – 600 mm.
(iii) Maximum aggregate size shall be 20mm and fine aggregate proportions
shall be between 45% and 55% of the total aggregate content.
(iv) An anti-washout liquid admixture specially developed for concrete placed

under water shall be included in the mix at the rate of 0.8 – 1.6 lit/100kg
cementitious material in accordance with the manufacturer’s
recommendations.
c) Concrete to be placed under water shall be placed continuously and sufficient

supplied of aggregates, cement and water shall be available at the mixing plant
prior to the commencement of the tremie concreting. No concrete shall be placed
until the Engineer has approved all preparations for the work.
3.5.8.2 Trial Pours
On- shore trials shall be carried out to ensure a proper understanding of the method
of working followed, if considered necessary by the Engineer, by underwater trials
which shall be carried out in such a way that the resultant work can be retrieved and
examined.

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3.5.8.3 Tremie Pipes
a) The maximum distance between tremie pipes shall be 4 to 5 meters and pipes
shall be located in such a way that concrete does not flow horizontally more than
3.0 meters from a pipe position.
b) When two or more pipes are used in the same pour simultaneously, care shall be
taken to ensure that the concrete level at each pipe position is maintained equal.
The pipes shall be suspended from staging mounted so that the pipe can be
moved vertically. The pipes will be fed through a hopper. Each pipe shall
comprise removable sections to allow the pipe to be shortened as concreting
proceeds.
c) All removable items and loose constructions shall have chain connections to
prevent loss.
3.5.8.4 Tremie Pipes
a) Tremie pipes shall be clean, watertight and of adequate diameter to allow the free
flow of concrete not less than 200 mm diameter nor greater than 300mm.
b) The method of plugging tremie pipes shall be approved by the Engineer.
c) The tremie pipe shall extend to the formation level prior to the commencement of
concrete pouring and care shall be taken to ensure that all water is expelled from
the pipe during the initial charging process.
d) A minimum embedment of 0.5m of the tremie pipe in concrete shall be maintained

throughout concrete pouring to prevent re-entry of water into the pipe.
e) Horizontal movement of the tremie pipe will not be permitted after

commencement of the pour.
3.5.8.5 Formation Preparation
a) The formation of each pour shall be kept clean, free of silt and other harmful
material.
b) If necessary the direction of the pour shall be ordered by the Engineer, to enable
harmful material to be displaced by the fresh concrete.
c) All gaps and lifting holes exceeding 10 mm minimum dimension in and between
formwork shall be sealed prior to pouring tremie concrete.
d) All surface laitance and poor quality concrete from previous pours shall be
removed prior to placing new concrete.

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3.5.8.6 Tremie Pours
a) The concrete pour shall be completed in such a manner and within such time that
the concrete above the foot of the tremie remains workable until the pour is
complete.
b) The method of placing shall be such as to prevent any concrete from dropping
through the water into the construction area, and to ensure that the maximum
density of the concrete is achieved in its final position. Divers shall be employed
as necessary to ensure that even placing of the concrete, which shall be placed
as far as possible in horizontal and not with steep unsupported faces.
c) The rate of placing concrete shall be such that the pressure on the formwork shall
not endanger its stability.
3.5.8.7 Minimum Cover to Reinforcement in Concrete
Table 3.17 Limiting values for composition and properties of concrete exposed to risk
of corrosion of reinforcement induced by chlorides. Maximum size of aggregate is 20
mm, cement and combination types based on BS 8500.
Table 3.17
Exposure Nominal Exposure Applicable Tolerance

class Cover* to Conditions Examples
reinforceme C
Table A. 1 of nt (mm)
BS 8500 – 1
XD2 40 +  c Wet & Reinforced 15 mm internal

Concrete
10 mm external
rarely dry Elements one
surface immersed
in water and
external surface
exposed to air at
dry surface
XD3 50 +  c Cyclic
Wet & dry R.C.C buried 10 mm internal

structures
10 mm external
XC2 45 +  c Moderate R.C.C buried 10 mm internal

structures
15 mm external

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Exposure Nominal Exposure Applicable Tolerance

class Cover* to Conditions Examples
reinforceme C
Table A. 1 of nt (mm)
BS 8500 – 1
humidity & Foundation
cyclic wet &

dry
XC3 40 +  c Cyclic wet & Buildings 5 mm internal &

dry external
Columns, beams
and parapets
XO 40 mm No Risk of -Ditto- –
Corrosion
*Expressed as the minimum cover to reinforcement plus a tolerance,  c, to accommodate fixing

precision. This tolerance is typically in the range 5 mm – 15 mm.
 XD means corrosion induced by chloride other than from seawater.

 XC means corrosion induced by carbonation.
 XO means no risk of corrosion.
 Cover to reinforcement refers to the minimum distance from the surface of the concrete to any
steel reinforcement links.
 The ends of binding wire should be turned away from the cover zone and into the body of the
concrete.
 The cement or combination content of concrete shall not exceed 450 kg/m³.
 Water – cement ratio limits are the ruling parameters over minimum strength class or minimum
cement content.
3.5.8.8 Spacing Blocks and Temporary Construction Ties
a) Internal spacing blocks and construction ties shall be avoided as far as, in the
Engineer's Representative opinion, possible and practicable.
b) Where it is intended that the spacing blocks or construction ties shall be removed
whether before or after the concrete has set, the making good of the concrete
shall be subject to the Engineer's Representative's approval.
c) The removal of the blocks or ties must not jeopardise the stability of the
construction.

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d) If, with the approval of the Engineer's Representative, the spacing blocks and
construction ties are allowed to remain in the concrete then they shall be of such
material and of such quality that they do not prejudice the strength of the work.
e) Concrete spacing blocks shall be made of concrete at least equal in quality to the
main concrete. Metal ties shall be positioned such that they do not come into
contact with any of the reinforcement or fittings and no part of the tie shall be
permanently embedded in the concrete nearer than 5 cm to the exterior surface of
the concrete.
3.5.9 Concreting Deep lifts and large Volume Pours
3.5.9.1 Deep Lift Construction – General
The main advantage of construction in deep lifts is the reduction in the number of
horizontal joints. This results in both an improvement in surface appearance and a
reduced number of potential zones of weakness (or leakage in the case of liquid
retaining structures).
3.5.9.2 Achieving successful deep lift construction
For successful deep lift construction the contractor shall have the following planning:
a) Techniques for placing and compacting concrete at the base of deep lifts must be
decided in advance of construction and proper consideration given to access and
construction sequence.
b) Formwork shall be designed to resist high hydrostatic pressures and particular

attention shall be paid to sealing joints in the formwork.
c) Formwork shall remain in place long enough to prevent excessive deflection

leading to misalignment of panels.
d) Concrete pour lift height at a stretch is to be minimised to a maximum of 3m and

the concrete dropping height to be restricted to 1.0m.
e) A full-scale mock-up of any particularly difficult section shall be constructed and

filled with concrete in order to identify and prevent any potential problems during
construction.
f) The contractor shall provide his method statement of work and can demonstrate
his capability by providing a work procedure, defining management, method,
programme and inspection and testing regime, which takes account of the unique
features of the pour to be cast.

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3.5.9.3 Plant
a) For deep lifts, the contractor shall give following considerations with regard to
plant:
(i) The limited space on the working platform at the top of the lift
(ii) The limited access for concrete distribution and compaction and possible
poor visibility within the pour.
(iii) The high pressure on the formwork, and the need to prevent leakage.
b) The delivery of concrete to the pour may be by any of the conventional methods,
e.g. crane and skip, pumped. However, boom pumps have an advantage in that
the line takes up space and required less handling.
c) To distribute concrete to the bottom of the form without segregation, tremie pipes,
drop chutes or flexible hosing shall be used. In the latter case, this may fixed to
the end of the pump boom.
d) As it is difficult to control the location of a poker at the bottom of a deep lift, it may
be appropriate to consider jigs with fixed vibrators which are raised as the lift
progresses. Because of the difficulty of raising pokers from the base of a deep lift
before inserting them in a new position, a greater numbers of pokers than normal
may be required.
e) External vibrators shall also be used to overcome access problems. These may
either be attached to the form work in fixed positions, or demountable fixings
which would allow a smaller number of vibrators to be moved up the formwork as
the height of the concrete rises. It shall be noted, however, that formwork shall be
specifically designed with external vibration in mind and shall be both rigid
enough to with stand the effects of the vibration and capable of transmitting this
vibration to the concrete.
f) Formwork design is also important with regard to stability, stiffness and the
avoidance of grout leakage at joints.
g) Lighting may also be required in very deep lifts where visibility is poor and for
concreting at night.
3.5.9.4 Contractor’s Check List
In the planning stage, the contractor shall pay particular attention to the following and
the methods of works are to be provided for Engineer’s approval.
a) Advanced warning to all parties involved, and in particular, the material supplier.
b) Concrete production – if ready mixed concrete is to be used the contractor must

check:

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(i) Location of the plant in relation to transit time and risk of delays (e.g. in rush
hours)
(ii) Throughput as determined by storage capacity, mixing rate, number of

delivery trucks.
(iii) Quality control in relation to risk of rejecting non-compliant mixes
(iv) Back-up plants, or use of several plants.
c) Access to the site – separating incoming and outgoing mixer trucks, provision on
site space for queuing and washdown.
d) Concrete distribution – appropriate selection of plant to achieve the required

placing rate. Pumps are most commonly used for very large volume placement
but skips, chutes and conveyors are also used. Arrangement of back-up plant in
case of breakdown. Lighting may be needed for deep lifts and is essential for time
concreting.
e) Concrete placing sequence – planning of sequence of placing from one or more

points, and thickness of layers.
f) Placing and compaction – ensure sufficient labour and plant for through
compaction.
g) Finishing – this may be delayed if the mix has a slow set.
h) Condition for non-standard working hours-check local by-laws for night and
weekend working. Agree conditions with labour force, e.g. shift working, and
cover during breaks.
i) Quality control – rate of sampling of concrete; storage of test specimens; action

the event of non-conformance. In the case of contract concrete subject to third
party certification, the quality assurance scheme of the concrete producer must
be examined and approved by both contractor and designer.
j) Temperature monitoring – location of measuring points; method recording

temperature; agreed action limits; actions in the event of non-conformance.
k) Achievement of specified temperature limits – mix selection, trials to measure

temperature rise or heat of hydration, cooling of the fresh concrete, in-situ cooling
with embedded pipes, thermal curing.
l) Contingency plans for:
(i) Delays or failure of concrete delivery
(ii) Breakdown of plant for concrete distribution and compaction

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(iii) Extension beyond anticipated pour time (particularly if running beyond

normal working hours)
(iv) Severe weather, especially heavy rain.
3.5.9.5 Effect of formwork on surface finish
a) The formwork panels must be flat and flush with each other with no steps or gaps.
Welding steel panels may introduce distortions that will be apparent when the
formwork is removed.
b) The formwork material and its interaction with the CPF liner must minimise
blowholes. Although blowholes are usually concentrated at the top of the lift, they
can occur throughout the height of the pour if the formwork materials are
unsuitable or poorly covered in release agent. This is particularly noticeable with
low workability or ‘sticky’ concrete mixes.
c) Impermeable materials such as steel, plastics or resin-coated plywood are

particularly prone to excessive blowholes as water and air moving away from
internal vibration becomes trapped at the concrete-formwork interface. In contrast
more permeable materials absorb some of this water and reduce blowholes.
d) Controlled Permeability Formwork (CPF) is an effective means of eliminating

blowholes in vertically formed surfaces. Although the surface is darkened as a
result of a low water/cement ratio, the darkening is uniform due to the controlled
permeability of surface. This technique has to be applied to deep lift construction.
3.5.9.6 Insulation
a) Insulation shall be used to minimise temperature differentials by enabling the

surface temperature to increase. However, when appropriate, insulation can be
achieved by various methods, including:
(i) maintaining the formwork in place if it has insulating properties e.g. plywood
or steel backed with expanded polystyrene or CPF liner.
(ii) foam mats, blankets and quilts
(iii) soft board
(iv) sand on polythene
(v) tenting
(vi) ponding
b) Applicable method shall be adopted depend on whether the surface is vertical or

horizontal, the period for which the insulation must maintained, and the access
required to the surface.

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c) Guidance on the minimum period for insulation in relation to the minimum pour
dimension is given in Reference and is reproduced in Table 3.18 below. For very
thick elements, the insulation may need to remain in place for up to three weeks.
Table 3.18 - Minimum periods of insulation to avoid excessive temperature

differentials
Minimum pour dimension Minimum period of insulation
(m) (Days)
0.5 3
1.0 5
1.5 7
2.0 9
2.5 11
4.5 21
d) When using insulation care must be taken to avoid its early age removal, as this
can generate thermal differentials which are much worse than might have
occurred if no insulation had been used.
e) Once the commitment to insulate has been made it must be maintained until the
temperature within the pour has cooled to a level which can accommodate the
change which will occur when the insulation is removed.
3.5.9.7 Monitoring of concrete temperatures
a) In large volume pours, the avoidance of excessive temperature rises and

differentials is essential to minimise problems of thermal cracking.
b) The temperature limits is important in this respect, the following shall be

considered:
(i) Maximum placing temperatures
(ii) Maximum temperature achieved within the section
(iii) Maximum temperature differential between the centre and surface of the
section

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(iv) Maximum temperature difference between the centre of the pour and
ambient temperature
(v) Maximum temperature differential between successive pours of lifts.
c) The quantitative limits placed on these parameters should reflect the

consequences of any cracking and the properties of the concrete actually used
during construction. The type of aggregate used in the concrete has a significant
effect on the temperature differential that can be sustained without cracking and
the effects of peak temperatures on in-situ concrete properties are much less
deleterious when composite cements are used.
d) Embedded thermocouples are an appropriate technique and may usefully be

combined with embedded strain gauges (e.g. vibrating wire gauges). The
minimum number of thermocouples together with additional thermocouples
together with appropriate location consists of a thermocouple at the centre of the
pour with additional couples close to the top, bottom and side surfaces of the
section. In view of the application, the thermocouples need only be accurate to
the order of  1C and reference calibration is not necessary. It is useful to have a
detailed monitoring of the first few pours, relaxing the requirements once a pattern
of behaviour has been established (perhaps just monitoring a smaller number of
selected locations).
3.5.9.8 Placing Methods
a) The four principal methods of concrete delivery into large volume pours are:
(i) Skip
(ii) Pump
(iii) Chute
(iv) Conveyor
b) The method selected shall depend on the required rate of placing, the ease of
access and the plan area of the pour.
c) However for large area, large volume pours, mobile boom pumps provide the
greatest degree of flexibility combined with very high placing rates, typically of the
order if 40-50 m³/hr, but with reported throughputs approaching 100 m³/hr for
individual pumps. This compares with typical rates of 8-12 m³/hr achieved using
crane and skip.
3.5.9.9 Compaction
a) For large volume pours, the only practical means of compaction is by the use of
immersion (poker) vibrators. Recognised good practice involves placing the poker

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vertically into the concrete and at about 0.6m centres. At each location, the time
required to ensure expulsion of air will depend on the workability of the concrete.
b) The use of internal (poker) vibrators with long airlines shall be proposed for
compacting concrete in deep lifts. However, if the vibrator is controlled from the
top of the form and just dropped into the concrete at the base of the form, it is
difficult to control its position and areas of poor compaction may result. More than
one poker may often be required in order to produce efficient compaction.
Increased numbers of vibrators are essential if the design of the reinforcement
does not permit the poker to be raised easily and repositioned. The workability
and consistence of the concrete will also influence the number and spacing of the
vibrators. The maximum diameter of the poker will, of course, be controlled by the
section dimensions and reinforcement spacing, and pokers of different diameters
may be needed for different sections of the lift. In some circumstances, it may be
possible to prefabricate a jig for holding the pokers in such a way as to allow more
accurate positioning and controlled upward movement. Vibrators should be
inserted vertically and allowed to sink under self-weight. The radius of action (or
area of influence) of the vibrator should preferably be larger than the wall
thickness in narrow sections as shown in table below.
Table 3.19 Typical radius of action of poker vibrators
Vibrator dia Radius of action
(mm) (mm)
20-40 80-150
30-60 130-250
50-90 180-360
80-150 300-510
130-180 400-610
c) Vibrators should be inserted at spacing generally around 1.5 times the radius of
action so that the areas affected by vibrators overlap. Vibrators should always be
withdrawn slowly from the concrete.
d) If possible contact between the vibrator and the formwork of reinforcement should
be avoided.
e) Proper access for poker operations must be provided, as this is much more
difficult operation in deep lift construction than in other forms of construction.

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Concrete pumps and articulated placing booms can be used as a means of

reducing the number of placing personnel required on the access platforms, thus
allowing the poker operators adequate room for manoeuvre.
3.5.9.10 Finishing
Large volume pours will generally be either trowelled or floated. Normal practice shall
apply, but it must be recognized that the concrete mix may have been designed to
have an extended stiffening time to avoid cold joints. For this reason, there may be a
longer than usual delay before initial stiffening has taken place and the moisture film
has disappeared from the surface.
3.5.9.11 Thermal Control
The control of temperature rise and temperature gradients is often a key feature of
large volume concreting and various precautionary measures shall be taken to
minimize the risk of early age thermal cracking, or to limit its extent as follows:
a) Select a low heat generating mix by minimising the cement content, within the
constraints of the specification and requirements of the fresh concrete.
b) Use composite cements (i.e. blends of PC with ggbs) to reduce the rate of the
evolution and the peak temperature rise.
c) Select aggregates with a low coefficient of thermal expansion
d) Select aggregates which result in concrete with a high strain capacity
e) Reduce the concrete mix temperature by cooling of the component materials or

the use of ice with the mix water.
f) Use liquid nitrogen to cool the fresh concrete
g) Cool the concrete in-situ by the use of embedded cooling pipes.
h) Use insulation to increase surface temperatures and to minimize thermal

gradients.
3.5.9.12 Reducing the mix temperature
a) Reducing the mix temperature has a number of benefits:
(i) It reduces the rate of workability loss
(ii) It delays the stiffening time
(iii) It slows down the rate of heat generation
(iv) It reduces the peak temperature and thus the temperature drop from peak
to ambient.

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b) As aggregates comprise the largest single component, cooling them will have the
greatest effect on the concrete mix (except where ice is used). This can be
achieved practically by:
(i) Shading aggregate stockpiles, to prevent solar gain
(ii) Sprinkling the stockpiles with water (preferably chilled).
c) Other more extreme measures include immersion in tanks of chilled water,

spraying chilled water on aggregate on a slow moving belt, or blowing chilled air
through the stockpiles. When the aggregates are cooled with water, this water
must be taken into account during batching, by adjustment to the added mix
water.
d) An alternative method is to cool the aggregate using liquid nitrogen (LN2).
e) While the aggregate constitutes the greatest mass in the mix, the water has the
greatest heat capacity, and hence cooling efficiency. The specific heat of water is
about five times that of the aggregate and cement (4.18 kJ/kgK compared with
0.75 kJ/kgK respectively). In addition, water is much easier to cool and the
temperature can be controlled more accurately. As it is practical to cool water to
about 2C this is a very effective method of cooling the mix.
f) For very effective cooling, ice can be used. The latent heat of ice is 334kJ/kg, and
the heat absorbed by 1 kg of melting ice is equivalent to cooling 1 kg of water
through about 80C or 1 kg of aggregate through 445C. Hence, a relatively small
volume of ice can have a significant cooling effect. Ice is usually added to the mix
in crushed or shaved form as it is important to avoid incorporating larger fragment
that melt slowly leading to the formation of voids in the hardened concrete. To
obtain an indication of the requirements for cooling the individual mix constituents,
the following general rules shall be applied. To cool the concrete by 1 requires
that:
(i) The aggregate is cooled by 3C
(ii) The mixing water is cooled by 7C.
(iii) 7 kg of mixing water is replaced by ice.
3.5.9.13 Monitoring and actions in the event of non-compliance
a) Temperature monitoring is required in order to demonstrate compliance with

specified temperature limits. The simplest and most cost-effective method,
particularly in very deep or thick pours greater than 500 mm is to use embedded
thermocouples. These are simple to install and to monitor. The output can be
monitored with simple manual devices. On large projects, automatic logging
systems can be set up.

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b) In its simplest form, the monitoring will involve thermocouples at the centre of a
section and close to the surface (about 10 mm). The maximum value at the centre
and the difference between the centre and the surface will then be assessed
against specified limits.
c) The contractor shall obtain specific details from the designer on how compliance
is to be demonstrated in relation to the location and number of monitoring points
and the interpretation of the results obtained.
3.5.9.14 Full Scale Mock-up
a) Full-scale mock-ups are to be conducted for providing data on temperature

profiles and hence for identifying the precautions needed in terms of insulation,
and increasing use is being made of computer models.
b) If the pour is a one-off, or if it is the first of many, pairs of thermocouples should

be installed at critical locations to provide back-up in the event of a failure. The
mix selection and adopted site procedures should be such that the temperature
limits will be met. However, contingency plans should be defined which can be
implemented when the results exceed ‘action levels’. If the allowable temperature
differential is being approached, and is likely to be exceeded, additional insulation
may be applied.
c) If the maximum allowable temperature is approaching its limit, no actions can be

taken in thick sections unless embedded cooling pipes are being used. However,
this value is much easier to predict based either on the mix constituents and the
mix temperature or, if available, on laboratory test results for adiabatic
temperature rise.
d) If allowable limits on temperature differential are exceeded the following action

shall be taken:
(i) inspect the surface for cracks after the pour has cooled back to ambient
(ii) if the cracks are excessive, initiate remedial measures
(iii) Consider the consequences of internal cracking- it is possible that this may
occur even if there is no evidence of surface cracking. In this case, it is
difficult to establish the extent of cracking without extensive coring and even
this is unlikely to indicate crack widths. The value of carrying out a detailed
investigation to find cracks which do not propagate to the surface is,
therefore, still doubtful, except in circumstances where such cracks are
clearly detrimental to the performance and safety of the structure.
3.5.9.15 Formwork Striking and Curing
a) There are a number of potential problems when formwork is removed from deep
concrete lifts, the most serious being collapse of the structure of excessive
deflection. Factors to be considered are:
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(i) collapse
(ii) excessive deflection
(iii) mechanical damage
(iv) freeze/thaw attack
(v) thermal cracking
b) The minimum striking time is usually based on an assessment of the in-situ

strength and the temperature gradient of the concrete.
c) Minimum 30N/m m² in-situ strength and the temperature differential of 20C are
recommended for deep lift construction. This is primarily to ensure that the lift is
able to withstand wind loads without causing deflections that will produce
misalignment with adjacent panels.
d) In massive deep lift construction, striking times may be controlled more by

thermal requirements than concrete strength.
e) Following the removal of the formwork, it is important that the concrete surface is
protected from moisture loss (particularly in thin sections) in order to promote
continued cement hydration leading to strong durable concrete.
f) This may be achieved in a number of ways, including:
(i) covering the surfaces with wet hessian and then with polythene
(ii) application of an efficient membrane forming curing compound
g) Recommended minimum curing periods are given in BS EN 1992-1-1:2004. The

choice of curing method will be influenced by practical considerations and any
subsequent treatment to be applied to concrete.
3.5.10 Cementitious Mortar, Grout & Anchoring System
3.5.10.1 Cement mortar
a) Normal cement mortar shall be composed of ordinary Portland Cement and sand
in the following proportions :
Grade OPC Sand
G1 1 1
G2 1 2
G3 1 3

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b) The amount of water added shall just be sufficient to make the mortar workable
consistent with its purpose.
c) The sand used in mortar must be dry when proportioning. Allowance for bulking
shall be made when gauging by volume. The mean compressive strength at 28
days for each mortar shall conform to BS EN 1052-1:1999.
d) Sand shall be natural sand or crushed natural stone or a combination of both as

e) Mortar shall be mixed by approval mechanical mixers. No handmixing will be

permitted and instead small drum type mixer shall be used. Mortars containing
plasticisers shall not be overmixed. Mixers shall be kept clean at all times.
f) Mortar shall be used within thirty minutes after mixing. Hardened mortar shall not
be used in the work and shall be removed immediately from the site. Mortar shall
be prepared in the proportions shown with the addition of a minimum quantity of
water for workability.
3.5.10.2 Cementitious Mortar, Grout and Anchoring System
Only non-shrink, corrosion resistant grouts and anchoring which shall be either
cementitious, Epoxy and Polyester resin based to be used for various
applications to suit the locations as instructed and approved by the Engineer.
Table 3.20: Properties of Cementitious Mortar, Grout and Resin Anchoring

Systems
Location to use Type of Consistency Compressive Flexural Strength Bond

Grout Strength in N/m In N/m m² Strength
m² (Pull off)
7 days 28 days 7 days 28 days
A Heavy duty Epoxy Free Flow 100 - 26 - -

support beneath Resin minimum minimum
machine plate & Based
similar structural
elements
B Filling voids up to Cementiti Free Flow 55 64 9 11 -

section thickness ous minimum minimum minimum minimum
100mm between shrinkage Or
base plate & compensa
Pumped
substructure, ted
concrete anchors,
machine
foundation

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m² (Pull off)
C Filling annulus Cementiti Free Flow Or - 5 - - -

gap of abandoned ous minimum
pipe lines Pumped
D Bolt Anchoring Polyester Poured 115 - 30 - 70 kN

Dowels, Resin minimum minimum minimum
Foundation Bolts Based Or
& Similar
Pumped
E For concrete Fibre Trowel or wet - 50 9 - 2.5N.m m²

Repairs reinforced spray
Polymer application
modified
repair
mortar
F Structural repairs Free Free flow 65 80 7 10 3N/m m²

of deteriorated flowing
Concrete micro
concrete
for
Grouting
repair
G Water Proof Cementiti Trowel 60 80 8 10 3N/m m²

Concrete ous silica application
fume
modified
rigid
sealing
mortar
H Damaged Epoxy Trowel - 75 25 35 10N/m m²

Concrete joints resin
edges, vertical patch
and overhead mortar
filling of cavities
I On top of Grano Epoxy Roller & by 65 80 - - Concrete

Concrete resin hand Failure
flooring
with
enhanced
slip
resistance

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m² (Pull off)
J Resin anchor Capsule Mixed in bolt 115 - 30 - 70KN

system to fix bolts contains holes with
in concrete resin drilling
quartz machine
granules
and phial
of
hardener
K Sealing cracks on High Mixed with - - - - >3N/m m²

concrete, joints performan low speed drill Elongation
between rigid & ce epoxy >400%
flexible surfaces resin
and joints with based
extreme adhesive
movement
3.6 FORMWORK AND CONCRETE PRACTICE
3.6.1 Shop Drawing
Contractor shall submit details of fabrication and placement drawings for all formwork
and reinforcement steel which are correlated with forming and concrete placement
techniques and requirements.
a) Reinforcing shall be detailed based on construction joint locations which shall

have been shown on shop drawings reviewed and approved by the Engineer.
b) The drawings shall be in such detail as to assure that difficulties in execution of

the work in the field are minimized.
c) The drawings shall consist of sections, plans and details clearly showing
locations, sizes and spacing of all reinforcing steel, supporting bars and
accessories including bends, sizes and lengths of all reinforcing steel beams.
d) A separate set of shop drawings, which shows the construction joint locations,
shall show all floor openings, wall openings and edges of concrete. Floor wall
openings and sleeves for all mechanical, plumbing and electrical work shall be
coordinated with the respective trades and shown on these shop drawings in
accordance with the criteria indicated on the contract drawings and contained in
the various applicable Sections of the Specification.

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e) No work shall be fabricated until all shop drawings have been reviewed and
approved by the Engineer (with corrections and resubmittals as required by the
Contract Documents). After review and approval by the Engineer, furnish all
copies needed for use of other trades.
f) Be fully responsible for furnishing and installing all materials called for or required
by the Contract Documents even through these materials may have been omitted
from the reviewed shop drawings.
g) Submit shop drawings for all formwork showing locations of joints, tie bolts,
cones, dummy cones, openings, chambers, inserts, fittings and accessories for
the approval of the Engineer before fabrication of formwork.
h) Submit design calculations in accordance with BS 5975 – falsework wherever

required for the supporting system of the formwork along with the shop drawings
for the supporting system, for approval of the Engineer.
3.6.2 Blinding Concrete (Sealing Coats)
a) Where aggressive soil or aggressive ground water is expected the concrete

should not be weaker than Grade C25 and if necessary SRC or other special
cement may be used for blinding layer concrete.
b) Immediately following the hand excavation to formation level for floors or

foundations where shown on the Drawings or as ordered by the Engineer, one
layer of 1000 gm/ m² gauge, 250 micron thick polyethylene sheet shall be spread
over the formation and a sealing coat of blinding concrete of minimum specified
thickness shall be placed on the surface of Polyethylene at the formation and
carefully spade finished to an even surface. The utmost care shall be taken to
preserve the natural water content of the ground below formation level as far as
possible. Should the ground be exposed to the weather by delay on the part of
the Contractor in placing the blinding concrete and become wetter or drier than its
natural state the Contractor shall excavate such ground as may be affected and
replace it with concrete of the same grade as the blinding.
c) Floors or foundations shall be laid on the blinding as soon as may be practicable,

this being especially important during hot weather. If required by the Engineer the
blinding shall be kept thoroughly damp by watering.
3.6.3 Design and Construction of Formwork
a) Contractor shall be responsible for the design of the formwork and shall submit
b) to the Engineer for approval.
c) Formwork shall in every respect be adapted to the structure and the required
surface finish of the concrete. It shall include all special moulds with insulation for
forming the concrete to the required shape, temperature condition and finish and
for the support of such moulds. It shall be fixed in perfect alignment and securely
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ledged and braced so as to be able to withstand, without displacement deflection

or movement of any kind, the weight of the construction and working platform for
the movement of persons, materials and plant. Joints shall be close enough to
prevent the leakage of liquid and fine materials from the concrete
d) The Engineer's Representative may at any time require the prior submission for
approval of the Contractor's proposals for design and construction of formwork
including supports and insulation details. The formwork shall be constructed so as
to permit its removal without damage to the concrete.
e) It shall be designed and constructed so that the concrete can be efficiently placed
and compacted without displacing or deforming the reinforcement. It shall be
firmly supported, braced, guyed or tied back so that it is stable against vertical
and horizontal forces. It shall be capable of adjustment and sufficiently strong not
to distort significantly by the pressure of the concrete or by other loads and
influences.
f) Internal spacers and ties shall be of types that do not produce holes completely
through the concrete and any permanently embedded parts shall not be nearer
the finished surface than the cover to the reinforcement. All permanently
embedded parts shall be of materials compatible with the coating of fusion
bonded epoxy coated reinforcement and all permanently embedded metallic parts
shall be treated with patching material obtained from the reinforcement coating
factory applied in accordance with their recommendations.
g) Joints in the formwork shall be close fitting to prevent leakage. Temporary

openings shall be provided, if necessary, for cleaning and inspection. The
arrangement shall allow for removal of formwork from the sides of members
without disturbing soffit formwork.
h) Where timber is used for the soffits of slabs, the boards shall be placed and laid
perfectly true with close joints to prevent the percolation of liquid or fines from the
concrete. Tongue and groove planks shall be used if specified. All requisite
bearer and struts shall be adjusted in position and placed where necessary on
bearers as specified in the case of beam forms.
i) Exposed formwork shall be used for surfaces of concrete, which will be exposed
to view or to liquids. It shall be constructed from material of sufficiently high
quality to produce a smooth denser concrete surface of uniform texture free of
blowholes and appearance without visible imprint of grain or steppings or ridges.
Where lined the same type of lining shall be used throughout any one structure.
j) If the use of metal-faced formwork is proposed details shall be submitted to the

Engineer for approval prior to use. Metal forms shall be insulated to prevent
excessive temperature fluctuations at the concrete surface.

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k) If movement or deflection of the formwork or loss of liquid occurs, and if the

Engineer so directs, the Contractor shall cut out and replace the concrete
supported by such formwork at his own expense.
l) Formwork, or an approved alternative, shall be used for upper inclined surfaces of

concrete where the slope is greater than 30° to the horizontal.
m) Formwork shall be designed so that splays, fillets, chamfers and projections are
cast as the work proceeds. The Drawings, particularly those prepared to small
scales, may not detail chamfers but unless specifically deleted all external angles
on exposed concrete shall have a 25 mm by 25 mm chamfer.
n) Before placing the concrete all extraneous matter shall be removed from the
interior of formwork. All faces of lined formwork against which concrete is to be
placed shall be carefully cleaned.
o) The surface temperature of the reinforcement and formwork shall not exceed the
temperature of the concrete at the time of placing.
p) The Contractor shall provide facilities for examination of the formwork after its
erection and before concrete is placed and shall give 24 hours notice to enable
the Engineer to examine the formwork if he so wishes. The Contractor shall place
concrete only after obtaining approval from the Engineer but this shall in no way
relieve the Contractor of any of his responsibilities under the Contract.
3.6.4 Type of Formwork
All concrete faces shall be left as struck with a fair face, true to line finish.
3.6.4.1 Job Mock-up
Prior to commencement of related formwork operations erect a job mock-up, to a

reasonable size including all items such a sheeting, stiffeners, soldiers, ties,
insulation layer etc. (and CPF liner where used) for the following types of formwork
and obtain approval before proceeding:
a) Columns
b) Walls, RAFT foundation
c) Slabs and beams
d) Staircases
e) Fair faced concrete (show method used to conceal tie holes)

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3.6.4.2 Methods
a) Prior to commencing work, submit to the Engineer details of methods and

techniques proposed for the design and completion of formwork and the height of
each lift proposed for wall concrete.
b) A Controlled Permeability Formwork (CPF) liner shall be used on the inside faces
of the formwork for all water retaining structures to produce a denser concrete
with a surface that is free of blowholes and other surface blemishes.
c) The CPF liner shall have a British Board of Agreement (BBA) certificate or other
similar independent third party certification from an approved authority.
d) The CPF liner shall have the following characteristics:
(i) Material: non-woven polypropylene, needle punched and thermally bonded
(ii) Weight : 250 g/m²
(iii) Thickness at 2kPa: 1.2mm
(iv) Pore size: < 30 microns
(v) Air permeability at 800 kPa : 100-500 l/ m²/sec
(vi) Tear strength (ASTM D1117) : Min: 125 N
e) The CPF liner shall be used up to a total of 3 uses.
f) Release agents shall not be used with the liner and any residual release agent
remaining on forms from previous use shall be removed.
g) The CPF liner shall be installed either by mechanical tensioning or gluing and
shall be used in accordance with the manufacturer’s technical guidelines.
3.6.5 Tolerances and Finishes of Concrete Surfaces
Unless tolerances for particular surfaces are specifically shown on the Drawings,
tolerances for the exposed surfaces shall be as follows:
1. Floor and roof slabs: The level of the surface at any point shall be within 5 mm
of the level derived from the drawings. There shall be no abrupt irregularities.
2. Walls: The position of the face at any point shall be within 10 mm of its position
derived from the drawings. There shall be no irregularity exceeding 3 mm in a 3
m template. The level at any point on the top of the wall shall be within 3 mm of
the value derived from the Drawings.
3. Beams and Columns: The position of each face at any point shall be within 3
mm of its position derived from the Drawings.

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4. Measuring Flumes: Any point on the invert of the flume channel shall be within
2 mm of the level derived from the Drawings. The width of the throat at any
cross section shall be within 2 mm of the required width and the surfaces shall
be smooth.
5. Weirs: Any point on a weir shall be within 2 mm of the level derived from the
Drawings and the surfaces shall be smooth.
Note: For the purpose of this clause, 'exposed surfaces' includes those with RTR or PVC liners.
3.6.6 Tolerances for Unexposed Surfaces
3.6.6.1 General
Tolerances are not specified but thicknesses shall not be less than shown on the
drawings.
3.6.6.2 Surface Finishes
a) Unless specifically detailed on the drawings, exposed concrete finishes shall

comply with the following:
(i) General: There shall be no abrupt irregularities or visible surface

imperfections.
(ii) Concrete Roads: Surfaces shall have a brushed or tamped finish with float
finished edges and arrissed angles.
(iii) External Walkways: Surfaces shall be float finished and then except for
margins at exposed edges, slightly roughened by brushing to produce an
even textured surface.
(iv) Concrete Floors and Tops of Walls: Surfaces shall be steel float finished to
be uniform and smooth.
b) The surfaces of walls and other exposed surfaces cast against formwork that will
be exposed to view or to liquids shall be rubbed down smooth in an approved
manner within three days after formwork has been removed. After inspection by
the Engineer any holes shall be filled with matching cement mortar.
3.6.7 Preparation of Formwork for Concreting
a) Immediately before the concrete is deposited, the formwork shall be thoroughly

cleaned out and freed from sawdust, shavings, wire cuttings, dust, sand, clay and
all other deleterious and extraneous materials.
b) Temporary openings shall be provided in the formwork to facilitate this work.
c) The inside surfaces of the formwork shall, immediately prior to final erection, be
installed the specified CPF liner in accordance with manufacturer’s guidelines.

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d) The CPF liner shall be of approved type and shall be applied uniformly and the
quantities used shall be the minimum consistent with its purposes.
e) The Contractor shall ensure that all steel reinforcement and adjoining concrete
surfaces are kept free of all kinds of contaminations.
f) All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.
3.6.8 Approval of Formwork before Concreting
a) The Contractor shall in all cases request the approval of the formwork by the
Engineer’s Representative in sufficient time to allow an inspection to be made and
shall not commence concreting until such approval is obtained.
b) The period between the Contractor’s request for approval and his intention to
commence concreting shall be not less than one clear normal working day and
the Engineer’s Representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.
c) Such approval shall not absolve the Contractor of his responsibilities under the
Contract.
3.6.9 Removal of Formwork
All formworks shall be struck without jarring the concrete or subjecting the same to
sudden shock.
3.6.10 Formation of Holes for Fixing
a) The Contract may include for the formation of holes and pockets for the later
building in of holding down bolts, other fixing devices, services and structural
steelwork. Boxes for the formation of such holes shall be adequately supported
and preferably fixed rigidly to the main formwork.
b) All holes shall be formed in positions to be detailed for the various items of
machinery.
c) Where a group of holes has to be formed for a number of bolts for fixing one item,
the formers shall be securely fixed together before the concrete is poured around
them. The boxes shall be suitably protected to avoid extraneous matter falling
onto them.
3.7 BATCHING, TRANSPORTING, PLACING & COMPACTION OF CONCRETE
3.7.1 General
a) All concrete used on the Works shall be made at batching plants where quality
can be monitored and controlled.

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b) Measurement of all the aggregates and cement shall be by weight. Allowance

shall be made for the water content or absorption of the aggregates as
appropriate.
c) For this purpose the Contractor shall determine the moisture content of
aggregates at least twice a day during continuous concrete production using an
approved method.
d) The quantity of water for each batch shall be accurately measured by means of a
calibrated device. After the device has been set to discharge the given quantity of
water it shall not be altered without the consent of the Engineer. Concrete shall be
mixed with a machine of a type and size complying with the approved standard
and shall be used within 80 to 100% of its rated capacity unless otherwise
approved.
e) All plant and equipment used in mixing concrete shall be maintained in good
working order and shall be kept clean and free of hard or partially set concrete.
3.7.2 Ready Mixed Concrete
a) Ready mixed concrete shall be as defined in BS 8500-1:2006 batched off the site
and shall comply with all requirements of the Contract.
b) Concrete shall be transported in:
(i) a truck mixer or agitator; or
(ii) b non-agitating vehicle where permitted by the Engineer.
c) Where non-agitating vehicles are used, procedures shall be followed that have
been proven to minimise:
(i) segregation;
(ii) any change in entrained air content except for the case where the loss of air
has been taken into account (see BS 8500-1:2006, B.1)
(iii) loss of any constituent
(iv) ingress of foreign matter or water.
3.7.3 Time of Transport
a) Concrete shall be delivered and placed within 2 hours after the time of loading
where transported in truck mixers or agitators or within 1 hour after the time of
loading where non-agitating equipment is used, unless a shorter time is specified
or a longer time permitted by the concrete manufacturer/ specifier.
b) A longer time after loading can be appropriate in cool, humid weather or where
ggbs, or retarding admixtures have been used. A shorter time can be essential in

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hot weather with cement-rich concretes, or where accelerating admixtures have

been used.
3.7.4 Concrete Placement
a) Inspection: Before placing concrete, inspect and complete formwork installation,

reinforcing steel, and items to be embedded or cast in. Notify other crafts to
permit installation of their work; cooperate with other trades in setting such work.
b) General: Deposit concrete continuously or in layers of such thickness that no

concrete will be placed on concrete that has hardened sufficiently to cause the
formation of seams or places of weakness. If a section cannot be placed
continuously, provide construction joints as herein specified. Deposit concrete to
avoid segregation at its final location.
c) Temperature: The Contractor shall take measures to ensure under all

circumstances that the temperature at the time of placing does not exceed 30°C.
In the event that conditions become such that these requirements cannot be met,
concreting shall be suspended immediately and not resumed until the
requirements can be met again. Under such circumstances, additional
precautions should be taken to avoid the temperatures being exceeded on future
pours.
d) Protection: During concreting throughout the first stage of hardening, the concrete
shall be protected from the harmful effects of sunshine, drying winds, rain or
running water. Concrete shall not be subject to disturbance between 4 hours and
24 hours after compaction except with the agreement of the Engineer.
e) Placing concrete in Forms: Deposit concrete in forms in horizontal layers not

deeper than 500 mm and in a manner to avoid inclined construction joints. Where
placement consists of several layers, place each layer while preceding layer is
still plastic to avoid cold joints.
(i) Consolidate placed concrete by mechanical vibrating equipment

supplemented by hand-spading, rodding or tamping.
(ii) Do not use vibrators to transport concrete inside forms. Insert and withdraw
vibrators vertically at uniformly spaced locations not farther than visible
effectiveness of machine.
(iii) Place vibrators to rapidly penetrate placed layer and at least 150mm into
proceeding layer.
(iv) At each insertion limit duration of vibration to time necessary to consolidate

concrete and complete embedment of reinforcement and other embedded
items without causing segregation of mix.

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f) Placing concrete of Raft Foundation & Roof Slabs: Deposit and consolidate
concrete slabs in a continuous operation, within the limits of construction joints,
until the placing of a panel or section is completed.
(i) Consolidate concrete during placing operations so that concrete is

thoroughly worked around reinforcement and other embedded items and
into corners.
(ii) Bring slab surfaces to correct level with straightedge and strike of. Use bull
floats or darbies to smooth surface, free of humps or hollows. Do not disturb
slab surfaces prior to beginning finishing operations.
(iii) Maintain reinforcing in proper position during concrete placement.
g) Hot-weather placing: When hot weather conditions exist or rate of moisture

evaporation exceeds 1.0kg/ m² per hour, subject to the Engineer’s decision, that
would seriously impair quality and strength of concrete.
3.7.5 Compaction of Concrete
a) All concrete shall be compacted to produce a dense homogeneous mass. Unless

otherwise agreed by the Engineer, it shall be compacted with the assistance of
vibrators. Sufficient vibrators in serviceable condition shall be on site so that
spare equipment is available in the event of breakdown. A 50 mm diameter
internal vibrator shall be deemed capable of compacting 20 m³/hr. Internal
vibrators shall be capable of producing not less than 10,000 cycles per minute.
b) Vibration shall not be applied by way of the reinforcement. Where immersion

vibrators are used, contact with reinforcement and all inserts shall be avoided.
c) Concrete shall not be subject to vibration between 4 and 24 hours after placing.
d) Vibrators shall be so manipulated as to work the concrete thoroughly around the

reinforcement and embedded fixtures and into corners and angles of the forms.
Vibrators shall not be used as a means to cause concrete to flow or its position in
lieu of placing. The vibration at any point shall be of sufficient duration to
accomplish compaction. After initial set of the concrete, the forms shall not be
jarred and no strain shall be placed on the ends of projecting reinforcement.
e) Concrete when deposited shall have a temperature of not more than 30oC unless
otherwise specified. Concrete shall be compacted in its final position within 30
minutes of discharge from the mixer unless carried in purpose made agitators
operating continuously, when the time shall be within 1 hour of the introduction of
cement to the mix and within 30 minutes of discharge from the agitator.
f) Except where otherwise agreed by the Engineer, concrete shall be deposited in

horizontal layers to a compacted depth not exceeding 400 mm where internal
vibrators are used or 300 mm in all other cases.

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g) Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 1m. When trunking or chutes are used they shall
be kept clean and used in such a way as to avoid segregation. Where steep
slopes are required for placing concrete with chutes, the chutes shall be equipped
with baffle boards or be in short lengths that reverse the direction of the
movement. Chutes and the use of chutes must be approved by the Engineer. All
chutes shall be kept clean and free from coating of hardened concrete by
thoroughly flushing with water after each run. The water used for flushing shall be
discharged clear of the concrete already in place.
3.7.6 For underwater Concrete
a) Full details of the method proposed shall be submitted in advance to the Engineer
and his approval obtained before placing begins. Where the concrete is placed by
the tremie, its size and method of operation shall be in accordance with BS EN
1997-1:2004
b) “Foundations”. During and after concreting under water, pumping or dewatering

operations in the immediate vicinity shall be suspended until the Engineer permits
them to be continued.
c) Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement against
which concrete is to be placed shall be shielded against the direct rays of the sun
and shall be sprayed with water to prevent excessive absorption by the surfaces
of water from the fresh concrete.
d) A complete record shall be kept of the date, time, temperature and conditions of
placing the concrete in each portion by the Engineer at any time.
3.7.7 Placing of Concrete in Water (Tremie Concrete)
a) Tremie concrete shall be deposited in water only if specified on the drawings and
/ or directed by the Engineer and under the Engineer’s supervision.
b) Concrete to be deposited in water shall have the cement content increased by

25% at the Contractor’s expense.
c) Concrete shall be carefully placed in a compact mass in the space in which it is to

remain by means of tremie bottom dump bucket or other approved method that
does not permit the concrete to fall through the water without adequate protection.
d) The concrete shall not be disturbed after being deposited.
e) No concrete shall be placed in flowing water and forms which are not reasonably
watertight shall not be used for holding concrete deposited under water.

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3.7.8 Concreting in High Temperatures
When concrete is to be manufactured, transported and placed in hot weather the

following limitations shall apply:
a) The temperature of the concrete when placed shall not exceed 30oC nor shall
concrete be mixed or placed when the shade air temperature is 40oC or above, or
is expected to reach such a level during concreting.
b) For all concrete section the Contractor shall take precautions to limit the effects of
heat of hydration.
c) In general, the recommendations for “Hot Weather Concreting” contained in ACI

305:1977 shall be followed. The Contractor may, however, take any of the
following measures in order to control the temperature of concrete at the time of
placing:
(i) Effectively shade aggregate stockpiles, cement silos, water tanks and
concrete handling plant;
(ii) Paint all concrete handling plant white;
(iii) Run all concrete handling plant with flake ice to reduce the temperature of
the machinery before mixing / transporting concrete;
(iv) Add flake ice to the mixing water;
(v) Concrete at night
d) The following measures shall be taken:
(i) All forms, moulds, mixed and placed concrete shall be shaded from sunlight
and protected from any drying wind;
(ii) Transit time shall be restricted to a minimum to be agreed in advance

between the Engineer and Contractor, taking into account the use of
admixtures etc.
e) The size of concrete pours may be restricted if the Engineer decides that
shrinkage and other factors are a consideration for particular elements of the
construction.
f) For concrete sections 500 mm and greater in thickness, the Contractor shall
submit to the Engineer for approval detailed proposals of the measures to be
taken. These measures shall include but are not limited to control of concrete mix
constituents; curing water; formwork type; surface insulation. All submissions
shall be based on measured values of heat of hydration generated by the
proposed mix to meet the criteria set out below:

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(i) Maximum temperature difference between the core and the surface of any
pour. Design target 15oC. Field maximum 20oC.
(ii) Maximum temperature difference between a new pour and a previous:

Design target 12oC. Field maximum 15oC
(iii) Absolute maximum temperature anywhere in a pour. Design target 60oC.

Field maximum 70oC.
(iv) Instrumentation shall be installed in the works to verify compliance with the
above criteria. Temperature measurements shall be made by means of
thermocouples positioned in a line perpendicular to the concrete faces. The
thermo couples shall be fixed; at the concrete faces; at the centre of the
section; and at equal intervals of approximately 300 mm.
(v) Temperatures shall be measured and logged continuously from the start of
the pour until instructed to stop by the Engineer. The Contractor shall
submit to the Engineer for approval details of the proposed methods and
equipment for the measuring and logging of temperatures.
(vi) If temperature measurements exceed any of the criteria above then action
in accordance with the sub-section on defective concrete.
3.7.9 Concrete Curing and Protection
a) General: Protect freshly placed concrete from premature drying and excessive
cold or hot temperatures. In hot, dry, and windy weather, protect concrete from
rapid moisture loss before and during finishing operations with an evaporation-
control material.
b) Initial curing: Start initial curing as soon as free water has disappeared from
concrete surface after placing and finishing. Weather permitting, keep
continuously moist for not less than 7 days.
c) Curing Methods: Perform curing of concrete by curing and sealing compound, by

moist curing, by moisture-retaining cover curing, and by combinations thereof, as
herein specified, as approved by the Engineer.
d) Moisture Curing: Provide moisture curing by following methods.
(i) Keep concrete surface continuously wet by covering with water.
(ii) Use continuous water-fog spray.
(iii) Cover the concrete surface with specified absorptive cover e.g. hessians,
thoroughly saturate cover with water, and keep continuously wet.
(iv) Place absorptive cover to provide coverage of concrete surfaces and edges,
with 100mm lap over adjacent absorptive covers. Leave the cover for at
least a further 7 days following 7 days of curing.
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e) Moisture Cover: Provide moisture-cover curing as follows:
(i) Cover the concrete surfaces with moisture-retaining cover for curing
concrete, placed in widest practicable width with sides and ends lapped at
least 75mm and sealed by waterproof tape or adhesive. Immediately repair
any holes or tears during curing period using cover material and waterproof
tape.
(ii) Leave the cover for at least a further 7 days following 7 days of curing.
f) Curing and Sealing Compound: Provide curing and sealing compound to exposed
interior slabs and to exterior slabs, walks, and curbs as follows:
(i) Apply specified curing and sealing compound to concrete slabs as soon as
final finishing operations are complete (within 2 hours and after surface
water has disappeared). Apply uniformly in continuous operation by power
spray or roller in accordance with manufacturer's directions. Re-coat areas
subjected to heavy rainfall within 3 hours after initial application. Maintain
continuity of coating and repair damage during curing period.
(ii) Use membrane-curing compounds that will not affect bonding of the
concrete surfaces to be covered with finish materials applied directly to
concrete.
g) Curing Formed Surfaces: Cure formed concrete surfaces, including underside of

beams, supported slabs, and other similar surfaces, by moist curing with forms in
place for full curing period or until forms are removed. If forms are removed,
continue curing by methods specified above, as applicable.
h) Curing Unformed Surfaces: Cure unformed surfaces, such as slabs, floor topping,
and other flat surfaces, by addition of water providing or by application of
appropriate curing method.
(i) Within ten minutes of placing and compaction, the unformed surfaces of the
concrete shall be completely covered with white reflective polythene
sheeting with substantial close fitting taped laps.
(ii) The polythene sheeting may be raised a short distance above the concrete
so that it does not mark the surface.
(iii) At the edges of the pour, the polythene shall drape over the forms and it
shall be securely fixed to prevent billowing due to the wind.
(iv) Within three hours of placing and compaction the polythene shall be quickly
removed and replaced with wet hessian laid onto the concrete surface. The
polythene shall then be replaced and secured as above.
i) Final cure concrete surfaces shall be performed using one of the following
methods:
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(i) liquid floor hardener or finish flooring by use of moisture retaining cover;
(ii) addition of water to concrete surface by fog spray;
(iii) addition of water by sprinkling.
j) Potable Water for Curing: potable water shall only be used for curing and the
temperature of water shall not be lower than 10oC cooler than surface
temperature of the concrete at the time the water and concrete come in contact.
3.7.10 Concrete in Adverse Weather
a) No concreting shall take place in the open during storms or heavy rains.
b) Where such conditions are likely to occur the Contractor is to arrange for
adequate protection of the material, plant and formwork so that the work may
proceed under proper cover.
c) Where strong winds are likely to be experienced additional precautions to ensure

protection from driving rain and dust shall also be taken.
d) The Engineer may withhold approval of commencement of concreting until he is

satisfied that full and adequate arrangements have been made.
3.7.11 Batching of admixtures
a) Where air entrainment agents or other admixtures are specified or approved they
shall be added at the mixer.
b) Unless alternative methods to the recommendations of the admixture supplier are

approved the admixture shall be batched in solution in a portion of the mixing
water by means of a mechanical batcher which is capable of dispensing the agent
in quantities varying by not more than 5 per cent from the quantities required and
in such a manner as to ensure uniform distribution of the agent throughout the
batch during the time of mixing.
c) The capability of the apparatus to achieve the required dosing and mixing
requirement shall be demonstrated to the Engineer and the apparatus shall be
checked each day before concrete mixing commences.
3.7.12 Concreting at Night
Where approval has been given to carry out concreting operations at night, the
Contractor is to provide adequate lighting to all points where mixing, transportation
and placing of concrete are in progress.
3.7.13 Striking Formwork
a) The Engineer shall be informed in advance when the contractor intends to strike
any form work.

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b) Formwork shall not be removed until the concrete temperature differentials

reached below 20C between surface and core temperature. Formwork shall not
be struck until the structure has attained sufficient strength to carry its own
weight, plus any constructional or other loads likely to come upon it, without
excessive deformation. Also the concrete shall have matured sufficiently to resist
physical damage. Formwork shall be struck in such in a manner that no damage
shall result to the concrete.
c) Formwork shall not be struck except with the Engineer’s permission. The work of
striking or removing such moulds, shuttering or centering shall be conducted only
under the direct supervision of a competent foreman.
d) The method statements for each structure shall include proposals for the methods
and times for the striking of shutters. Table 3.21 showing the minimum intervals of
time between the placing of concrete and the striking of shuttering at 16C and
above but these periods may be varied by the Engineer if environmental
conditions make this permissible or desirable.
e) Method statements may include proposals for different periods by reference to

recognised standard publications on concreting practice. Where it is proposed to
remove soffit shuttering in advance of props the method statement shall clearly
indicate the sequence and means of dismantling the soffit with a view to
maintaining adequate support.
f) The Contractor shall be responsible for any injury to the work and any
consequential damage caused by or arising out of the removal of the formwork.
Any advice, permission or approval given by the Engineer relative to the removal
and striking of the formwork shall not relieve the Contractor from the responsibility
here defined.
Table 3.21 - Minimum Formwork Striking Times
Type of Formwork Ordinary & Sulphate Resisting

Portland Cement Concrete (Surface
temperature 16C and above)
Beam sides, columns and foundations 4 days
Walls & Floor slab 7 days or temp differential reached to

min 20C & below
Soffits to slabs (props left under) 7 days
Soffits to beams (props left under) 7 days
Props to slabs 14 days

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Type of Formwork Ordinary & Sulphate Resisting

Portland Cement Concrete (Surface
temperature 16C and above)
Props to beams 14 days
3.7.14 Re-use of Formwork
a) CPF Liner on formwork shall be a total of 3 uses.
b) Care should be taken, when re-using formwork, that its surface shall be smooth
and clean and that it shall be free from warping or other deformations.
c) Any formwork which has, in the opinion of the Engineer, deteriorated sufficiently
to render it unsuitable for the work shall be rejected and must be removed from
the Site within 48 hours or must be broken up at once.
d) New formwork with CPF Liner shall be provided at the Contractor’s expense.
3.8 GRANOLITHIC CONCRETE SCREEDS TO FLOORS, SURFACINGS, BENCHINGS

AND CHANNELS
a) Granolithic concrete screeds should preferably be placed and compacted within

three hours of casting the base in which case the base concrete shall be left
rough and the screed shall be spread and consolidated onto the whole of each
bay or structure.
b) Where this cannot be achieved the base concrete shall the cast with a rough
surface. Weak surface laitance and any other contaminating materials must be
completely removed and the coarse aggregate cleanly exposed. This surface
shall be thoroughly cleaned and then soaked overnight, any surplus water being
removed. The surface shall then be brushed with a 1:1 sand/cement grout and
the granolithic concrete screed applied.
c) The granolithic concrete shall be compacted and screeded to levels or falls with a
screeding board and wood float. Further trowelling shall be done with a steel
trowel after about two hours. The thickness of a surfacing where it is inclined at
45 or greater to the horizontal shall not exceed a nominal 15 mm and if this is
inadequate to complete the work the surface shall be left rough and keyed with a
trowel. A further surfacing coat shall be applied within 24 hours.
d) Screeds shall be cured as specified for exposed surfaces and shall be protected
from traffic or other loading for a period of at least 7 days.
e) Where benching and channels are to be protected by epoxy mortar or in situ GRP
lamination the final surface of the concrete shall be left rough.

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3.8.2 Inspection of Concrete
The contractor shall not proceed with the surface finish or making good of concrete
surfaces until he has received the Engineer’s Representative’s permission to do so
and he shall not apply cement slurry or mortar or any other coating to the concrete
surfaces from which the shuttering has been struck until the concrete has been
inspected and approved by the Engineer’s Representative.
3.8.3 Repairs to Concrete
The method of repairing and replacing defective concrete which the Contractor
proposes to adopt shall be submitted to the Engineer’s Representative for prior
approval and the repair shall be carried out in such manner as the Engineer may
direct or approve.
3.8.4 Supervision of Concrete Work
Throughout the progress of the concrete work the Contractor shall employ and
provide such supervision as is necessary to ensure.
a) the day to day control of the quality of the concrete and
b) the mixing, transporting, placing , compacting, curing and protection of the

concrete, and
c) the carrying out of all testing as specified herein and any further testing which the
Engineer’s Representative may require
3.8.5 Cracks in Concrete Structures
The filling of cracks will not be permitted unless approval is given by the Engineer in
writing. Where required by the Engineer the Contractor shall follow the repair
procedures recommended in CIRIA publication 2002.
3.8.6 Quality of Finish
a) The quality of concrete finish shall be as indicated on the Drawings, and shall not
be inferior to that described herein.
b) If any portion of the facework should prove unsatisfactory on removal of the

formwork it shall, without delay, be cut out and made good as directed. No
plastering of concrete surface shall be allowed. At the discretion of the Engineer,
board marks of minor discontinuities on exposed faces may be removed by
rubbing down with carborundum, and pinholes, small voids or minor porosity of
the surfaces, may be filled, by rubbing down with cement and sand mortar of the
same richness as in the concrete. Treatment shall be made immediately after
removing the formwork. The cement used shall consist of a mixture of white and
grey ordinary sulphate resisting cement mixed in such proportions that the colour
of the mortar matches that of the surrounding hardened concrete.

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c) Such rectification shall be carried out as directed and shall in no way relieve the
Contractor from his obligation to cut out and reconstruct work if, in the opinion of
the Engineer, such rectification does not give the required standard of surface
finish. Any concrete, the surface of which has been treated without consent, shall
be liable to rejection.
3.8.7 Classes of Finish Formed Surfaces
On formed surfaces the under listed classes of finish shall be used where ordered.
a) Class ‘A’ finish is of surfaces prominently exposed to view where good

appearance uniform colour and alignment are of special importance. To achieve
this finish, which shall be free of board marks, the formwork shall be faced with
plywood and CPF liner or equivalent material in large sheets. The sheets shall be
arranged in an approved, uniform pattern. Wherever possible, joints between
sheets shall be arranged to coincide with architectural features, or changes in
direction of the surface. All joints between panels shall be vertical and horizontal
unless otherwise directed. Suitable joints shall be provided between sheets to
maintain accurate alignment in the plane of the sheets. Un-faced wrought
boarding or standard steel panels will not be permitted for Class A finish.
b) Class ‘B’ finish is for surfaces which are permanently exposed to view but where
the highest standard of finish with a surface free of blow holes and after surface
blemishes. Forms to provide a class B finish shall be faced with CPF liner
wrought and thickness boards with square edges arranged in a uniform pattern.
Alternatively, plywood or metal panels with CPF liner may be used if they are free
from defects likely to detract from the general appearance of the finished surface.
Joints between boards and panels shall be such as to require no general filling of
surface pitting, but fine surface discoloration and other minor defects shall be
remedied by approved methods.
c) Class ‘C’ finish is for surfaces against which mass-fill concrete will be placed.
Formwork shall consist of sawn boards, sheet metal of any other material which
will prevent the loss of material from the concrete when it is vibrated.
3.8.8 Classes of Finish Unformed Surfaces
On unformed surfaces the under listed types of finish will be required.
3.8.8.1 Class U/A
a) Class U/A is a hard, smooth steel-trowel finish for surfaces of concrete paving,
tops of walls, copings and other members exposed to weathering, surfaces of
beds and slabs to receive thin flexible sheet, and tile paving bedded in adhesive,
and seating for bearing plates and the like where the metal is in direct contact
with the concrete.

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b) Trowelling shall not commence until the moisture film has disappeared and the
concrete has hardened sufficiently to prevent excess laitance from being worked
to the surface. The surfaces shall be trowelled under firm pressure and left free
form trowel marks.
3.8.8.2 Class U/B
a) Class U/B is a floated finish for surfaces of beds and slabs to receive mastic
paving or block or tile paving bedded in mastic, and for exposed surfaces of
paving where a hard smooth steel trowelled surface is not required.
b) Floating shall be done only after the concrete has hardened sufficiently, and may
be by hand or machine.
c) Care shall be taken that the concrete is worked no more than is necessary to
produce a uniform surface free from screed marks.
3.8.8.3 Class U/C
a) Class U/C is a screed finish for surfaces of roads or of blinding under foundations,
bed, slabs, bonded concrete topping or cement mortar beds to receive paving,
and on exposed surfaces of paving where a superior finish is not required.
b) The finishing also the first stage for finishes U/A and U/B. The finishing operations
shall consist of levelling and screeding the concrete to produce a uniform, plain or
ridged surface, surplus concrete being struck off by a straight edge immediately
after compaction.
3.8.9 Defective Concrete
a) Defective concrete shall be defined as one or more of the following:
(i) Not conforming to required levels, lines, details and elevations.
(ii) Defective in required concrete strengths.
(iii) Defective in appearance in ultimate exposed areas due to:
1. Improper placement or preparation of concrete formwork resulting in

bowed formwork.
2. Improper formwork joints.
3. Honey combing.
4. Damaged surfaces.
5. Surface cracks.
6. Exposed reinforcement.

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7. Improperly placed snap on or cone ties
8. Unsatisfactory conditions for the performance of sandblasting work etc.
b) Defective concrete work must be reported to the Engineer.
(i) No remedial work shall be performed without the prior agreement of the
Engineer, with respect to timing, method of repair, final acceptable standard
and appearance of completed repair work.
(ii) Surface cracks less that 0.20 mm width shall be ground out ‘V’ cut and filled
with epoxy mortar (5 mm wide ) or as recommended by the coating/lining
manufacturer unless otherwise directed by Engineer.
(iii) Cracks wider that 0.20 mm shall be fully resin injected as directed by the
Engineer.
c) The engineer will make detailed inspection and may instruct for additional test on
In-place Hardened concrete.
(i) When the routine cube test results indicate specified concrete strength and
other characteristic have not been attained in the structure.
(ii) Surface cracks observed.
(iii) Variation of cube strength observed from specified job mix with the
tolerance limits.
(iv) Reinforcement appears to be near to the surface. Faulty concrete works.
3.8.10 Concrete Surface Repairs
a) Plastic cracking: if plastic shrinkage cracking occurs, the construction affected

shall be rectified and the contractor shall take all necessary steps to prevent a
recurrence. Rectification method and results shall be subject to the approval of
the Engineer.
b) Random Drying Shrinkage Cracking and Plastic Settlement Cracking: if any

cracking of the concrete occurs in an uncontrolled manner the construction
affected shall be rectified and the Contractor shall take all necessary steps to
prevent a recurrence. Rectification method and results shall be subject to the
approval of the Engineer.
c) Patching Defective Areas: Repair and patch defective area with cement mortar
immediately after removal of forms, when acceptable to the Engineer.
(i) Cut out honeycomb, rock pockets, voids over 6 mm in any dimension, and
holes left by rods and bolts, down to solid concrete but in no case to a depth
of less than 25mm. Make edges of cuts perpendicular to the concrete
surface. Thoroughly clean, dampen with water, and brush-coat the area to
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be patched with specified bonding agent. Place patching mortar before

bonding compound has dried.
(ii) For exposed-to-view surfaces, blend white Portland cement and standard
Portland cement so that, when dry, patching mortar will match colour
surrounding. Provide test areas at inconspicuous location to verify mixture
and colour match before proceeding with patching. Compact mortar in place
and strike-off slightly higher than surrounding surface.
d) Repair of Formed Surfaces: Remove and replace concrete having defective

surfaces if defects cannot be repaired to satisfaction of the Engineer. Surface
defects, as such, include colour and texture irregularities, cracks, spalls, air
bubbles, honeycomb, rock pockets, fins and other projections on surface, and
stains and other discoloration that cannot be removed by cleaning. Flush out form
tie holes, fill with dry-pack mortar, or Precast cement cone plugs secured in place
with bonding agent.
e) Repair concealed formed surfaces, where possible, that contain defects that
affect the durability of concrete. If defects cannot be repaired, remove and replace
concrete.
f) Repair of unformed Surfaces: Test unformed surfaces, such as monolithic slabs,

for smoothness and verify surface plane to tolerances specified for each surface
and finish. Correct low and high areas as herein specified. Test unformed
surfaces sloped to drain for trueness of slope and smoothness by using a
template having required slope.
(i) Repair finished unformed surfaces that contain defects that affect durability
of concrete. Surface defects, as such, include crazing and cracks in excess
of 0.20mm wide or that penetrate to reinforcement or completely through
non-reinforced sections regardless of width, spalling, pop outs, honeycomb,
rock pockets, and other objectionable conditions.
(ii) Correct high areas in unformed surface by grinding after concrete has cured
at least 14 days.
(iii) Correct low areas in unformed surfaces during or immediately after

completion of surface finishing operations by cutting out low areas and
replacing with patching compound. Finish repaired areas to blend into
adjacent concrete. Propriety underpayment compounds may be used when
acceptable to the Engineer.
(iv) Repair defective areas, except random cracks and single holes not
exceeding 25mm in diameter, by cutting out and replacing with fresh
concrete. Remove defective areas to sound concrete with clean, square
cuts and expose reinforcing steel with at least 20mm clearance all around
bonding compound. Mix patching concrete of same materials to provide

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concrete of same type or class as original concrete. Place, compact, and

finish to blend with adjacent finished concrete. Cure in same manner as
adjacent concrete.
g) Repair isolated random cracks and single holes not over 25mm in diameter by
dry-pack method. Groove top of cracks and cut out holes to sound concrete and
clean of dust, dirt, and loose particles. Dampen cleaned concrete surfaces and
apply bonding compound. Mix dry-pack, consisting of one part Portland cement to
2/½ parts fine aggregate passing a No.16 mesh sieve, using only enough water
as required for handling and placing. Place dry-pack before bonding compound
has dried. Compact dry-pack mixture in place and finish to match adjacent
concrete. Keep patched area continuously moist for not less than 72 hours.
h) Perform structural repairs with prior approval of the Engineer for method and
procedure, using specified epoxy adhesive and mortar.
i) Notwithstanding the provisions specified in above clauses and irrespective of any

cause of cracks, all cracks wider than 0.2 mm in concrete structures, other than
water retaining or in contact with earth, shall be rectified at the Contractor’s own
cost and time by approved epoxy resin injection method. All cracks in structures
in contact with earth or retaining liquid shall be rectified as above irrespective of
width of cracks.
j) Repair methods not specified above may be used, subject to acceptance of the
Engineer.
3.9 JOINTS IN CONCRETE STRUCTURES
3.9.1 Construction Joints
3.9.1.1 Description
Construction joints are provided for convenience of construction and, in some

instances, to assist in the control of shrinkage cracking.
Where the positions of construction joints are not shown on the Drawings they may
be proposed by the Contractor to suit his methods of working.
Construction joints are required to give monolithic construction and to be leakproof.
a) Locate and install construction joints as indicated or, if not indicated, locate so as
not to impair strength and appearance of the structure, as acceptable to Engineer.
b) Provide keyways at least 40 mm deep in construction joints in walls and slabs and
between walls and footings. Accepted bulkheads designed for this purpose may
be used for slabs.

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c) Place construction joints perpendicular to main reinforcement. Continue

reinforcement across construction joints except as otherwise indicated. Do not
continue reinforcement through sides of strip placements.
d) Where kickers are required they shall be placed integrally with the floor slab. This
may necessitate a special design for the formwork. Kickers shall have a height of
not less than 70 mm and not more than 170mm above the floor slab or splay.
Concrete in kickers shall be of the same mix as the main member. The concrete
shall be vibrated into place and prepared as for other joints.
e) Joints in column and walls shall only be formed about 15mm above the soffits of
suspended floors, at floor levels, or at the tops of kickers which shall not be less
than 70 mm. There may be a joint between haunches or column capitals and the
column.
f) Vertical joints in walls generally shall not be spaced at intervals greater than 6m
and in no case shall be more than 10m. Where, however, a wall changes
direction by at least 60 degrees, the overall spacing of joints may be increased to
10 m subject to the length of pour in either leg of the wall being no more than 5m.
Where possible, joints shall be positioned at least 2m away from corners.
g) Use bonding agent on existing concrete surfaces that will be joined with fresh
concrete.
h) Water Stops: unless specified otherwise, provide PVC Water stops in construction
joints as indicated. Install water stops to form continuous diaphragm in each joint.
Make provisions to support and protect exposed water stops in accordance with
manufacturer’s printed instructions.
i) Isolation Joints in Slabs-on-Ground: Construct isolation joints in slabs-on-ground

at point of contact between slabs-on-ground and vertical surfaces, such as
column pedestals, foundation walls, grade beams, and elsewhere as indicated.
j) Contraction (Control) joints in Slabs-on-Ground: Construct contraction joints in

slabs-on-ground to form panels of patterns as shown. Use saw cuts 3 mm wide
by ¼ depth or inserts 6 mm side by ¼ of slab depth, unless otherwise indicated.
(i) Form contraction joints by inserting pre-moulded plastic, hardboard, or

fibreboard strip into fresh concrete until top surface of strip is flush with slab
surface. Tool slab edges round on each side of insert. After concrete has
cured, remove inserts and clean groove of loose debris.
(ii) Contraction joints in unexposed floor slabs may be formed by saw cuts as
soon as possible after slab finishing as may be safely done without
dislodging aggregate.

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(iii) If joint pattern not shown, provide joints not exceeding 5 m in either direction
and located to confirm to bay spacing wherever possible (at column
centrelines, half bays, third bays).
(iv) Joint sealant material is specified in the architectural specifications.
(v) Contractor to submit shop drawing for contraction joints layout for approval
by the Engineer.
k) No horizontal construction joints in beams, footings, pile caps and rafts shall be
permitted unless approved beforehand by the Engineer. Raft slab of 1.20m to 1.5
m can be cast into one go, without any horizontal joint. Casting can be made of
several pours. Maximum pour should not exceed 500mm in depth. At the sole
discretion of the Engineer, thicker raft slabs may be allowed to be cast with one
horizontal construction joint. Where rafts footings, pile caps etc are allowed to be
poured in two castings, then the horizontal construction joint must be prepared in
accordance with the following:
(i) Additional shear reinforcement to withstand horizontal interface shear shall

be calculated and provided by the Contractor at his own cost.
(ii) The concrete surface of the first pour is to be roughened to full amplitude of
approximately 5 mm. (broom finish).
(iii) Before the next pour, the contact surface is to be water-blasted to make the
surface clean and free of laitance. The clean concrete surface should be
approaching dryness and be free from surface moisture at the time new
concrete is placed on it.
(iv) The second concrete pour is to be carried out within 21 days after the first
pour. The concrete surface is to be kept saturated during the period
between the first and the second pour.
(v) All starter bars for columns and walls are to be brought down to the bottom
layer of the raft foundation reinforcement.
(vi) Only one horizontal joint shall be allowed in the depth of the raft, located
approximately at mid-depth.
l) Separation Strips: provide separate strips at locations as specified elsewhere.

Place concrete in the separation strips after concrete in adjacent areas has been
cured and has been in place for the duration noted on the drawings or specified
herein.
m) Settlement Joints: Place concrete in the settlement joints if specified elsewhere,

after the structure of the lowest tower has reached roof. Remove supports only
upon concrete has gained adequate strength.

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3.9.2 Movement Joints
a) Movement joints are provided for expansion, contraction or flexibility. They are
detailed in the Specification and on the Drawings. All movement joints are
required to be leak proof.
b) Expansion and contraction joints shall be formed as detailed in this Specification

and on the Drawings. The Contractor shall ensure that there is no adhesion
between the two concrete faces of the joint and that debris does not enter the
joints.
3.9.3 Expansion Joints
a) Expansion joints shall be constructed at positions shown on the Drawings or as

directed by the Engineer and shall be formed according to the instruction and
dimensions shown on the Drawings.
b) Type of joints, sealants, and on their selection & correct application shall be as
recommended in BS 6213:2000+A1:2010 .
c) Filled expansion joints shall be provided at every 6 m or as shown in the drawings

and /or directed by the Engineer for the kerb and concrete backing.
d) Any excavated surface for the concrete bedding should be watered and
compacted to a minimum 95% of optimum density.
3.9.4 Water Bars
3.9.4.1 General
a) Water bars shall be obtained from experienced manufacturers (minimum 10

years) and shall be the latest shapes and forms generally adopted in the industry.
Water bars shall comply with Table 3.22.
b) Technical back-up service during installation shall be provided by the

manufacturer at no additional cost to the employer.
3.9.4.2 Waterstop Across Joints in Concrete Structures
a) Seepage of water through any joints in a water retaining or water excluding

concrete structure shall be prevented by the use of PVC Waterstop or other
material as directed and approved by the engineer. They shall be placed centrally
as a water barrier across the designated joint in in-situ concrete structures and
cast centrally into the edges of adjacent concrete components.
b) Waterstop shall be used at all Expansion and Contraction joints in concrete

structures below water table. For a Construction Joint, requirement of a
Waterstop shall be indicated in the drawing. The Engineer may also require the
Contractor to provide Waterstop at any additional Construction Joint approved at
his request.
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3.9.4.3 Material
a) Unless otherwise specified all Water stops shall be extruded from a high-grade
elastomeric polyvinyl chloride compound as basic resin and manufactured from
virgin materials necessary to meet the performance requirements of this
specification.
b) Comply with the requirements of BS 2782 or US Corps of Engineers specification

CRD C572-74.
c) Suitable for storage, handling, installation and service within a range of 15C to
50C.
d) External water bar shall be the ribbed type to provide better watertight sealing
than dumbbells at floor, roof and kicker joints.
e) Intersection & Transition pieces shall be pre-formed factory moulded type and or
factory prefabricated type.
(i) Site jointing shall be limited to butt joints and shall be strictly in accordance
with the manufacture’s instruction.
(ii) Joints shall be heat sealed.
Table 3.22 – Physical properties of water bars
Property Test Method Minimum

Requirements
Tensile Strength ASTM D 638 15 N/m m²
Ultimate Elongation ASTM D 638 370%
Tear Resistance ASTM D 624 50 kN/m
Stiffness in Flexure ASTM D 747 4.14 N/m m²
Hardness, Shore A/15 ASTM D 2240 70 to 80
Water Absorption ASTM D 570 Max 0.3%
Tensile Strength after CRD – C 572 13.5 N/m m²

accelerated extraction
Elongation after CRD – C 572 300%

accelerated extraction

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Property Test Method Minimum

Requirements
Specific Gravity ASTM D 792 Max 14%
Low temperature ASTM D 746 No failure at - 37C

Brittleness
Volatile Loss ASTM D 1203 Max 0.5%
Effect on Alkali after 7 CRD –C 572 Max + 0.25% /-

days
0.10% Max
Weight change
 5% Max
Hardness Change
f) Waterstop shall be extruded from high grade grey PVC Compound.
g) Flat Dumbbells plain web Waterstop shall be used for a Construction Joint while
for an Expansion Joint or a Contraction Joint, a centre bulb Waterstop shall be
used.
h) The width of the Waterstop shall depend upon the concrete thickness, the
aggregate size and the position of reinforcement. In general, the following shall be
taken as guide to select the width w of a Waterstop:
W < t, but w > (6a+j)
Where,
t = Concrete thickness
a = largest aggregate size
j = width of Expansion Joint
i) Care shall be taken to prevent damage to water bars. Water bars shall normally
include eyelets for fixing and shall not be nailed unless they incorporate a
reinforced outer nailing flange.
j) Water bars shall not be displaced during the placing of concrete, which shall be
fully compacted around them.
3.9.4.4 External Water stops
a) Base Slab Expansion Joints:

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(i) Up to 250 mm wide with four ribs.
(ii) Centre bulb shall be:
1. 25 mm wide
2. Flat to accept a filler board
(iii) Height of ribs shall be 25mm
(iv) Shall have an outer nailing flange with a reinforced and profiled edge to
resist tear when fixed to shuttering with double headed nails.
(v) Provide additional key when cast into the concrete.
b) Base Slab Construction and Contraction Joints:
(i) Up to 250 mm wide with four ribs
(ii) Height of ribs shall be 25 mm
(iii) Shall incorporate groutite fins in the central section.
(v) Provide additional key when cast into the concrete.
c) Angle Guard
(i) Minimum 125 mm horizontally and vertically with four ribs.
(ii) Height of ribs shall be 25 mm.
(iii) Shall incorporate groutite fins in the central section.
3.9.4.5 Internal Water stops
Wall and Roof Expansion Joints:
a) Up to 250 mm wide with four ribs.
b) Shall have a centre bulb accommodate movement.
c) Centre bulb shall be flat to accept a filler board.
d) Web shall be 10 mm thick with a thickened central section to transfer stresses to

the centre bulbs.

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e) Shall have a brass reinforced eyeleted outer flange for secure fixing of the
Waterstop into position.
3.9.4.6 Self-Swelling Water stops to use in construction joints of minor structure like
inspection chamber.
a) Polymer based
b) Size 25 x 10 mm
c) Physical Properties: as per below.
Physical properties of self-swelling water stops
Property Test Method Minimum Requirement
Elongation ASTM D 638 200%
Hydrostatic Pressure
Resistance 5 bar
Water migration at or none

through joint
d) Water bars shall be arranged so that there is a minimum distance if 25 mm from

the water bar to the reinforcement.
e) The Water stop shall be a high performance system forming a continuous network
as shown on the Contract drawings. Site jointing is to be limited to butt joints and
shall be performed strictly in accordance with the manufacturer’s instructions.
f) The ribs of the centrally placed water stop shall line up with the ribs of the
externally placed water stop. All jointing shall be carried out in strict accordance
with the manufacturer’s instructions using purpose made metal jigs and welding
equipment.
3.9.5 Bond Breakers
Bond breakers shall be polyethylene tape, closed cell expanded polyethylene foam in
flat strip or solid circular core section, or other approved material which is suitable for
preventing short or long term adhesion between the sealant and the base material of
the sealant groove.

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3.9.6 Joint Fillers for Expansion Joints of Water Retaining Structures
a) The joint fillers are used as a support to the joint sealing compound to resist the
liquid pressure.
b) Unless otherwise shown on the Drawings joint fillers shall be non-absorbent,

semi-rigid, cellular polyethylene to the approved standard with the following
minimum characteristics: -
(i) Density 60 kg/cum
(ii) Maximum load to compress to 50 % of original thickness 0.15N/sq.mm
(iii) Recovery after compression 98%
3.9.7 Expansion Joint Filler for Precast Units
a) Expansion joint filler shall be composed of approved durable non-extruding

fibrous material suitably impregnated to prevent deterioration. Sheet bitumen
fillers will not be accepted.
b) Performance strips of expansion joint filler shall be of such a nature as not to be

permanently deformed or broken by twisting, bending or other normal handling on
site. Samples shall be submitted for approval before ordering.
c) The vertical expansion joints in kerbs and parapets shall be formed with approved
vertical seal. Such vertical seal shall adhere to the vertical face sealed and shall
not flow under maximum local sun temperature not shall it be sticky to the touch.
(i) Expansion joints for Precast kerbs shall be at 6 m.
(ii) For flush kerbs cast in-situ, at 2 m max.
(iii) For Precast slabs, every 4 m min
3.9.8 Submittals for Sealants
3.9.8.1 Manufacturer’s Literature
The Contractor shall furnish the following information from the manufacturer
a) Published data or manufacture’s letter, clearly indicating that each product to be

furnished complies with these Specifications is recommended for the application
shown and is compatible with each other material in the joint system.
b) Complete instructions for handling, storage, mixing, priming, installation, curing

and protection for each type of sealant.
c) Test certificates for each type of joint sealant delivered to site.

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3.9.8.2 Samples
a) Samples of each type of sealant: Provide samples 300 mm long installed between
two samples of the materials to be sealed, fully cured.
b) Samples will be reviewed by the Engineer for colour and texture only.
c) Compliance with all other requirements is the exclusive responsibility of the

Contractor.
3.9.8.3 Compliance with Performance Requirements
Not-withstanding the types of sealant specified herein, the Contractor shall in all
cases be responsible or providing sealant materials the best of their respective kinds,
compatible with adjoining materials and suitable for the purpose intended, all at no
additional expensive to the Employer.
3.9.8.4 Guarantee
a) Guarantee stating that the sealant system installed will be watertight and free
from defects for a period of not less than ten (10) years other than sealant for
water retaining structures from date of Taking –Over of the Works.
b) In the event any defects occur within the period stipulated, the Contractor shall at
the convenience of the Employer, effect all repairs and replacements necessary
to remedy defects all to the complete satisfaction of the Engineer at no additional
cost to the Employer.
3.9.9 Environmental Conditions
a) The Contractor shall not proceed with the installation or application of sealant
during inclement weather unless all requirement and manufacturer’s instructions
can be complied with and unless the work can proceed in accordance with the
agreements of the pre-installation meeting.
b) The Contractor shall not proceed with the installation of sealant under extreme
temperature conditions which would cause joint openings to be at either
maximum or minimum width, nor when such extreme temperatures or heavy wind
loads are forecast during the period required for initial or normal cure of sealant.
c) Whenever possible, schedule the installation and cure of sealants during period of
relatively low temperatures (but well within manufacturer’s recommended range)
so that subsequent tensile stress upon the cured sealants will be minimised.
3.9.10 Pre-Installation Meeting
a) Prior to the installation of sealants, and at the Engineer’s direction, meet at the
project site to review the material selections, installation procedures and co-
ordination with other trades.

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b) Meeting shall include the contractor, manufacturer’s representative, the Engineer

and representative of other trades or Sub-Contractors affected by the sealant
installation.
c) Examine sample applications to determine and record whether all parties agree
that the proposed installations are likely to perform as required.
3.9.11 Sample Application
a) Provide sample applications of sealants at locations designated by the Engineer.
b) Samples shall represent the primary types of materials, substrate surfaces, and
joint size. Exposure and other conditions to be encountered.
c) Preparation, priming, application and curing shall comply with manufacturer’s

recommendations and actual proposed methods.
d) Schedule the applications with allowance for sufficient curing time, so that
samples may be examined and any necessary adjustments made at least one
week prior to date scheduled for commencing installation of the work.
e) Samples shall be visually examined for standing, dirt pickup, shrinkage, colour,
general workmanship and appearance.
f) Cut and pull the sealant from each sample joint to examine for internal bubbles or
voids, adhesion and general compatibility with substrate.
3.9.12 Delivery, Storage and Handling
3.9.12.1 Delivery
Deliver materials in manufacture’s unopened containers, fully identified with brand,

type, grade, class and all other qualifying information.
3.9.12.2 Storage
a) Storage materials in a dry location in such a manner as to prevent damage or

instruction of foreign matter.
b) Conspicuously mark “Rejected” on materials which have once been wet or

damaged and remove from the job site.
3.9.13 Materials - General
3.9.13.1 Product Variation
If more than one of the manufacturer’s products complies with the requirements for
any item specified herein, provide the specific product recommended by the
manufacturer for the particular condition of use in each case.

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3.9.13.2 Manufacturers
a) Products and manufactures specified hereinafter are specified for the purpose of
establishing minimum quality standards.
b) Products equal in quality to, or better than those specified will be considered
acceptable to no additional cost to the Employer.
c) Decision of acceptability will rest with the Engineer.
d) Manufacturer shall operate a Quality System which is registered to ISO 9000

series or approved equal.
3.9.13.3 Compatibility
a) Provide only sealant and joint primers which are compatible with the joint surfaces
and backing or filler materials as stated in the manufacturer’s published data or as
certified by the manufacturer for each application.
b) Confirm compatibility of sealant that may be in contact with each other.
3.9.13.4 Hardness
Determine the proper hardness or consistency of elastomeric sealants in consultation

with the manufacturer considering joint movement and exposure for the size of joint
shown.
3.9.13.5 Ranges of Hardness
In general provide sealants with the following ranges of hardness (fully cured sealant
at 24C):
Table 3.23
Exposure (Joints subject to) Shore A Hardness
Maximum movement, normal weather exposure 15 – 25

and abrasion.
Moderate movement, severe weather exposure 25 – 40

and moderate abrasion.
Minimum movement and severe abrasion 35
3.9.13.6 Modulus of Elasticity
a) In general, for elastomeric sealants, provide sealants having the lowest modulus
of elasticity which is consistent with the degree of exposure to wear and abrasion.
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b) Any sealant exposed to traffic must have strength and modulus sufficiently high to
resist damage by traffic.
3.9.13.7 Colour
a) For fully concealed joints, provide the manufacturer’s standard colour of sealant
which has the best overall performance characteristics for the application shown.
b) For exposed joints provide the colour shown in the drg or if the colour is not
shown, provide the colour as follows:
The colour in each case will be selected by the Engineer from manufacturer’s
standard colours to match or blend with adjoining materials in a manner to be
3.9.13.8 Manufacturer’s Representative
At the start of the installation, and periodically as work progresses, provide the
services of the manufacturer’s technical representative at the job site as often as
deemed necessary by the manufacturer to advice on all phases of this work at no
additional cost to the Employer.
3.9.14 Types of Area and application other than Water Retaining Structures
Table 3.24
Type Area of Application
1. One part elastomeric low 1. Exterior joints in masonry

modulus silicone rubber
sealant. 2. Around aluminium doors, window
frames
a. Conform to BS ISO
11600:2003+A1:2011 3. GRP materials
4. Glazing
2. One Part Elastomeric, high 1. Sanitary ware

modulus, Silicone Rubber
Sealant. 2. Kitchen units
a. Conform to BS ISO 3. Glazing

11600:2003+A1:2011 or
FS-TT-S-001543A
3. Two Part Polysulphide Joint 1. Ceramic tiles

Sealant
a. Resistant to corrosion and

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Type Area of Application
chemicals
4. Two Part Polysulphide Sealant 1. Expansion and Contraction joints in

Concrete
a. Conform to BS EN ISO
11600:2003+A1:2011
5. Two Part Tar/Polysulphide 1. Expansion joints subject to heavy

Sealant traffic.
a. Non-bio degradable
6. Bitumen based sealant 1. Sealing and filling gaps on roofs
a. Conform to BS 6920 2. Pointing chases for water proofing

membrane
7. Two Part Polysulphide sealant 1. Fuel and chemical spillage

with minimum 40% polymer area
content Type I
11600:2003+A1:2011
8. Sealant for fire rated structures 1. Pipe and cable penetration
11600:2003+A1:2011
3.9.14.1 Miscellaneous Materials
a) Joint Cleaners, Primers and Sealers
Products as recommended by the manufacturer of the sealant for each specific

joint surface and condition
b) Bond Breaker Tape
As specified
3.9.14.2 Execution
Acceptable Conditions
a) Examine the component surfaces and fillers of the joints to be sealed and the
conditions under which the work is to be done.
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b) Do not proceed with the work until unsatisfactory conditions have been corrected
in a manner acceptable to the Engineer.
3.9.14.3 Preparation
a) Clean bonding joint surfaces to remove all traces of deleterious material such as
form oil, curing compounds and any surface laitance which might interfere with
bond or otherwise impair the work.
(i) Do not apply elastomeric sealants to joint surfaces previously painted or

treated with sealer, curing compound, water repellent or other coatings
unless a laboratory durability test of bond-cohesion has been performed
and successfully demonstrated that bond will be durable.
(ii) Test method shall comply with procedures referenced as applicable to the
particular sealant.
b) Do not apply paint and other coatings or substances to surfaces adjoining joint
surfaces until sealants have been installed and are normally cured, so that
adhesion will not be impaired by migration of such substances onto the joint
surfaces.
c) Concrete and Masonry Joint Surfaces
Sealant manufacturer’s recommended primer shall be applied for sealing of

expansion and construction joints in concrete.
a) Comply with the manufacturer’s instructions for the use and installation of each
type of sealant, unless otherwise shown or specified.
b) Prime the sides of the joint with the relevant primer as recommended by the
sealant manufacturer:
(i) Avoid migration of primer or sealer onto adjoining surfaces and remove any
spillage promptly.
(ii) Apply sealant after applied surface becomes tack free but no more than 60
minutes.
c) Install bond breaker tape in joints as shown and wherever recommended by the
sealant manufacturer to prevent bond of the sealant to surfaces where such bond
might impair the performance of the sealant.
d) Do not puncture surface or skin of compressible rod type bond breaker.
e) Have the manufacture’s technical representative present when beginning the

installation of each major type of sealant.

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f) Comply with manufacturer’s printed instructions and recommendations, except as

may be otherwise shown or except as may be otherwise directed (and recorded)
by the manufacturer’s representative.
g) Employ only tradesmen who are experienced in the use of the materials specified.
h) Unless otherwise specified all sealants shall be gun applied.
i) Use only the types of equipment recommended by the sealant manufacturer.
j) Apply compounds in continuous beads or rivets, filling joint from the bottom
without openings, voids or air pockets.
(i) Force compound to sides of joint so as carefully and thoroughly “wet”

opposite joint bond surfaces, forming equal areas of contact with sealant.
(ii) Confine compounds to joint areas shown by use of masking tapes or other
precautions to prevent spilling and migration onto adjoining surfaces.
(iii) Apply compounds in concealed compression joints accurately so that

excess compound will not exude from the joint.
k) Apply sealants in the depth shown or, if none is shown, apply in accordance with
the manufactures recommendations.
l) Tool exposed surfaces so as to compress sealants to the profile shown or, if none
is shown, tool surface slightly concave except provide a slight wash on horizontal
joints where horizontal and vertical surfaces meet.
m) Against rough surfaces or in joints of uneven widths avoid appearance of excess

sealant by locating the sealant well back into wherever possible.
n) Remove excess sealant promptly as the work progresses and clean the adjoining
surfaces as may be necessary to eliminate any evidence of spillage.
o) If job progress or any other condition requires the installation of sealant at

temperature below those recommended by the manufacturer, consult the
manufacturer’s representative and establish the minimum provisions required to
ensure satisfactory work.
p) Record in writing the conditions under which such installations must proceed and
the provisions made to ensure satisfactory work.
3.9.14.5 Curing and Protection
a) Cure the sealants in accordance with the manufacturer’s instructions to obtain

maximum bond to surfaces, cohesive strength and durability at the earliest
possible date.

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b) Protect the sealants during the remainder of the construction period, so that they
will be without any indication of deterioration of damage at the time completion of
the Works.
3.9.14.6 Performance Test
a) After curing exterior joints exposed to the weather, test for leaks by applying a
stream of water perpendicularly from a 19 mm hose at normal city water pressure.
b) Test approximately 5% of the exposed joint system where leakage could be

observed.
c) Conduct tests in the presence of the Engineer who will determine the actual
percentage of joints to be tested and the period of water flow exposure based on
any observed leakage.
d) Repair leaks and re-test as directed.
3.9.15 Joint Sealing in water retaining Structures
a) BS 6213 :2000+A1:2010 provides guidance on types of construction sealant and

their selection and correct application. The Contractor shall provide a minimum 20
years guarantee for the service life of sealant proposed for the water retaining
structure. Selection of sealants for each joint shall take account of:
(i) Appropriate width/depth ratio of the joint
(ii) Material lifetime in the exposure condition concerned
(iii) Chemical resistance
(iv) Movement accommodation as a percentage of joint width
(v) Compatibility with adjacent materials
(vi) Ease of Replacement
(vii) Pot life in the local environment
(viii) Joint backing materials
b) Sealant slots to expansion, contraction and, where included, construction joints

shall be carefully constructed to the dimensions detailed on the Drawings or,
subject to approval of the Engineer to the manufacturer’s recommendations.
Jointing materials shall be capable of accommodating repeated movements
without permanent distortion and shall not be displaced by fluid pressure.
c) The Contractor shall take care to avoid spalling of concrete on the edges of slots.
Slots to expansion joints may be formed by installing joint filler to the concrete
surface and then using a special cutter to remove filler to the required depth.

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Alternatively, and for contraction joints, slots may be formed by pre-formed PVC
or timber formers with sloping sides to assist removal.
d) Before placing sealants, the slots must be thoroughly cleaned and all laitance and
oil removed by an abrasive method. Immediately prior to sealing the slots, all
loose surface debris, sand and dust must be blown out using compressed air, and
the slots must be dry and free from collected rainwater etc. to ensure maximum
adhesion.
e) Sealants must in all cases be carefully selected as appropriate for their climatic
and environmental exposure and must, where appropriate, be resistant to bio-
degradation. The Contractor must supply to the Engineer copies of written
recommendations(s) and guarantee(s) from the manufacturer as to the suitability
of the product(s) for each individual structure and for the methods of installation.
f) Primers for use with joint sealants shall be compatible with, and obtained from the
same manufacturer as, the adjacent sealant. Primers shall have no harmful
effects on concrete.
g) Where required by the Engineer masking tape shall be applied to protect the
concrete surface on either side of the joint priming and sealing operations. Such
masking tape must be carefully stripped away after joint sealing to leave neat
edges to the seal.
h) The recess to joints to be sealed with Polysulphide based sealant and shall not be
painted with bituminous products due to reactivity.
3.9.16 BOND BREAKING COMPOUND FOR DOWEL BARS
Bond breaking compound for dowel bars shall consist of a bitumen paint containing
66 per cent of 200 pen bitumen, blended hot with 14 per cent light creosote oil with
the addition, when cold, of 20 per cent solvent naphtha. It shall in no way retard or
otherwise affect the setting of concrete.
3.9.17 Expansion Joint Sealing Compound
3.9.17.1 General
a) The sealing compound shall be of an approved Polysulphide compound, non-

pouring grade for vertical application and pouring grade for horizontal application.
b) Expansion joints in contact with sewerage structures shall be a highly chemical

resistant two part polysulphide sealant with high polymer content conforming to
the requirements.
c) All joints Type I & III are to be treated with Hypalon Elastomer strip as specified in
Section 3.13 of this Specification Clause.

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d) The sealants shall have high resistance to acid and alkalis and must be carefully
selected from Type I to III as appropriate for their climate and environmental
exposure.
3.9.17.2 Type I Joint Sealants
Type I Joint Sealants are those to be used for structures in contact with sewerage in
immersed condition (for expansion joints), which shall comply with the following
conditions:
a) Two part Polysulphide conforming to the requirements of BS EN ISO

11600:2003+A1:2011
b) Colour : Black
c) Hardness Shore ‘A’ (ASTM D2240) : Minimum 35
d) Movement Accommodation Factor : 20% 5
e) Polymer Content : min 40% (for sewage grade)
f) Elongation (ASTM D 638) : min: 200%
g) Resistance to weathering, ultra-violet light, chemicals and biodegradation.
h) Ability to withstand repeated cycles of compression and expansion over a wide

temperature range.
i) Shall comply either the requirement as specified in “Sealants”.
j) Contractor must apply written recommendations and guarantees from the

manufacturers as to the suitability of the product for each individual structure and
the method of installation.
k) The Sealant shall be resistant to the sewage environment and
(i) shall have no harmful effects on concrete.
(ii) as recommended by the sealant manufacturer.
l) Resistant to 10% sulphuric acid @ 100 days: shall not show any deterioration
after the test in accordance with ASTM C581.
m) Type 1 sealants are to be covered with Hypalon sealing strips as specified in

Section 3.13
3.9.17.3 Type II - Joint Sealants
a) Type II sealants are to be used in structures not in contact with sewerage but
exposed to sunlight (for Expansion Joints).

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b) Expansion joint sealants in other structures will be a two part polysulphide sealant
conforming to BS EN ISO 11600:2003+A1:2011 and US Federal Specification TT-
S-00227E.
c) The sealant will have the following properties.
1. Shore A hardness (TT-S-00227E): Min. 20

2. Movement Accommodation factor: 25%5
3. Elongation (ASTM D 638): Min. 350%
4. UV Resistance for 300 hours (ASTM G53) : No deterioration
3.9.17.4 Type III – Sealant for Sewage Tanks and other similar Structures (for Construction
Joints)
Epoxy modified polyurethane sealant conforming to the requirements.

This sealant shall have the following properties:
1. Shore A hardness (TT-S-00227E): 75%  10

2. Movement Accommodation factor: 10% 5
3. Elongation (ASTM D 638): Min. 50%
4. Resistance to 10% sulphuric acid @ 100 days: Shall not show any deterioration after
the test in accordance with ASTM C581.
Type III sealants are to be covered with Hypalon sealing strips as
specified in Section 3.13 of this specification clause.
3.9.18 Properties of Sealant to fix GRP MH Liners
The sealant shall have the following properties:
Table 3.25: Properties of Sealant
Properties Requirements
Movement Accommodation Factor 10% 5
Cure Time @ 20C @35C
Initial: 24 hours 12 hours
Full: 3 days 2 days
Application temperature + 5C to 45C
Service temperature - 10C to 70C
Specific Gravity 1.31

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Shore ‘A’ hardness 60-80
Chemical Resistance Good resistance to most common

mineral acids-alkalis, petroleum based
fuels and stream.
Resistant to 10% sulphuric acid @100 Shall not show any deterioration after
days tested in accordance with ASTM the test
C581
3.9.19 Dowel Bars
a) Dowel bars shall be straight, free from burred edges or other irregularities, and
shall have their sliding ends sawn.
b) The sliding half of each dowel bar shall be painted with a thin coat of bond
breaking compound, and the end of this half shall be provided with a close fitting
plastic or waterproof cardboard cap at least 100 mm long, the end 20 mm of
which shall be filled with a disc of joint filler or a pad of cotton waste.
3.9.20 Bond Breaker Tape
a) Forced, non-absorbent polyethylene backing strip or equals
b) As recommended by the sealant manufacturer to prevent adherence of sealant to

backup material.
3.9.21 Sealing Strip Membrane Based On Hypalon-Elastomer
a) Hypalon elastometer strip with 2-part epoxy resin adhesive.
b) Shall allow considerable movements in more than one direction while maintaining
a high quality seal.
c) Strip width: 150 mm
d) Strip thickness: 2 mm
Table 3.26 – Sealing Strip Membrane – Physical Properties
Property Minimum Requirements
Strip Membrane:
Tensile Strength > 6 N/m m²

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Property Minimum Requirements
Peel Strength 4.5 N/m m²
Elongation at Break > 400%
Bending Test No Cracking at - 30C
Service Temperature -30C + 60C
Adhesive:
Density 1.7 kg/l
Pot life at 40C 25 min
Compressive Strength > 50 N/m m²
Bond Strength to Steel > 3 N/m m² (Concrete failure)
Final sealing strip system shall be able to accommodate movement which results in
the de-bonded area being extended up to 100% of the de-bonded width.
3.9.22 Slip Membrane and Installation
3.9.22.1 Slip Membrane
a) The slip membrane shall be of low friction bearing strip to form a thin sliding joint
provided in two layers, each 1.5 mm thick.
b) The slip strips shall be manufactured from specially formulated polyethylene

resistant to most chemicals, solvents and weathering.
c) The bottom layer shall be bonded to substrate with high quality solvent borne
adhesive based on polychloroprene rubber.
d) Slip membrane shall have a coefficient of static friction of 0.15.
3.9.22.2 Installation of Slip Membrane
a) The roof slab of the reservoir is designed as a continuous flat slab.
b) Two layers of slip membrane shall be provided at the wall support to slab soffit.
3.10 REINFORCEMENT STEEL
3.10.1 General
a) This work shall consist of furnishing, fabricating and placing steel reinforcement
bars of the grade, type, quality, size, shape and quantity designated, all in
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accordance with these Specifications and the details shown on the Drawings. The
epoxy coated reinforcement steel shall be used on the project.
b) The Contractor shall be responsible for furnishing reinforcing steel in sufficient

quantity and of the proper sizes, lengths and shapes shown on the Drawings for
any given structure.
3.10.2 Material Specifications
a) All reinforcement bars shall be of a deformed type in accordance with BS

4449:2005+A2:2009, except that plain bars may be used where specifically
indicated on the Drawings. Plain bars shall be in accordance with BS 4449
:2005+A2:2009.
b) All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars, Grade 500 (ribbed bars), unless otherwise
shown on the Drawings or specified by the Engineer.
Table 3.27 - High Yield Steel Reinforcement Bars – Compliance Requirements
(Test Method BS4449:2005+A2:2009, Grade 500)
Bar Nominal Cross sectional Mass per metre , Test Results

Diameter area m² kg
6mm 28.3 0.222
8mm 50.3 0.395
10mm 78.5 0.617
12mm 113 0.888
16mm 201 1.58
20mm 314 2.47
25mm 491 3.85
32mm 804 6.31

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Bar Nominal Cross sectional Mass per metre , Test Results

Diameter area m² kg
40mm 1257 9.86
50mm 1963 15.4
Tolerances : The permissible deviation from nominal mass per metre shall not more
than +/- 4.5% on nominal diameters greater than 8 mm , and +/- 6% on nominal
diameters less than or equal to 8 mm .
Yield Stress (N/m Characteristic = 500

m²)
Minimum = 485
Maximum = 650
Tensile Stress As per BS

(N/m m²) 4449:2005+A2:2009
Elongation, % As per BS
(gauge length) 4449:2005+A2:2009
Bend Test As per BS

4449:2005+A2:2009
Rebend test As per BS

4449:2005+A2:2009
Chemical Analysis
Carbon %
As per BS
4449:2005+A2:2009
Phosphorous %
Sulphur %
c) Mild steel where specified or called for shall be either deformed or plain bars
complying with BS4449:2005+A2:2009 or any equivalent National Standard as
directed and approved by the Engineer.

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d) Tying wire shall be No.18 gauge stainless steel wire or the equivalent BS
specification for tying wire and uPVC coated suitable for epoxy coated rebar.
e) Welded wire fabric shall be used as reinforcement for concrete where shown on
the Drawings and as directed. Welded wire fabric shall conform to the
requirements of BS 4483 ..
f) The Contractor shall be responsible for obtaining the Engineer’s approval to the
steel bars prior to coating commencing. A certificate of product conformity in
accordance with Clause 8 of BS4449:2005+A2:2009 shall be issued. Such
approval will in no way relieve the Contractor of his responsibilities under the
Contract.
Table 3.28 - Fusion Bonded Epoxy Coating Materials – Compliance

Requirements
Properties Requirement Results Test Methods
Finish & colour Light green (to be filled Manufacturer’s spec

by the
applicator)
Gel time Manufacturer’s spec (to be filled Manufacturer’s spec

by the @200oC
applicator)
Cure time Manufacturer’s spec (to be filled Manufacturer’s spec

by the @200oC (min. time to
applicator) quench)
Dry film thickness 7~12 mils ASTM A775/A775M
(175~300µ) ASTM G12
Continuity of coating 3 holidays/m ASTM A775/A775M

(67.5 volt DC holiday
detector)
Flexibility & No cracking ASTM A775/A775M

adhesion
No dis-bonding (180o bending)
Impact resistance No shattering, ASTM A775/A775M

cracking, bond loss
of coating ASTM DG 14 (80 in
lbs)

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Properties Requirement Results Test Methods
Abrasion resistance  100 mg ASTM A775/A775M
ASTM D4060
Cathodic dis-bond  4 mm (from the ASTM A775/A775M

edge)
ASTM G8
(1.5v*3%NaCl*24oC*1
68h)
g) Coating material shall be epoxy resin powders as specified in ASTM A775 for
coating of reinforcing bars.
(i) Epoxy resin powders which do not meet the above requirements must be
tested for the properties specified by an approved independent testing
laboratory and accepted by the Engineer prior to use.
(ii) Only fusion bonded epoxy coated reinforcing steel will be accepted.
(iii) No other means of epoxy coating will be approved.
h) Patching Material:
(i) shall be furnished by the epoxy manufacturer
(ii) compatible with the coating
(iii) inert in concrete
(iv) suitable for repairs to the coated reinforcing bars to be made by the coating
applicator and the Contractor at the project site.
3.10.3 Testing of Reinforced Steel
3.10.3.1 Testing of Reinforced Steel (Uncoated)
a) Testing shall be carried out on uncoated steel bars in accordance with

BS4449:2005+A2:2009 unless otherwise specified here in and shall submit a
compliance statement in accordance with the summary sheet attached.
b) The following tests shall be carried out for each delivery of reinforcement.
(i) Cross-sectional area and mass
(ii) Deformation/bond characteristics of deformed bars
(iii) Tensile test

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(iv) Yield stress
(v) Elongation
(vi) Bend test
(vii) Re-bend test
(viii) Chemical composition
(ix) Carbon equivalent value
c) Testing frequency shall be in accordance with BS4449:2005+A2:2009.
d) Test results for each bar size shall be submitted to the Engineer three (3) weeks
before concrete work commences on site.
e) Further tests may be called for when the source of supply of reinforcement
changes in which case the cost of such extra testing will be borne by the
Contractor.
f) When any test results do not confirm to the relevant standard, the reinforcement
steel shall be removed from the site and all costs resulting therefrom shall be
borne by the Contractor.
3.10.3.2 Test on epoxy coated reinforcing bars
a) Adhesion and flexibility of the epoxy coating shall be evaluated on test bars
coated with each production lot.
b) Test bars shall be furnished extra
c) At least 1 percent of the length or 6 metres. Whichever is less, of each size of bar
to be coated shall be furnished as test bars.
d) Test bars may be in one length or multiple lengths as required to have one test
bar of each size with each production lot.
e) The flexibility of epoxy coated production bars shall be evaluated by bending 180
degrees (after rebound) around a mandrel of a diameter corresponding to size of
bar. Bend shall be made at a uniform rate and may take up to one minute to
complete. Bend test shall be conducted at room temperature 20 C - 30 C after
the specimen has been exposed to room temperature for a sufficient time to
ensure that it has reached thermal equilibrium.
3.10.4 Construction of Reinforcement
a) Steel reinforcing shall be stored on timber packing clear of the ground. The steel
bars shall be free from sharp deformations, rolled-in slivers, deep recesses or
surface faults/blemishes which could result in inefficient or inadequate coating.
When fixed in the work and immediately prior to concreting, steel reinforcing shall
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be entirely free from loose mill scale, loose rust, oil, grease, paint, mould oil, and
all other deleterious and extraneous material. All hooks, bends, etc., unless
otherwise shown on the Drawings shall be to BS EN ISO 4066:2000 & BS
8666:2000.
b) Cut end of reinforcement is to be patched before any visible oxidation appears.

The patching material shall be furnished by the epoxy coating manufacturer.
c) Before ordering reinforcing steel, the Contractor shall prepare bar bending
schedules at his own cost and submit them to the Engineer for his approval. Bar
schedules shall show the weight of each bar, the total weight of each bar size and
the total weight of bars, and bending diagrams for bars in accordance with BS EN
ISO 3766:2003 & BS 8666:2005. Unless otherwise specified laps, hooks and bends
shall be to the minimum dimensions detailed in the approved standard .
d) The Contractor shall also provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of bar bending schedules or for the completion of the
Works.
e) The Engineer’s approval of the Contractor’s working drawings and bar bending
schedules shall in no way relieve the Contractor of responsibility for the
correctness of such drawings or schedules.
f) Steel reinforcement shall be bent accurately to the shapes and dimensions shown
on the approved bar bending lists or drawings. Bars shall be bent round mandrels
of the requisite diameter.
g) Steel reinforcement shall be cut and bent in accordance with BS EN ISO 3766:2003
& BS 8666:2005. Cutting or bending by the application of heat is not permitted.
Where fabric reinforcement is required to be bent it shall be done cold, either
using a bending machine or swage blocks and hooks. Fabric reinforcement shall
be cut to cover the areas detailed plus the following laps:
(i) Rectangular mesh: 450 mm for longitudinal members; 75 mm for transverse

members.
(ii) Square mesh: 300 mm in each direction.
h) Welding of reinforcement shall only be permitted when approved in writing by the

Engineer. If such approval is given then the workmanship shall be in accordance
with BS EN 1011-2:2011 & BS EN 1011-1:1998. The Contractor shall submit full
technical details of his proposed procedures prior to seeking approval.
i) Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than four
times the nominal size of the bar.

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j) Links, hoops, stirrups are generally to be bent round pins of the same diameter as
the bars they are to embrace. Where however, such bars are less in diameter
than twice the diameter of the link, the radius of the bend shall be equal to the
diameter of the link.
3.10.5 Placing Reinforcement
3.10.5.1 General
a) The number, size, form and position of all reinforcement shall, unless otherwise
directed or authorised by the Engineer, be strictly in accordance with the
Drawings.
b) Nothing shall be allowed to interfere with the disposition of the reinforcing bars.
c) Bars generally must be of the required lengths. Welding of the bars will not be
permitted.
d) Lapping of the bars other than the lap splices shown on the Drawings should be
avoided. The Engineer may approve certain lapping under special conditions. All
lapping should comply strictly with the BS/ASTM specifications, namely Article
1.5.6. Clause "c".
e) All intersecting bars shall be bound together with stainless steel wire with the
ends of the wire turned into the main body of the concrete.
3.10.5.2 Maintaining Reinforcement in Position
a) Concrete cover blocks shall, unless otherwise directed, be used between the
reinforcement and the bottom and sides of the forms to ensure correct placing
and cover of the bars. The strength of such concrete cover blocks shall be not
less than that of the main concrete.
b) The reinforcement shall be assembled as dimensioned on the Drawings within

tolerances appropriate to the structure. It shall be firmly held in position by wire
ties and concrete blocks or other approved spacers designed to maintain the
correct clear cover of concrete over steel reinforcement. They shall be as small as
possible consistent with their purpose, and of a shape acceptable to the Engineer.
Minimum cover to reinforcement shall be as specified. The position of spacers
and their method of use shall be approved by the Engineer. No concrete or
reinforcement shall be cut in any way except by permission in writing from the
Engineer.
c) Concrete cover blocks shall be manufactured to the same specification as the

surrounding concrete. When tested in accordance with the approved standard the
water absorption shall not exceed 2% for samples up to the age of one month at
the time of test. Wire cast in the block for the purpose of tying it to uncoated
reinforcement shall be of stainless steel or epoxy coated wire and shall be rust
and contaminant free.
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d) Spacers shall be of rust-proof material and shall not produce staining, or

otherwise be detrimental to the concrete or steel.
e) All chairs, spacers, tie-wires (including wire cast in blocks) or other devices used
to support or fasten epoxy coated reinforcement shall be made of or coated with a
dielectric material such as nylon, epoxy or plastic compatible with the coating of
the reinforcement.
f) Nothing shall be allowed to interfere with the disposition of any member of the
reinforcement and the Contractor shall take special precautions that it is not only
correctly placed, but remains undisturbed during the placing and setting of the
concrete, and that it has not been contaminated with release agent or any other
substance which will prevent the best possible bonding of steel and concrete.
g) With the approval of the Engineer mild steel reinforcement may be temporarily
bent aside at construction joints. This shall be done with care to a minimum
internal bending radius of 4 bar diameters and to avoid damage to the concrete
during bending and re straightening. The bending of high yield bars, epoxy coated
reinforcement and fabric reinforcement at construction joints is not permitted.
h) The greatest care shall be taken to prevent any displacement or bending of the
members of the reinforcement adjusted and temporarily fixed in position before
commencement of the concreting. Reinforcement temporarily left projecting from
the concrete at construction of other joints shall be adequately protected against
displacement both during concreting and afterwards and shall not be bent out of
position unless agreed by the Engineer's Representative. During the concreting
competent steel fixer shall be in attendance to re-set any reinforcement
inadvertently displaced.
3.10.5.3 Approval of Reinforcement Before Concreting
a) The Contractor shall in all cases request the approval of the Steelwork by the
Engineer's Representative in sufficient time to allow an inspection to be made and
shall not commence concreting until such approval is obtained.
b) The period between the Contractor's request for approval and his intention to
commence concreting shall not be less than one clear normal working day and
the Engineer's Representative may require a longer period if, in his opinion, the
reinforcement is of such complexity as to require it.
c) Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

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DEPARTMENT
SECTION 4
PIPES, PIPEWORK, MANHOLES AND CHAMBERS
DM/SRPD Section 4 Pipes, Pipework, Manholes and Chambers Rev 00 June
2016

Dubai Municipality
DM/SRPD Section 4 Pipes, Pipework, Manholes and Chambers Rev 00 June Page i of iii
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Dubai Municipality
SECTION 4
PIPES, PIPEWORK, MANHOLES AND CHAMBERS
CONTENTS
4 PIPES, PIPEWORK, MANHOLES AND CHAMBERS ...................................................... 1
4.1 PIPE MATERIALS ......................................................................................................... 1
4.1.1 Pipe Classifications and Pressure Ratings ........................................................... 1
4.1.2 Joint Requirements and Limitations ...................................................................... 1
4.2 RIGID PIPES.................................................................................................................. 4

4.2.1 Reinforced Concrete Pipes ................................................................................... 4
4.2.2 Ductile Iron Pipes ................................................................................................ 13
4.2.3 Joints .................................................................................................................. 17
4.2.4 Other Ferrous and Non-ferrous Pipes & Fittings ................................................ 25
4.3 THERMOPLASTIC PIPES........................................................................................... 25

4.3.1 Unplasticised Polyvinyl Chloride Pipes and Fittings (uPVC) .............................. 25
4.3.2 POLYETHYLENE PIPES (HDPE) ...................................................................... 27
4.4 GRP PIPES & FITTINGS ............................................................................................. 38

4.4.1 Definitions and Requirements ............................................................................. 38
4.4.2 Glass Reinforced Plastic Pipe & Fittings (GRP) for use in Gravity and Pressure
Flow Systems ................................................................................................................... 41
4.4.3 Compulsory Requirements Particular to Pipes, Couplers and Joints ................. 44
4.4.4 Type Test for GRP Pipes and Joints .................................................................. 47
4.4.5 GRP Pipes and Fittings for Pumping Stations and Valve Chambers.................. 59
4.4.6 GRP Pipes and Fittings for Irrigation and Potable Water Distribution &
Transmission .................................................................................................................... 61
4.5 STORAGE AND HANDLING OF PIPES ..................................................................... 72

4.5.1 General ............................................................................................................... 72
4.5.2 Glass Reinforced Plastic Pipes (GRP) ............................................................... 72
4.5.3 Thermoplastic Pipes (uPVC) ............................................................................. 73
4.5.4 Reinforced Concrete Pipes (RCP) ...................................................................... 73
4.5.5 HDPE Pipes ........................................................................................................ 74
4.6 GRANULAR MATERIAL FOR PIPE BEDDING AND SURROUND ........................... 74

4.6.2 Stone for Land Drains ......................................................................................... 75
4.6.3 Compaction Fraction Test ................................................................................... 75
4.7 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION ........................... 76

DM/SRPD Section 4 Pipes, Pipework, Manholes and Chambers Rev 00 June Page ii of iii
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4.7.1 General ............................................................................................................... 76

4.7.2 Nominal Trench Width for Flexible Group ‘B’ Pipes ............................................ 76
4.7.3 Pipelines in Wide Trenches ................................................................................ 76
4.7.4 Pipe Laying and Jointing ..................................................................................... 77
4.7.5 Pipelines in Concrete Cradles and Surrounds .................................................... 79
4.7.6 Pipelines on Granular Beds ................................................................................ 79
4.7.7 Placing Surrounds to Pipelines ........................................................................... 80
4.7.8 Group A Rigid Pipes Bedding, Surround Materials and the Trench Width ......... 80
4.7.9 Group B Pipe Materials ....................................................................................... 80
4.7.10 Compaction of Pipe Surrounds ........................................................................... 81
4.7.11 Pipelines below Permanent Groundwater Level ................................................. 81
4.7.12 Backfilling of Trenches - Pipelines/Structures .................................................... 81
4.7.13 Deflection Measurements on Group B Pipelines ................................................ 81
4.7.14 Deflection Measurements - GRP Pipes .............................................................. 82
4.7.15 Deflection Measurements - uPVC and other Plastic Pipes ................................. 82
4.7.16 Deflection Criteria on Group B Pipelines ............................................................ 83
4.7.17 Stanks to Pipelines in Granular Bedding ............................................................ 84
4.7.18 Thrust and Anchor Blocks to Pressure Pipelines ................................................ 84
4.7.19 Pipes Protruding from Structures, Concrete Surrounds and Anchor Blocks....... 85
4.7.20 Protection of Pipelines and Pipeline Component ................................................ 86
4.8 PIPEWORK WITHIN STRUCTURES .......................................................................... 96

4.9 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES ...................................... 97
4.9.1 General ............................................................................................................... 97
4.9.2 Construction of Manholes, Chambers, and Special Structures .......................... 97
4.9.3 Access Covers, Frames, and Grates .................................................................. 99
4.10 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS ................ 104
4.10.1 Repair Mortar for Metal Products ...................................................................... 106
4.10.2 Approved List of Suppliers ................................................................................ 107
DM/SRPD Section 4 Pipes, Pipework, Manholes and Chambers Rev 00 June Page iii of iii
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4 PIPES, PIPEWORK, MANHOLES AND CHAMBERS
4.1 PIPE MATERIALS
4.1.1 Pipe Classifications and Pressure Ratings
For structural purposes pipes shall be classified into two groups: -
Group A: Rigid pipes which do not depend on lateral support from the bedding and
trench sides for structural strength. Pipe materials include:
a) Stainless steel
b) Ductile Iron
c) Reinforced Concrete (RC)
Group B: Flexible pipes which depend on lateral support from the bedding and
trench sides for structural strength and to prevent distortion. Pipe materials include:
a) GRP (Glass Reinforced Plastic)
b) uPVC (Un-plasticised Polyvinyl Chloride)
c) HDPE (High Density Polyethylene)
d) PP (Polypropylene)
4.1.2 Joint Requirements and Limitations
Unless pipes are detailed with rigid joints or are specified differently all pipelines shall
be jointed with approved mechanical, flexible joints with elastomeric joint rings. The
whole joint assembly shall be compatible with the pipe construction and with the
specified performance of the completed pipeline.
4.1.2.1 Flexible Joints
Flexible joints shall be as a separate sleeve coupling and double spigot assembly
with two sealing rings.
Elastomeric joint sealing rings shall be manufactured to BSEN-681-1:1996 from

ethylene propylene rubber (EPDM) and shall have a hardness measured in
International Rubber Hardness Degrees (IRHD) compatible with the pipe material.
Deflection: The completed joint shall be capable of accepting the following ranges of
deformation when subjected to internal pressure without losing its seal at the
specified test pressure, without direct contact between spigot and socket/coupling
and without inducing stresses or strains in the pipe material beyond the safe working
limits.
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Table 4-1: Minimum Allowable Angular Deflection for Flexible Joints

Pipe Material Pipe Diameter (mm) Angular Deflection
(Degrees)
All materials (except up to 200 3

concrete and clay pipes)
Over 200 to 500 1.75
Over 500 to 1350 1
Over 1350 0.5
Straight draw: Not less than 10 mm or the following proportions of the length of the
longest pipe/unit at any joint:
- 1% for polyethylene pipes

- 0.5% for polypropylene
- 0.3% for GRP and uPVC pipes
In case of difference between this specification and the manufacturer’s specifications

then the most stringent requirements shall prevail.
Shear: Pipe materials which are listed in structural Group A shall be loaded to 10
times DN (mm) in Newton in accordance with BS EN-512:1995. Pipe materials which
are listed in structural Group B shall be subjected to a load of 17.5 N/mm of pipe
diameter in accordance with ASTM D-4161.
If the approved standard for a pipe material does not include a shear test for the
jointing system, this test shall be carried out in accordance with test procedure of
another appropriate pipe material standard.
4.1.2.2 Flanged Joints
Flanged pipes shall incorporate an annular gasket at the Joints and these gaskets
shall be manufactured to BS 1514-1:1997 from ethylene propylene rubber (EPDM)
3.0 mm thick and shall be dimensioned to full face of the pipe flange and to suit the
flange drillings. The hardness of the rubber (IRHD) shall be to the manufacturer's
recommendations to suit the pipe material but for pipe materials in Group A shall be
in the range 66 to 75.
4.1.2.3 Dismantling Joint and Flange Adaptor
a) Dismantling Joint
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This shall be used on GRP, ductile iron and stainless steel pipes and joints between
each of the materials as shown on the drawings. This shall provide flexibility at
installation stage of flanged pipework systems.
The dismantling joint is to comprise a flange adaptor, flange spigot piece and tie bars,
in a complete package and to allow a greater adjustment length allowance at the
installation stage. Adjustability is to be provided by the combination of a flange
adaptor and flanged spigot. Up to 50 mm of longitudinal adjustment (dependent upon
diameter) is to be available due to telescopic action of the spigot within the flange
adaptor. Once the final installation position is achieved bolt up procedures for the
flange adaptor and tie bars are to be applied.
The dismantling joint shall be fitted in accordance with the manufacturer’s

recommendation. Flanges shall be PN 10/16 rating.
(i) Steel for spigot and flange adaptor body in accordance with BS EN
10025:2004 Grade Fe 430 A
(ii) Rubber gasket to BSEN 681 – 1:1996 or to suit service.
(iii) Stainless steel for studs to BS 970: Part 1:1983 Grade 070 M20.
(iv) Stainless steel for tie bolts to BS 1506:1990: Table 1: Type 630-860
b) Flange Adaptor
This shall be used on GRP, ductile iron and stainless steel pipes to enable plain-
ended pipe to be connected either to flanged pipe or flanged valves or other fittings.
Flange adaptor to be provided with flat mating faces, suitable for bolting to raise
faces.
Flange Adaptors shall be of the restrained type where specified.
Flange adaptors to suit pressure rating of the flange PN16 or PN10 as specified.
The overall pressure rating of the assembled adaptor to be equal to that of the lower
rated component either pipe or flange.
Form of adaptor (straight sleeve, expanded sleeve or tapped flange) to be chosen as

per site requirements.
Material:
(i) For < 150 mm dia. body – ductile iron, end flange-malleable cast iron
(ii) For > 150 mm dia. body – ductile iron
(iii) For < 300mm dia. end flange – rolled steel.
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(iv) For > 300 mm dia. body – fabricated rolled steel, end flange – rolled steel.
4.1.2.4 Bolted Couplings
Bolted couplings shall be flexible couplings and shall be capable of withstanding the
pressure tests of the pipeline in which they are installed. They shall also be capable
of accommodating the deflections and movements specified for flange adaptors.
4.1.2.5 Nuts and Bolts
All bolts, nuts and washers shall be of stainless steel grade 316 S16 to BS 970: Part
1 or DIN 17440:4571 and shall remain unpainted. PTFE washers shall be fitted
beneath stainless steel washers for both bolt head and nut.
4.1.2.6 Shipping and Handling
All elastomeric joint sealing rings and gaskets for flanged pipes shall be supplied and
transported in light proof packaging so as to prevent damage due to ultra violet
radiation. The Contractor shall provide suitable storage facilities to prevent ultra violet
exposure until use.
4.2 RIGID PIPES
4.2.1 Reinforced Concrete Pipes
4.2.1.1 General
This section of the specification gives the requirements for Reinforced Concrete (RC)
pipeline materials and the installation and testing thereof in diameters 600mm and
above for use in gravity/low pressure systems.
4.2.1.2 Applicable Standards and Codes
RC pipes, fittings and accessories shall comply with the latest issue of the following
standards and other relevant standards noted elsewhere in this specification:
Standard Description
ASTM C76 Standard specification for reinforced concrete culvert, storm

drain and sewer pipe.
ASTM C361 Standard specification for reinforced concrete low head pressure
pipe.
ASTM D412 Standard test method for vulcanised rubber and thermoplastic
rubbers and thermoplastic elastomers- tension.
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BS 5911-1 Concrete pipes and ancillary concrete products. Specification for

unreinforced concrete pipes (including jacking pipes) with flexible
joints
BS EN 681 Elastomeric seals. Material requirements for pipe joint seals

used in water and drainage applications. Vulcanised rubber.
BS EN 1916 Concrete pipes and fittings, unreinforced, steel fibre and

reinforced
ISO 9000 Quality management systems.
4.2.1.3 Pipes and fittings
Reinforced concrete pipes and fittings with PVC internal lining shall be manufactured
to ASTM C76 class IV. Concrete for pipes and fittings shall be to the requirements of
Section 3 of the specification and shall be made using sulphate resisting cement type
V.
The entire interior surfaces of pipes and fittings shall be lined with a PVC or HDPE
lining to the product requirements as specified in the following text in this Section
of the specification.
a) Joints for reinforced concrete pipes
(i) All buried joints shall be spigot and socket type with EPDM rubber sealing
rings in accordance with ASTM C361 or BS EN 681. The sealing rings shall
be supplied by the pipe manufacturer.
(ii) The EPDM rubber sealing ring shall be of acceptable composition and must
be contained in a groove on the spigot end of each pipe to ensure proper
positioning and confinement in the annular space.
(iii) The sealing rings shall be extruded or moulded and cured in such a manner
that they will be dense, homogeneous and free from porosity, blisters,
pitting and other imperfections. The rings must be extruded or moulded with
smooth surfaces to the specified size within a tolerance of ±6 percent on
any dimension, measured at any cross-section. Joints in the ring shall be
vulcanised and not glued.
(iv) Joints shall be capable of withstanding a draw of 13mm over and above the
initial jointing allowance and remain watertight. The initial jointing allowance
is the gap between the spigot and the shoulder of the socket measured
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parallel to the centre line of the pipeline and must not be less than 6mm or
greater than 13mm or as recommended by the pipe manufacturer.
(v) For pipes up to and including 600mm nominal internal diameter joints shall
be capable of withstanding a deflection of not less than one and a half
degrees in any direction and remaining watertight. For pipes over 600mm
nominal internal diameter joints shall be capable of withstanding a deflection
of half degree in any direction and remaining watertight.
(vi) The pipe joints shall be capable of withstanding an external pressure

equivalent to 15m head of water without leakage in both the straight and
deflected positions.
(vii) Ensure that all pipes including cut lengths and all fittings before despatch
from the pipe manufacturer's works are indelibly marked as follows.
- The manufacturer's name, initials, or identification mark.

- The nominal internal diameter in mm.
- The length in m.
- Mark the classification i.e. pressure rating.
- The date of manufacture and batch number.
- A stamp to show that they meet the required inspection requirements and
hydraulic tests at the point of manufacturer.
- Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture delivery and testing of
that pipe.
- The angle of bends or branches.
- The manufacturing standard.
- The project or contract number.
b) Fabrication and fabrication tolerances
(i) Reinforced concrete pipes shall have a minimum nominal length of 2.5m
and a maximum length of 6m unless otherwise specified or for special
purposes such as curves or closures.
(ii) Use steel made forms with butt joints throughout when casting pipes.
- The surfaces of the forms adjacent to the pipe walls shall be smooth and
true.
- Forms shall be sufficiently tight with suitable gaskets provided at all form
joints to prevent leakage of mortar.
- The forms shall be braced and sufficiently stiff to withstand without
detrimental deformation all operations incidental to the placement and
compaction of concrete within the form.
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- The forms and end rings shall be constructed such that the pipe when
manufactured has circular and cylindrical inner surfaces and they can be
stripped from the pipe without damage to the pipe or its surfaces.
- Clean and oil the forms at the start of each continuous production.
Discard defective forms and end rings or adequately repair to the
(iii) Accurately place reinforcement steel in the concrete wall. The minimum
concrete cover over reinforcement shall be 25mm. Permissible variations
shall be within the tolerances specified in ASTM C76 or BS 5911.
- Tie the reinforcement steel in the pipe barrel to the reinforcement steel in
the pipe joint. Fabricate the reinforcement as a rigid cage of bars or wire
fabric. Fabricate transverse reinforcement either as complete hoops,
welded or lapped, or as a continuous helix. When the transverse
reinforcement is formed as a cylindrical helix, finish off both ends of the
cage as a complete hoop.
- Use lapped or butt welded type splices.
(iv) Butt weld splice must develop the full strength of the bar. Submit for testing,
samples of welds proposed for use when required by the Engineer.
(v) Lap splice must extend 30 diameters when bars are being used for
reinforcement and 40 diameters when wire is being used.
- Use suitable devices to hold the cage of reinforcement in its circular

shape, and to maintain the cage in place within the forms during the
placing and consolidating of the concrete.
- Use sufficient longitudinal reinforcement to provide a rigid cage of
reinforcement. Providing enough longitudinal steel to provide a cage
sufficient to retain its shape and position in the forms during the
manufacturing process.
c) Internal Lining
(i) Line internally with a PVC or HDPE lining covering the entire interior of the
pipe.
(ii) Cast PVC or HDPE lining into the pipe at the time of manufacture of the
concrete pipe. Line the pipes entirely unless otherwise noted.
(iii) Cast sheets of PVC or HDPE lining as large as practicable to adequately fit
the intended use.
- Form large sheets by lapping basic size sheets a minimum of

13mm and fusing the sheets together in such manner as to produce a
continuous welded joint. Do not allow tears, cracks, or separation in the
laps.
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- Cast joint strips of 100mm, ±1 mm in width x 2mm minimum

thickness and bevel each edge prior to application.
- Cast welding strips of 25mm, ±2mm in width x 3mm minimum to 4mm
maximum thickness. Use bevelled edges for all welding and outside
corner strips at time of manufacture.
- Maintain all lining sheets, including locking extensions or studs, all joints
corner, and welding strips free of cracks, cleavages, or defects adversely
affecting the protective characteristics of the material. The Engineer may
authorise the repair of such defects by approved methods.
- Apply and secure lining to the forms. Inspect and approve the lining
application prior to the placement of reinforcing steel.
- Position lining so that the locking extensions are parallel with the axis of
the pipe.
(iv) For pipes up to and including 600 mm diameter form the lining around the
spigot and socket to extend to the outside of the joint ring. Hold the lining
accurately in position to provide finished surfaces to match the dimensions
of an equivalent unlined pipe with the gasket held in a containing groove on
the spigot face of the pipe.
(v) For pipes of 750mm diameter and larger set the lining flush with the inner
edge of the socket or spigot end of the pipe section. Extend the lining to
approximately 60mm beyond the opposite end for jointing after pipe laying.
d) Installation of PVC and HDPE lining
(i) All work for and in connection with the installation of the lining including any
accessories and welding of joints shall be carried out in strict conformity
with the manufacturer’s recommendations.
(ii) On completion the lining shall be continuous and free of holes in the lining
itself and in the joints.
(iii) The lining shall be in sheets made or cut to fit the forms to which it is to be
closely fitted and properly secured, using a minimum number of separate
pieces. Care shall be taken not to puncture the lining in any way.
(iv) Joints between adjacent sheets shall not be more than 3mm wide and shall
be sealed on the concrete side to prevent loss of grout during concreting.
(v) Concrete poured against the lining shall be compacted by suitable methods
in a careful manner so as not to damage the lining and produce a dense,
homogenous concrete securely anchoring the ribs or anchors into the
concrete. The Engineer shall reject any work if he considers that any part of
that work contains defective concrete and the work shall be removed and
reinstated at no cost.
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(vi) After pouring, the concrete shall be left to cure for a minimum of 48 hours
prior to striking the formwork. When removing formwork care shall be taken
to protect the lining from damage.
- Sharp instruments or tools shall not be used to pry formwork from the
lining.
- Any formwork materials that remain in the lining shall be removed and the
resulting holes clearly marked.
- Formwork tie holes shall be marked before ties are broken off and all
areas of abrasion or damage shall be marked.
(vii) All abraded areas in the lining shall be patched. Any one patched area shall
not exceed 0.25m2 or as directed by the Engineer.
- Patch shall be made of the same material as the parent lining.

- All surfaces shall be prepared and all patching work shall be carried out
in accordance with the manufacturer’s recommendations.
(viii) Unless otherwise shown on the drawings the lining shall be returned at least
100mm onto built in items such as manhole frames, gate guides and pipes
or to where the type of lining is changed or new work is built against existing
unlined concrete. At each return the lining shall be sealed to the adjacent
material with an approved adhesive system or if this is not acceptable an
alternative proposal shall be submitted to the Engineer for approval.
(ix) The lining at joints shall be free of all foreign matter and shall be clean and
dry before the joints are welded.
(x) All jointing materials shall be similar to that of the parent lining for
thickness, corrosion resistance and impermeability unless otherwise
(xi) Welded joints shall show no cracks or separations.
(xii) Welding strips which extend beyond the edge of the lining shall be tested as
follows:
- Welding strips shall extend 50mm beyond the edge of the lining to
provide a tab to which a 5kg pull will be applied.
- Force shall be applied normal to the face of the structure by means of a
spring balance.
- Lining adjacent to the welding strip shall be held against the
concrete during application of the force.
- The 5kg force shall be maintained if a weld failure develops until no
further separation occurs.
- Defective welds shall be retested after repairs have been made and
following successful testing the tabs shall be neatly trimmed away.
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(xiii) Hot joint compounds such as coal tar shall not come into contact with the
lining.
e) Field Jointing of Internal Lining
Field jointing of the internal lining shall be carried out as follows:
- Do not make field joint to the lining until the lined pipe has been backfilled
and pipe tests have been completed. Where groundwater is encountered,
do not make any field joint until pumping of the groundwater has been
discontinued and no visible leakage is evident at the joint. Ensure that
the lining at joints is free of foreign materials and is clean and dry before
joints are made.
- Hot joint compound shall not be brought in contact with the lining.
- Do not apply coating of any kind over any joint, corner, or welding strip,
except where non-skid coating is applied to lining surfaces.
- Do not apply adhesive to the surfaces of pipe joints, or the lining or the
joint strips.
- Ensure that the surface is clean to permit visual inspection and spark
testing. Physically test all welds with a nondestructive probing method.
The Engineer may request to test installed lining using a spark type
detector set at 20,000 volts. Properly repair and retest all areas of lining
failing to meet the field test.
- Use a spark detector approved by the Engineer when spark testing the
liner.
- Test each transverse welding strip, which extends to a lower edge of the
lining. Extend the welding strips below the lining providing a tab. Apply a
5kg pull normal to the face of the pipe by means of a spring balance.
Ensure that the lining adjoining the welding strip is held against the
concrete during application of the force. Maintain the 5kg pull if the weld
failure develops, until no further separation occurs. Retest defective
welds after repairs have been made. Trim neatly tabs after the welding
strip has passed inspection. Provide all test equipment required in the
manner recommended by the manufacturer and as described above.
The personnel provided to perform the testing shall be qualified.
f) External Epoxy Coating
(i) Coat exterior of pipe with an approved solvent free 2 component epoxy
system. All blowholes and surface defects must be filled with a two
component solvent free epoxy filler prior to top coating.
(ii) Pipe manufacturing shall be by vertically cast method or other

manufacturer's method as approved by the Engineer prior to pipe
fabrication.
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g) Application of Epoxy Coating
(i) Please refer to Section 7.2.2.1 (e) for the Application of Epoxy Coating.
h) Concreting
(i) Mix, transport, place, and test concrete in accordance with Section 3 of the
specification. Prevent separation of the concrete materials and the
displacement of reinforcement steel in the forms. Use external mechanical
vibrators in an approved manner to vibrate the concrete when placing in the
forms to avoid damage to the lining and produce a dense, homogeneous
concrete securely anchoring the locking extensions into the concrete. Use
the external vibrators particularly along the lower terminal edge of the
plastic lining.
(ii) If approved, use stiffeners along the locking extensions of the lining.
Withdraw the stiffeners completely during the placement of concrete in the
forms. Revibrate the concrete to consolidate the concrete in the void spaces
caused by the withdrawal of the stiffener.
(iii) Protect the lining from damage when removing forms. Do not use sharp
instruments to pry forms from the lining surfaces. When forms are
removed, pull out any nails that remain in the lining without tearing the
lining. Clearly mark the resulting holes. Mark form tie holes before ties are
snapped or broken off. Mark areas of serious abrasion of the lining.
Abraded areas shall be repaired in accordance with the requirements of
Section 3 of the specification.
i) Concrete Curing
(i) Concrete pipes and fittings. Provide adequate plant, piping, enclosures,
and other facilities for curing the pipe. Control the temperature and humidity
of the enclosures to keep the pipe surfaces moist at all times and maintain
the temperature continuously between limits described below. Apply one of
the methods of curing described below to the pipe, or any other method or
combination of methods that will give satisfactory results as approved by the
Engineer. Allow the pipe to be cured for a minimum 14 days so that the
concrete will develop the specified compressive strength at 28 days or less.
- Accelerated Curing. Place the pipe in a curing facility or otherwise

covered by a suitable enclosure that will allow proper circulation of moist
air or steam. Maintain the ambient temperature within the enclosure
between 15°C and 38°C by the introduction of heat until the initial set of
the concrete occurs. After a delay period of one to four hours, increase
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the temperature at a rate not to exceed 2°C/hour, and thereafter,

maintain the temperature between 32°C and 66°C.
- Water Curing. Apply water curing as soon as the concrete has set
sufficiently to prevent damage to the exposed concrete surfaces.
Maintain all exposed concrete surfaces moist by intermittent or
continuous water spraying for a minimum 14 days. Maintain the total
cure, consisting of the water cure and the ambient air cure sufficient to
produce the concrete strengths specified.
- Curing membranes shall not be used.
4.2.1.4 Quality Control Tests
The crushing strength of concrete pipes shall not be less than the values specified in
ASTM C76 or BS 5911 for the respective classes of pipes shown on the drawings.
Linings shall be tested for pin holes, using an approved electrical spark tester set at a
minimum of 20,000 volts. Holes in sheets shall be satisfactorily repaired and re-
tested prior to shipment to the pipe manufacturer.
The concrete pipes shall be substantially free from fracture, large or deep cracks and
surface roughness. The planes of the ends of the pipe shall be perpendicular to their
longitudinal axis.
Carry out inspection procedures and tests in accordance with BS 5911 or ASTM
C361.
Concrete pipes shall be rejected for any of the following reasons.
- Failure to pass the hydrostatic test.

- Transverse reinforcing steel found to be in excess of 6 mm out of
specified position after the pipe is moulded.
- Unauthorised application of any wash coat of cement or grout.
- Any crack showing two visible lines of separation for a continuous length
of 600mm or more, or an interrupted length of 900mm or more anywhere
in evidence, both inside and outside except where such cracks occur
during the external loading test.
- Exposure of any wires, and positioning spacers or chairs used to hold the
reinforcement cage in position, or steel reinforcement in any surface of
the pipe.
- Any shattering or flaking of concrete at cracks.
- Honeycombing on the exterior surfaces of the pipe exceeding 6 mm in
depth unless pointed with mortar or other approved material.
- Any crack having a width of 0.25mm or more throughout a continuous
length of 300mm or more.
- Any crack extending through the wall of the pipe and having a length in
excess of the wall thickness.
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- When required by the Engineer, fill with cement grout any crack that is
0.25 mm wide or wider and is not a cause for rejection. Use neat cement
grout composed of cement mixed with water to fluid consistency for
filling the cracks.
- A deficiency in the specified wall thickness of the pipe larger than
permissible. The deficiencies in wall thickness permitted herein do not
apply to gasket contact surfaces. Submit the tolerances of such contact
surfaces for approval by the Engineer.
- A variation from the specified internal diameter in excess of 1% of interior
surfaces which have been reworked after placing of the concrete. The
variation in internal diameter permitted herein does not apply to gasket
contact surface. Submit the tolerances of such contact surfaces for
approval by the Engineer.
4.2.2 Ductile Iron Pipes
4.2.2.1 General
This specification covers the general requirements for Ductile Iron (D.I.) pipes, fittings
and accessories including material specifications, internal lining, external coating,
joints, polyethylene sleeves etc. This specification sets the minimum acceptable
requirements. In case of difference between this specification and the specified
international standards then the most stringent requirements shall prevail.
DI pipes, fittings and accessories including coating and polyethylene sleeve shall
comply with the latest issue of the following standards and other relevant standards
noted elsewhere in this specification:
ISO 527 Plastics-Determination of tensile properties.
ISO 887 Plain washers for metric bolts screws and nuts.
ISO 974 Plastics-Determination of the brittleness temperature by impact.
ISO 2230 Vulcanised rubber-guide to storage.
ISO 2531/BS EN Ductile iron pipes, fittings, accessories and their joints for water
545 or gas applications.
BS EN Ductile iron pipes, fittings, accessories and their joints for

598:2007+A1:2009 sewage applications.
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ISO 3506 Corrosion - resistant stainless steel fasteners.
ISO 4014 Hexagon head bolts – Product grades A and B.
ISO 4032 Hexagon nuts, style 1 – Product grades A and B.
ISO 4179 Ductile iron pipes for pressure and non-pressure pipeline –
Centrifugal cement mortar lining – General requirements.
ISO 4587 Adhesives – Determination of tensile lap-shear strength of rigid-

to-rigid bonded assemblies.
ISO 4633 Rubber seals – Joint rings for water supply, drainage and
sewerage pipeline – Specification for materials.
ISO 6600 Ductile iron pipes, centrifugal cement mortar lining –

composition controls of freshly applied mortar.
ISO 6506-1 Metallic materials – Hardness testing – Brinell test – Part 1: Test
method.
ISO 6708 Pipe works components – Definition and selection of DN
ISO 7005-2 Metallic flanges – Part 2: Cast iron flanges
ISO 7268 Pipe components – Definition of nominal pressure.
ISO 7483 Dimensions of gaskets for use with flanges to ISO 7005.
ISO 8179-1 Ductile iron pipes – External coating – Part 1: Metallic zinc with
finishing layer.
ISO 8179-2 Ductile iron pipes – External coating – Part 2: Zinc rich paint
with finishing layer.
ISO 8180 Ductile iron pipes – Polyethylene sleeving.
ISO 8501-1 Preparation of Steel Substrates.
ISO 10804 Restrained joint systems for ductile iron pipelines – Part 1:
Design rules and type testing.
EN 1092-2 Circular flanges for pipes, valves, fittings and accessories, PN
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designated – Part 2: Cast iron flanges.
BS 146 Specification for Portland blast furnace cements. Cement.

Composition, specifications and conformity criteria for low early
BS EN 197-4:2004 strength blast furnace cements
BS 3416:1991 Specification for bitumen - based coatings.
BS 7079:2009 Specification for surface finish of blast-cleaned steel for

painting. General introduction to standards for preparation of
steel substrates before application of paints and related
products
BSEN 681:2000 Elastomeric Seals
BSEN 1563:2011 Founding Spheroidal graphite Cast iron
BSEN 10025:2004 Hot rolled products of non-alloy Structural Steels
DIN 30671 Thermoset plastics coatings for buried steel pipes
DIN 30672 Coatings of corrosion protection tapes and heat Shrinkable

material.
DIN 4226 Aggregates for concrete.
4.2.2.3 D.I. Material Characteristics
Ductile iron pipes, fittings and accessories shall meet the following requirements:
Material Characteristics Pipes Pipes not Centrifugally

Centrifugally Cast, Fittings and
Cast Accessories
Minimum tensile strength (MPa 420 420
Minimum yield strength (MPa) 300 300
Minimum elongation after fracture

(%)
DN 40 to DN 1000
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DN 1100 to DN 2600 10 5
7 5
Maximum Brinell hardness, (HB) 230 250
4.2.2.4 D.I. Pipes
All D.I. pipes supplied shall be truly circular, of uniform thickness and supplied in the
longest practicable length so as to minimise the number of joints.
Unless otherwise specified in the drawings or in the Particular Specification all pipes,
joints and fittings shall be suitable for the maximum pressure under which they will
operate (normal service pressure + surge pressure or the maximum site test pressure
whichever is greater) and shall sustain without damage or substantial leakage the
specified site hydrostatic test pressure.
The nominal iron wall thickness of pipes and fittings shall be in accordance with ISO
2531/EN 545 and calculated as a function of the nominal size, DN, by the following
formula, with a minimum of 6 mm for pipes and 7 mm for fittings:
e = K (0.5 + 0.001 DN)
Where:
e is the nominal wall thickness, in millimetres;
DN is the nominal diameter in millimetres;
K is a coefficient used for thickness class designation. It is selected form a series of

whole numbers: .8, 9, 10, 11, 12.
Unless otherwise specified in the Particular Specification all pipes used shall be class
K9 (K = 9).
All pipes shall be subject to Third Party Inspection during manufacturing.
The name of manufacturer, standard, nominal diameter (DN), type of socket, class
and date of manufacturing (month + year) shall be cast inside the socket. The
contract number shall be painted on the pipe.
Pipes shall be hydrostatically pressure tested for leak tightness and certified at the
manufacturer's plant prior to coating or lining for at least 10 seconds at the following
minimum internal test pressures:
(i) 50 bar for pipes DN 300 and smaller
(ii) 40 bar for pipes DN 350 through DN 600

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(iii) 32 bar for pipes DN 700 through DN 1000
(iv) 25 bar for pipes DN 1100 through DN 2000
(v) 18 bar for pipes DN 2200 through DN 2600
Unless otherwise all D.I. pipes supplied shall be of socket and spigot end.
It shall be the Contractor’s sole responsibility to order a percentage (minimum 2%) of

the total length per diameter of pipes as calibrated pipes, for the purpose of cutting
etc. These pipes shall be clearly marked and shall not be used for normal pipe laying
unless it becomes clear that they are not required for the purpose of cutting any
more. The percentage to be ordered shall give due regard to any changes in route
which may occur during the course of the work for whatever reason.
4.2.2.5 D.I. Fittings
All D.I. fittings supplied shall be truly circular of uniform thickness according to ISO
2531 and BS EN 545. For gravity sewer application it shall be made to BSEN 598.
All fittings shall be subject to Third Party Inspection during manufacturing.
Dimensions and nominal iron wall thickness of fittings shall be in accordance with the
ISO 2531/BS EN 545.
For fittings the thickness e is the nominal thickness corresponding to the main part of
the body. The actual thickness at any particular point shall be increased where
necessary to meet localised high stresses depending on the shape of the casting
(e.g. at internal radius of bends, at the branch body junction of tees, etc).
Name of manufacturer, standard, nominal diameter (DN), type of socket, class and
date of manufacturing (month + year) shall be cast inside the socket or on the barrel
of the fittings. The contract number shall be painted on the fitting.
Fittings shall be pressure tested for leak tightness and certified at the manufacturer's
plant prior to coating or lining. The test pressure shall be carried out for at least 10
seconds either with air at a pressure of 1 bar or with water at the pressure indicated
below:
- 25 bar for fittings DN 300 and smaller (for fittings with PN 10 flanges test
pressure shall be 16 bar)
- 16 bar for fittings DN 350 through DN 600
- 10 bar for fittings DN 700 and larger
4.2.3 Joints
4.2.3.1 Flexible Joints
Flexible joints shall be of spigot and socket "push-on" type suitable for angular
deflection any direction and capable of axial movement to compensate for thermal
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expansion or contraction and ground movement. All flexible joints for D.I. pipes and
fittings shall be designed in compliance with ISO 2531.
Joints may permit angular deflection to accommodate ground movements and to

negotiate large radius bends. The maximum angle deflection shall be as per the limits
given below and manufacturer's recommendations.
Nominal Diameter Maximum Deflection
80/150 5º
200/300 4º
400/500 3º
600/700 2º
800/1000 1½º
Rubber ring joints shall be of a type that will not deteriorate under local conditions
either during storage or during operation. The rubber gasket shall be of EPDM
elastomar or equivalent in accordance with ISO 4633 suitable for drinking water
supply.
Where mechanical type joints are specified, proposed and approved they shall be
supplied complete with approved gaskets, glands, hot dipped galvanized or cadmium
plated bolts, nuts and all other necessary accessories. Where retainer glands are
specified they shall be supplied with bolts and/or other necessary accessories.
a) Flanged Joints
Flange ended pipes and fittings shall only be used when connecting to valves or other
special fittings as approved by the Engineer
The flanges shall be raised faced and integrally cast or welded on. Screwed on
flanges or glued on flanges are not acceptable. Rotatable flanges may be used for
pipes and fittings up to DN 600.
The dimensions and drilling of the flanges shall be to ISO 7005-2 or BS EN 1092-2.
The pressure rating of the flanges shall be as given in the Data Sheet or Particular
Specification. Flanged joints shall be supplied complete with gaskets, hot dipped
galvanized or cadmium plated nuts, bolts and washers.
Rubber gaskets shall be EPDM elastomer or equivalent approved in accordance with

ISO 4633 suitable for drinking water supply. The gasket shall be minimum 3 mm thick
and shall be metal reinforced for pressure rating of 16 bar and higher. The
dimensions of the flange gaskets shall be to ISO 7483.
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The nuts, bolts, washers shall be of steel having minimum tensile strength of 800
N/mm2 hot dipped galvanised or cadmium plated. Nuts and bolts shall be suitable for
the pressure rating specified in the Particular Specification. Nuts and bolts shall be to
ISO 4014 and 4032 and washers to ISO 887.
b) Restrained Joints:
D.I. pipes and fittings with restrained coupling shall be utilised where pipelines have
to cross roads through existing ducts or in areas with restricted accessibility where
the use of concrete anchor blocks is prohibited, or as directed by the Engineer. The
CONTRACTOR shall submit with his bid full details of the type of restrained coupling
he proposes to use.
Whenever in the course of work the contractor intends to utilise restrained couplings
he shall obtain prior approval from the Engineer.
Calculation of the number of pipe lengths with restrained coupling required shall
follow the manufacturer's recommendation and shall be subject to approval by the
Engineer.
Restrained joints shall be designed to resist the axial thrust forces but maintaining
flexibility and angular deflection. Restrained joints shall be designed in accordance
with ISO 10804-1.
The joint shall be capable of withstanding the greater of the test pressure or the
service pressure + the surge pressure.
The type of restrained joint shall be subject to the approval.
The thrust resisting mechanism shall be separated from the sealing action of the
gasket and shall not be in contact with potable water in the pipeline.
4.2.3.2 Internal Lining to D.I. Pipes and Fittings
a) General
Unless otherwise specified in the Data Sheet or Particular Specification all D.I. pipes
and fittings shall be internally lined with sulphate resisting blast furnace slag cement
mortar in accordance with the following specification and shall be certified as suitable
for use with potable water by an internationally accepted organisation such as UK's
WRC (Water Research Centre).
The cement mortar lining for D.I. pipes and fittings shall be in accordance with ISO
4179.
The internal surface of the socket bell of all zinc/bitumen coated D.I. pipes and fittings
shall be painted with a non-toxic solvent-free two part epoxy coating applied to a
minimum dry film thickness (DFT) of 100 microns or equivalent corrosion protection
system to be approved by the Engineer. The thickness of the coating may be reduced
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only at the gasket locating ring to conform to manufacturer's recommended

tolerances.
b) Surface Preparation
Prior to cement lining application the inner surfaces of pipes and fittings shall be
cleaned of dirt, loose rust particles, grease, oil or any other material which could be
detrimental to good contact between the metal and the lining.
c) Cement
Cement to be used for the lining shall be with high alumina type. Alternatively
sulphate resisting blast furnace slag cement type complying with the requirement of
BS EN 197-4, obtained by grinding a mixture of 70 percent by weight of granulated
blast furnace slag, to be completed with Portland clinker and a maximum of 3.5
percent calcium sulphate.
d) Aggregates
Only clean, crushed natural mineral aggregates shall be used in accordance with the
requirement of the latest issue of the German DIN 4226 standards.
The distribution of grain sizes shall be:
(i) the amount of particles passing through a standard sieve with an aperture
size of 0.125 mm shall not be more than 10% by mass.
(ii) the amount of particles with a diameter up to 1/3 of the normal lining
thickness shall not be less than 50% by mass.
(iii) the maximum particle diameter shall not be greater than 1/2 of the normal
lining thickness. The amount of shall not exceed 5% by mass.
e) Additives
The use of cement additives is allowed, subject to the Engineer approval, provided
that they do not adversely affect the quality of the lining, and that of the transported
water. Additives shall not contain any elements which impart potable change in
colour, taste or odour or present a health hazard. Certificates of non-toxicity prepared
and signed by recognised, independent laboratories, shall be made available to the
Engineer.
f) Water
Water used for the mortar shall be of potable quality and shall not contain elements
which influence the hardening of the lining or the quality of the water flowing through
the finished pipes.
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g) Mortar
Mortar for the lining shall be composed of cement, sand and water. The mortar shall
be well mixed and of proper consistency to produce a dense homogenous lining that
will adhere firmly to the DI pipe or fitting surface.
Weight of cement and sand shall be accurate to + 3%. The water/cement ratio shall
not be more than 0.40. The minimum compressive strength of the mortar shall not be
lower than 50 W/mm2. The cement mortar shall not contain less than one part of
cement to 3.5 parts of aggregates by weight as per ISO 4179.
h) Method of Lining
Lining application and quality for finished surface shall be in accordance with ISO
4179. All pipes shall be lined by a centrifugal process. The consistency of the mortar
and the time and speed of spinning the pipe shall be so adjusted to minimise the
segregation of aggregates from the cement.
Fittings shall be lined by a spray method.
In all cases a smooth finish of the lining shall be obtained, entirely free from cavities
or visible air bubbles.
The lining shall be uniform and extend from the spigot end up to the beginning of the
socket cavity on the other side. The socket shall be left free of mortar.
No seal coat shall be applied to the cement lining unless otherwise instructed and
i) Curing
After application to pipes and fittings, the cement mortar shall be cured under
controlled conditions (minimum 48 hours, at more than 15°C and 75% relative
humidity).
Alternative methods of curing are subject to approval of the Engineer.
j) Repair of Defective and Damaged Areas of Lining
Defective or damaged areas of lining may, at the Engineer's discretion, be patched by

cutting out the defective or damaged lining to the metal so that the edges of the lining
not removed are perpendicular or slightly undercut. The cut out area shall then be
trawled with fresh mortar in the following composition:
- One part cement (by weight).

- One part sand.
- Water of potable quality, with non-toxic additive dispension of synthetic
materials subject to the Engineer's approval.
Thickness of lining
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Thickness of the cement mortar lining shall be as follows:
DN (mm) Lining Thickness (mm)
Normal Minimum Mean Minimum Value at

Value One Point
80 - 600 5.0 4.5 3.5
700 – 1200 6.0 5.5 4.5
1400 - 2000 9.0 8.0 7.0
2200 – 2600 12.0 10.0 7.0
N.B.: The above figures differ from ISO 4179.
k) Mechanical Properties:
The cement mortar lining shall have adequate resistance against compression and
bending action. Representative test pieces shall have the following minimum
properties after 28 days.
Water Cement Ratio of Compression Strength Bending Strength

Test piece N/mm2
N/mm2
0.45 40 5.0
0.40 45 5.5
0.35 50 6.0
l) Quality of Lining, Tests and Records
The lining shall be free from voids, ridges or corrugations that reduce the thickness of
the lining to less than the specified minimum thickness.
Lining shall have a smooth surface. There shall be no cavities or entrapped air,
similarly there shall be no evidence of differences between portions of lining.
Linings shall be placed so that there is no gap between the pipe barrel and the lining.
In some circumstances thicker linings may be required and these shall be stated in
the appropriate specification.
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If a lining is damaged it may be repaired on site using a one to one cement/sand

mortar mix (proportions by weight). Repairs shall cure for at least 72 hours.
Mortar lining may show evidence of cracking, crazing or debonding after delivery to
site. The following conditions may be accepted.
(i) Cracking - provided that the longitudinal length of a crack is not more than
600 mm, width of crack not more than 0.8 mm, circumferential cracks are
not more than 50% of the circumference.
(ii) Crazing - provided that individual cracks are less than the limits given in a),
crazing over an area not exceeding 25% of the lining area may be
acceptable.
(iii) Debonding - area of disbondment and radial displacement shall not exceed
the values given in EN 545.
The following tests and measurements shall be conducted, recorded and filed with
frequencies according to ISO 4179 and ISO 6600.
- Determination of lining thickness.

- Cross sectional sample.
- Water cement ratio.
- Aggregates.
- Bonding and compression strength.
m) Seal Coat internal over cement mortar lining
In order to minimise the leaching of cement by soft water a bituminous paint seal coat
shall be applied over cement mortar lining to a minimum thickness of 500 micron.
4.2.3.3 External Coating to D.I. Pipes and Fittings
a) The external coating to DI pipes shall be in accordance with BS EN 598 and BS

EN 545.
Pipes shall be supplied with the external coating type required to provide
adequate corrosion protection as follows.
(i) Type 1 = Zinc coating with minimum mass 200g/m2 with 100 micron
thickness bitumen or epoxy finishing layer
(ii) Type 2 = Type 1 coating with Polyethylene Sleeving
(iii) Type 3 = Alloy of zinc and aluminium coating with minimum mass 400
g/m2 with bitumen or epoxy finishing layer
(iv) Type 4 = Extruded polyethylene coating in accordance with to EN 14628
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Or Polyurethane coating with minimum thickness of 800 microns thick to EN

15189
Or Type 1 coating tape wrap with 55% overlap
Protection Type 1 Type 2 Type 3 Type 4

system
Resistivity above Y Y Y Y
2500 ohm.cm for
wet soils or
Resistivity above
1500 ohm.cm for
dry soils
Resistivity between N Y Y Y
1500 ohm.cm and
2500 ohm.cm for
wet soils
Resistivity between
750 ohm.cm and
1500 ohm.cm for
dry soils
Resistivity between N N Y Y
500 ohm.cm and
750 ohm.cm for dry
or wet soils
Resistivity below N N N Y
500 ohm.cm
Made up ground N N N Y
with material likely
to damage pipe
Contaminated land N N N Y
pH less than 5 N N N Y
Y = Suitable N = Unsuitable
For pipes in made ground with material likely to cause damage, an imported
embedment should be used for the pipeline.
Evidence of the long term performance of the above mentioned solution (e.g.
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tests and references) should be provided by the manufacturer.
As far as possible, PE sleevings and tape wraps should be factory applied.
All coatings are subject to the prior approval of the Engineer.
Where non-toxic coating is specified, certification shall be required from an

internationally recognised independent laboratory certifying that the material is safe
for potable water service. At the discretion of the Engineer all special coatings on
pipes and fittings shall be subjected to thickness checks and for holiday testing on
site in order to satisfy the Engineer that the coatings are within the specified limits
and that no pin holes are present.
The thickness of the coatings may be reduced only at the gasket locating ring to
conform to manufacturer's recommended fitting tolerance.
b) Vendor Documentation
The Contractor shall furnish the following vendor data as a minimum, with his bid:
- Catalogues/Brochures of the proposed manufacturer's.

- Dimensional details of pipes and fittings.
- Detailed material specifications.
- Manufacturer's drawings, showing fittings dimensions.
- Complete details of testing facilities available at manufacturer's works.
- Local (UAE) agent name and address.
- Outline of Quality Assurance Procedures in use.
Bids not accompanied by any of above-mentioned information/data shall be

considered incomplete, and liable to be rejected.
4.2.4 Other Ferrous and Non-ferrous Pipes & Fittings
Stainless steel pipe shall be as specified in the specification for mechanical work.
4.3 THERMOPLASTIC PIPES
4.3.1 Unplasticised Polyvinyl Chloride Pipes and Fittings (uPVC)
uPVC non-pressure pipes and fittings for underground drainage & sewerage
applications shall be manufactured and tested to BS EN 1401 – 1 : 2009 and for soil
and waste discharge pipe & fitting within the building structure shall be manufactured
and tested to BSEN 1329-1: 2000.
UPVC pressure pipes and fittings shall be PN 16 for pipes up to and including
160mmø and PN 12.5 bar rated pressure class for pipes above 160mmø suited to
service temperature up to 45°C manufactured and tested to BS EN ISO 1452 –2:
2009. The Pipe material of the Pressure Pipe shall have a minimum required strength
(MRS) of 25 Mpa as defined in BSEN 1452 – 1:2009. The density shall be between
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1350 kg/m3 ≤ P ≤ 1460 kg/m3 when measured in accordance with ISO 1183. UPVC
(P) pipes shall be tested after installation in accordance with the Pipe manufacturer’s
recommendation. The site test pressure shall be as specified in CL 6.2.3.
UPVC pipes shall be installed in accordance with the manufacturer’s guidelines. Both
gravity and pressure pipes shall be BSI kite marked and copies of kitemark license
including its schedule of items covered shall be provided to the engineer to satisfy the
third party quality assurances. The choice of wide or narrow trench condition, Pipe
surround & bedding material etc. shall be decided based on the native soil modulus
below the invert and spring line level of the pipe and the stiffness of the proposed
pipe. UPVC fittings shall be injection moulded factory made and kite mark certified
and shall conform to BS EN 1401-1 (for gravity fittings (G) and BSEN 1452: P2 & Part
3 for pressure fittings). Fabricated fitting may be permitted only for non-standard
fittings not shown in Pipe manufactures Technical Catalogue. Fabricated fitting shall
be PVC welded at joints and laminate with 3 mm thick GRP lamination external for
gravity fittings & 6mm for pressure fittings and shall comply with the quality control
test specified.
uPVC pipes shall be capable of withstanding ultraviolet degradation. A rodent

inhibitor shall be incorporated in the material of the pipe. Pipes shall be manufactured
with integral flexible rubber ring joints made to BSEN 681-1: 1996 EPDM type ‘D’
material and kite marked.
Construction and testing of drains and sewer pipes shall be as specified in BSEN
1610: 1998.
uPVC pipes for gravity pipelines shall be SN4 stiffness class and have a standard
dimension ratio, D :t (diameter to thickness), of between 35 and 45. The ring stiffness
of the pipes is to be tested in Dubai Central Lab. in accordance with ISO 9969: 1995
and comply with the requirements. From the installation point of view, SN8 class pipe
may be used if the pipe line is installed in accordance with BS EN 752 2008 or BS
5955-8:2001 in order to achieve the intended resistance to long-term deformation.
Any pipes exhibiting cracks, notches or deep scratches or other damage will be
condemned and shall not be incorporated into the permanent work under any
circumstances.
The minimum and the maximum burial depth of pipe shall be as per pipe
manufacturer’s recommendations. Evidence of type test and the quality control test
referred in the relevant standards for the pipes and fittings are to be provided to the
Engineer to satisfy the product prequalification.
4.3.1.1 uPVC Gravity Pipes for Land Drains
Pipes for slotted land drains/slotted carrier drains shall be uPVC pipes. Prior to
perforation, the basic pipe shall be manufactured to BS EN 1401-1, kite marked, and
shall comply with the requirements of Clause 4.3.1 of this specification relating to
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uPVC pipes for non-pressure application. The slots shall be designed to give at least
the minimum infiltration rates laid down in BS 5911: Part 114. The final configuration
of the slots shall be subject to approval by the Engineer.
The slots shall be cleanly machine cut and be not less than 3 mm or greater than 4
mm in width. The slots shall be in 180° segment of the pipe barrel in one or more
longitudinal rows, the slots in each row being spaced equidistantly. Where more than
one row of perforations is provided the slots shall be staggered. No slots shall be
nearer to the ends of the barrel than the spacing between two adjacent slots. The
spacing between slots in any row may vary up to ± 20 mm.
The minimum cross-sectional area of the perforations, at the inside surface of the
pipe barrel, shall be 2700 mm2 per metre run of pipe but shall not affect the structural
integrity of the pipe. Care must be exercised to prevent impact damage when placing
stone surround and during backfilling operations over the pipes.
4.3.1.2 uPVC Duct Pipes
uPVC Duct Pipes (Socket Spigot) shall be manufactured & tested to BS 3506:1969.
The class of pipe shall be Type ‘D’ having the specified properties given in the
standard.
4.3.2 POLYETHYLENE PIPES (HDPE)
All activities relating to this section of the specification shall comply with the following
or approved equal standards.
ASTM D638 Standard test method for tensile properties of plastics.
ASTM D790 Standard test methods for flexural properties of unreinforced and
reinforced plastics and electrical insulating materials.
ASTM D1238 Standard test method for melt flow rates of thermoplastics by
extrusion plastometer.
ASTM D1505 Standard test method for density of plastics by the density-
gradient technique.
ASTM D1693 Standard test method for environmental stress-cracking of

ethylene plastics.
ASTM D2240 Standard test method for rubber property-Durometer hardness.
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ASTM F1055 Standard specification for electrofusion type polyethylene fittings

for outside diameter controlled polyethylene pipe and tubing.
BS EN 727 Plastics piping and ducting systems. Thermoplastics pipes and

fittings. Determination of Vicat softening temperature.
BS EN 728 Plastics piping and ducting systems. Polyolefin pipes and fittings.
Determination of oxidation induction time.
BS EN 744 Plastics piping and ducting systems. Thermoplastic pipes. Test

method for resistance to external blows by the round-the-clock
method.
BS EN 1053 Plastics piping systems. Thermoplastics piping systems for non-

pressure applications. Test methods for watertightness.
BS EN 1437 Plastics piping systems. Piping systems for underground drainage

and sewerage. Test method for resistance to combined
temperature cycling and external loading.
BS EN 12061 Plastic piping systems. Thermoplastics fittings. Test method for

impact resistance.
BS EN 12256 Plastic piping systems. Thermoplastic fittings. Test method for

mechanical strength or flexibility of fabricated fittings.
BS EN ISO 9967 Thermoplastics pipes. Determination of creep ratio
BS EN ISO Plastics. Determination of resistance to environmental stress

20088-3 cracking (ESC). Bent strip method.
DIN 8074 Polyethylene (PE) – Pipes PE63, PE80, PE100, PE-

HD.Dimensions
ISO 161 Thermoplastics pipes for the conveyance of fluids. Nominal

outside diameters and nominal pressures.
ISO 527 Plastics. Determination of tensile properties.
ISO 1133 Plastics. Determination of the melt mass-flow rate (MFR) and
the melt volume-flow rate (MVR) of thermoplastics
ISO 1167 Thermoplastics pipes, fittings and assemblies for the conveyance
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of fluids. Determination of resistance to internal pressure
ISO 1183-3 Plastics. Methods for determining the density of non-cellular

plastics. Gas pykonometer method
ISO 2505 Thermoplastics pipes. Longitudinal reversion
ISO 4427 Polyethylene (PE) Pipes for water supply. Specifications
ISO 6964 Polyolefin pipes and fittings. Determination of carbon black

content by clacination or pyrolysis Test method and basic
specification
ISO 9000 Quality management systems
ISO 11922 Thermoplastic pipes for the conveyance of fluids. Dimensions

and tolerances.
ISO 13479 Polyolefin pipes for conveyance of fluids – Determination of

resistance to crack propagation Test method for slow crack
growth on notched pipes
ISO 13967 Thermoplastics fittings. Determination of ring stiffness.
ISO 18553 Method for assessment of the degree of pigment or carbon black
dispersion in polyolefin pipes, fittings and compounds
WIS 4-24-01 Specification for mechanical fittings and joints for polyethylene
pipes for nominal sizes 90 to 1000.
4.3.2.2 HDPE Pipes and Fittings
Pipes and fittings shall be manufactured from polyethylene containing only those
antioxidants, UV stabilisers and pigments necessary for the manufacture of pipes
conforming to specification ISO 4427 and for its end use, including weldability when it
is possible. Minimum content of carbon black shall be 2,4%
All HDPE pipes and fittings shall be manufactured from material conforming to
polymer classification PE100 having a minimum required strength value (MRS) of
10MPa at 50 years and 20°C in accordance with ISO 4427. Design stress shall be
8MPa. Pipes shall have a standard dimension ratio (SDR, outside diameter/wall
thickness) of either 11 or 17 unless indicated otherwise by Engineer. Material shall be
procured from the manufacturer accepted to PE100+ Association
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The pipes and fittings shall be homogeneous throughout and free of visible cracks,
holes, foreign inclusions, voids and other injurious defects.
Butt fusion fittings shall be in accordance with ASTM D3261 and shall be
manufactured by injection moulding, a combination of extrusion and machining, or
fabricated from PE pipe conforming to this specification. Fabricated fittings shall be
manufactured using a Datalogger to record fusion pressure and temperature. Butt
fusion fittings shall have a pressure rating no less than that of the pipe. The fittings
shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions,
voids and other injurious defects.
Electrofusion fittings shall be manufactured from the same base resin as the pipe to
ASTM F1055 and shall have a pressure rating no less than that of the pipe.
Flanged and mechanical joint adaptors shall be manufactured to WIS 4-24-01 and
have a pressure rating no less than that of the pipe.
Pipes and fittings shall be fabricated to be capable of withstanding the working

pressures, test pressures and loadings specified.
Pipes and fittings must be designed to achieve a minimum working life of 50 years
under all applicable loadings, environmental and installation conditions.
Pipes and fittings shall be suitable for carrying raw sewage, treated sewage effluent,
surface water and potable water at temperatures up to 40°C as appropriate for the
particular application.
Nominal outside diameters of pipes and fittings shall conform to ISO 161 and the
tolerances on these diameters shall be in accordance with ISO 11922.
Only fittings supplied or recommended by the pipe manufacturer and approved by the
Engineer shall be used. Fittings shall be installed in accordance with the approved
method statement.
The pipe shall contain no recycled compounds.
The properties of the polymer, extruded pipe and fittings shall be as shown in Tables
below.
HDPE Resin Properties
Property Required Value Test Method Test Method

European ASTM
Density >940kg/m3 ISO 1183-3 D1505
Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238 4

index or rate (2.16) 4
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European ASTM
Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238 5

index or rate (5.00) T
Melt mass flow >8g/10min ISO 1133 condition D1238 6

index or rate (21.6) G
Environmental >250hrs BS EN ISO 20088 D1693

stress crack
resistance (10%
stabiliser)
Resistance to >165hrs ISO 4427 DIN 8047 -

internal pressure
Oxidation induction >20mins BS EN 728 -

time (200°C)
Flexural creep >900MPa - D790

modulus
Shore D hardness >50 - D2240

(40°C)
Tensile strength at >20MPa ISO 527 D638

yield (50mm/min)
Elongation at break >600% ISO 527 -
Modulus of >1000MPa - -
elasticity
Charpy impact No break - -
Vicat softening >125°C BS EN 727 -

point
Thermal expansion <0.20mm/m/ C - -

(20-90°C)
Thermal <0.6W/mK - -
conductivity (20°C)
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European ASTM
Carbon black >2.4 ISO 6964 -

content
Carbon black ≤60µm (grade 3) ISO 18533 -

dispersion
*- Maximum deviation of +/- 20% of the nominated value
HDPE Pipe Properties

European ASTM
Density >940 kg/m3 ISO 1183-3 D1505
Melt mass flow 0.2 to 1.4/10min* ISO 1133 condition D1238 5

index or rate 1T
(5.00kg, 190°C)
Oven test Defects shall not ISO 12091 -

develop
Resistance to No failure or ISO 1167 ISO 4427 -

internal pressure defects
(20°C, water in
water, hoop stress
12.4MPa, 100hrs)1

(80°C, water in
water, hoop stress
5.5MPa, 165hrs)1

(80°C, water in
water, hoop stress
5.0MPa, 1000hrs)1
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European ASTM
Creep ratio >900MPa BS EN ISO 9967 -
Longitudinal <3% ISO 2505 -

reversion (100°C)
Shore D hardness >50 - D2240
Tensile strength at >20MPa ISO 527 D638

yield (50mm/min)
Elongation at break >350% ISO 527 -
Ring flexibility Refer standard BS EN 1446 -
Impact strength TIR 10% BS EN 744 -
Ring stiffness To SN or SD BS EN ISO 9969 -

required
Quality Grade N ISO 11922 -
Thermal stability 20mins BS EN 728 -

(200°C)
Notch test (at 500 Refer Standard ISO 13479 -

hours)
Legend
1) Either on pipe or from sample pipe using same resin and process.
*- Change of MFR by processing +/- 20% of the compound value
HDPE Injection Moulded Fittings Properties

European ASTM
Density >940kg/m3 ISO 1183-3 D1505
Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238

index or rate 1T
(5.00kg, 190°C)
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European ASTM
Stiffness As required ISO 13967 -
Impact Refer standard BS EN 12061 -
Mechanical Refer standard BS EN 12256

strength or flexibility
Thermal stability >20 mins BS EN 728 -

(200°C)
Resistance to No failure ISO 1167 ISO -

internal pressure 4427
(80°C, water in
water, hoop stress
5.5MPa, 165hrs)1
Resistance to No failure ISO 1167 ISO -

internal pressure 4427
(800C, water in
water, hoop stress
5.0MPa, 1000hrs)1
Water tightness No leakage EN 1053 -
Legend
1) For moulded materials use either an injection moulded or extruded pipe

from same materials.
*- Change of MFR by processing +/- 20% of the compound value
4.3.2.3 Jointing
a) Butt Fusion Jointing
Butt fusion jointing shall only be used to join pipes of the same PE material with
compatible MFR and with the same nominal wall thickness and outside diameter.
The following procedures shall serve as a general guide only. The Contractor shall
obtain detailed jointing instructions from the manufacturer who shall have a technical
representative available at the Engineer’s request during the jointing process.
- The butt fusion machine should be sited within a shelter and the ends of the
pipe being joined should be covered or plugged to prevent through drafts.
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- Each component that is to be fused should be held in position in the purpose

built clamping jig. The lengths of pipe hanging outside the jig should be
supported by means of roller cradles.
- The pipe ends should be faced so that the finished surfaces are perfectly
smooth free of visible ridges, valleys or other surface imperfections.
- The outside diameters of the pipe ends should match closely without the
offset exceeding 10%
- The pipe ends should be heated to the pipe manufacturer’s recommended
temperature and interfacial pressure. The Contractor should use a pyrometer
or other surface temperature measuring device to confirm and record the
actual surface temperature for each weld. Temperature indicating crayons
should not come into contact with the surface to be welded.
- After the pipe ends have been properly melted, the heater tool should be
removed within the specified time. The molten pipe ends should be brought
together and allowed to cool without disturbance to form the permanent weld.
The proper bead size and geometry specified for the pipe being welded
should be formed.
b) Saddle/Sidewall Jointing
Saddle /sidewall fusion jointing shall be accomplished by using a mechanical saddle

fusion machine that has been designed for this purpose to ensure proper alignment,
temperature and force control. The following procedures shall serve as a general
guide only. The Contractor shall obtain detailed jointing instructions from the
manufacturer who shall have a technical representative available at the Engineer’s
request during the jointing process.
- Any dirt or coating that might interfere with the proper operation of the saddle
fusion machine should be removed from the pipe and the surfaces of the pipe
and saddle roughened to expose fresh material and any reside brushed away.
- Test fit the saddle fusion machine to ensure that alignment and contact are as
they should be.
- Commence the fusion process and periodically verify the surface temperature
using a pyrometer or other surface temperature measuring device. If
temperature indicating crayons are used, they should not be used on a
surface which comes into contact with the surfaces to be welded.
- After the heating period, remove the heater plate and check for the correct
melt pattern on both the fitting and the pipe. Join the fitting to the pipe with the
prescribed fusion force.
- Cool the joint without disturbance until the melt has formed a permanent
weld. The joint should not be subjected to any external stresses until the
fusion joint has cooled.
c) Electrofusion Jointing
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Electrofusion jointing involves heating the electrofusion joint internally, either by a

wire coil at the interface of the joint or by a conductive polymer. Heat is created by an
electric current passed to the conductive material in the fitting.
- Ensure that the fitting is dimensionally appropriate for welding to the pipe.
Clean the pipe surface in the joint area. Cut the end of the pipe square. Mark
on the pipe surface the proper position of the fitting to be installed. Scrape the
surface of pipe area to be joined, removing all surface degradation and
contamination. Avoid contamination of the scraped pipe surfaces.
- Place the pipe and fitting in the clamping fixture to prevent movement of
the pipe or fitting.
- Connect the electrofusion control box to the fitting and to the power source.
Apply electric current to the fitting as specified in the manufacturer’s
instructions. Turn off the current when the proper time has elapsed to heat the
joint properly.
- Allow the joint to cool for the recommended time and remove the clamping
fixtures. Do not remove prematurely from the clamps as any strain on a joint
that has not fully cooled can be detrimental to joint performance.
d) Mechanical joints and fittings
Many types of mechanical connection styles and methods exist. The Contractor shall
submit suitable mechanical joints. All such joints shall be recommended and
acceptance tested by the manufacturer of the pipe. Where marked on the drawings
end-load resistant fittings of an approved type shall be used.
When tightening polyethylene flanges care shall be taken to produce an equal torque
load to the limits given by the manufacturer. A torque wrench shall be used. Since
polyethylene creeps under load it is essential that the bolts are re-tightened several
times prior to commissioning to minimise the risk of leakage.
All joint materials and gaskets shall be suitable for use in the prevailing climate, soil,
ground water, potable water and irrigation water conditions.
4.3.2.4 Quality Control Tests
The routine factory quality control tests listed below shall be carried out at the
required frequencies and records of all tests and inspections shall be maintained by
the manufacturer. The Engineer shall be provided with two copies of all test
certificates and reports.
- Quality testing of all raw materials to ensure that they comply with the relevant
specification.
- Control of processing parameters in terms of temperature, pressure, flow
rates, haul-off speed and energy input.
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- Visual inspection of the pipes to check general appearance, dimensional

compliance and any indication of inclusions or processing flows in pipe barrels
and joining ends.
- Production short-term tests to identify any variations in the plant functioning.
- The following tests shall be performed in accordance with the relevant
standards in order to ensure the quality of the extruded pipes:
 Melt mass-flow rate of raw material.
 Density of raw material.
 Carbon black content.
 Carbon black dispersion.
 Long-term stress crack resistance at 80°C.
 Long-term MRS at 20°C on the raw material (data not older that 24
months)
 Appearance.
 Long term hydrostatic test at 20°C. (100hrs test)
 Welding.
 Slow tear test
 Oxidation induction time value.
 Visual inspection of pipes.
 Dimensional check of pipes.
 Heat reversion of pipes.
 Hydrostatic creep strength tests of pipes.
 Bend test / reverse bend test
When conditioning is required for laboratory tests, condition the specimens in

accordance with the appropriate standard.
Tensile testing for pipe resin, pipes and welds shall be performed on an approved
tensilometer capable of delivering safely and accurately 120 % of the stress required
by the sample. The tensilometer shall be connected to a computerised system
capable of delivering information in data and graphical form. The information
required from tensile measurements are tensile strength at yield and peak and
elongation at yield and peak.
- Test specimens shall be milled to exact size using approved designated

milling machines. Each specimen shall be measured to an accuracy of 10
microns.
- The Contractor shall submit statistical analysis based on minimum sample
populations of 32. Cumulative analysis based on overall and on individual pipe
resin batch based data shall also be provided.
- Welded samples shall be visually examined after tensile testing for signs of
adequate bonding and ductile and brittle failure. Weld samples with greater
than 25 % brittle failure shall be rejected.
- Tensile graphs indicating brittle failure shall be considered as failures.
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The selection of samples of pipe, resin and welds for testing shall be as directed by
the Engineer.
If the results of any test fail to meet the requirements of this specification, the test
shall be repeated once again. If, upon retest, failure occurs, the batch quantity of
product represented by the test shall be rejected.
The Contractor shall conduct quality checks at the manufacturer’s premises to ensure
that the in-process manufacturing quality checks are being conducted correctly and at
the stated frequency. Test certificates relating to the batch shall be furnished to
the Engineer before acceptance of the delivery. The test certificates shall contain all
the details in the agreed format of reporting.
Marking shall be applied to the pipe in such a manner that it is legible after installation
and durable throughout the construction period. Each standard and random length of
pipe and every fitting shall be marked before despatch from the pipe manufacturer’s
works as required in ISO 4427 and as follows:
- The manufacturer’s name, initials, or trade mark.

- The dimensions nominal outside diameter X nominal wall thickness.
- The outside diameter tolerance.
- The designation of the pipe material.
- The nominal pressure.
- The pipe series.
- The date of manufacture and batch number.
- Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture, delivery and testing of that
pipe.
- The manufacturing standard.
4.4 GRP PIPES & FITTINGS
4.4.1 Definitions and Requirements
The following definitions are used in this specification.
GRP Pipe: A tubular product containing glass-fibre reinforcements embedded in or

surrounded by cured thermosetting resin with or without aggregate.
Aggregate: Siliceous sand conforming to ASTM C33, except the gradation

requirement need not apply.
E-glass: Low Alkali content glass fibre.
ECR-Glass: Form of glass fibre specially developed for acid resistance.
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C-Glass: Alkali -Lime glass with added boron used for surface layer reinforcement.
(Good chemical resistance).
Reinforcement: Glass fibres used to provide strength and stiffness to a composite

material.
Resin: A polymer that has high molecular weight with no definite melting point used
as a basic material for plastics.
Orthophthalic resin: A general purpose polyester resin of limited chemical and

temperature resistance.
Polyester resin: Type of thermo-set resin with two or more ester group.
Thermo-set Resin: Resin which hardens irreversibly by use of additives. Once cured,
a thermo-set resin cannot be re-melted and insoluble.
Epoxy resin: A polymer containing two or more three member rings, each consisting
of one oxygen and two carbon atoms. The polymer is cured by cross-linking with
amine or anhydride hardener, with or without heat, catalysts or both.
Vinyl ester resin: High performance corrosion-resistant epoxy based resin.
Lining: Integral internal reinforced lining of a GRP pipe, normally of high resin content
consisting of a 'barrier layer' and a 'surface layer'.
Roving: A collection of parallel glass strands or filaments with binder.
Chopped fibre: Continuous fibres cut into short lengths (3-50mm).
Resin-rich Lining: A corrosion resistant lining containing approximately 65-80% of

resin by weight applied to the interior surface of GRP pipe to protect the structural
wall from corrosion.
Laminate: A composite of cured resin and reinforcement.
Filament winding: General term for pipe manufacturing method using continuous
rovings as the reinforcement.
Helical winding: Filament winding manufacturing method where continuous rovings

are applied at 60 - 70 degree to axis of pipe mould.
Barrier-Layer: The resin -rich anti penetrant layer forming part of the internal
corrosion resistant pipe lining applied behind the interior liner of pipe.
Inner surface layer: Resin-rich layer forming part of the internal corrosion resistant
pipe lining.
Exterior surface layer: A filled or unfilled resin-rich layer (reinforced or unreinforced)

applied to the exterior surface of the pipe wall.
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Barcol hardness: Measure of surface resin hardness, used to check the degree of
cure.
Cure: Conversion of liquid resin into solid.
Air inhibition: Failure of surface layer of resin cure because of contact with
atmosphere.
Stress: The force per unit cross section area.
Strain: Dimensional change per unit of length resulted from applied force or load
measured in (mm/mm).
Strain corrosion: Brittle failure mode caused by exposure of a strained laminate to a

corrosive environment.
Stiffness: The resistance of a pipe to circumferential deflection in response to

external loading applied along one diametrical plane.
Pressure class: Maximum sustained pressure for which the pipe is designed.
Pipe stiffness: A measure of the force required to deflect the diameter of a pipe ring a
unit amount.
Stiffness class: The nominal stiffness of a specified pipe.
Creep: Deformation or strain that occurs over time when a material under
sustained stress. GRP is subject to creep at all temperatures when subjected to
stress.
Hydrostatic Design Basis (HDB): The long -term hydrostatic hoop strength of a
specific fibre glass pipe material as determined by hydrostatic pressure test and the
data extrapolated to 50 years to use the data in pipe design calculation.
Long-term strain corrosion (SCV): The long-term strain corrosion strength of a

specific fibre glass pipe in acidic & under strained condition determined by deflection
test and the data extrapolated to 50 years to use in pipe design calculation.
Long-term Stiffness (Creep): The long term stiffness retention and creep factor of a
GRP pipe (under wet condition) determined by constant failure strain (deflection) test
and the test data analysed and extrapolated to 50 years.
Long-term Ring bending strain: The long term bending strength (in normal water
under immersed condition) of a GRP pipe determined by constant failure strain
(deflection test) and the test data analysed and extrapolated to 50 years strain to use
the data in pipe design calculation.
Design factor (FS): A number equal or greater than 1.0 which takes into
consideration the variables and degree of safety involved in a design. Test data are
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divided by the design factor to obtain design allowable values. Also called safety
factor.
4.4.2 Glass Reinforced Plastic Pipe & Fittings (GRP) for use in Gravity and Pressure
Flow Systems
Pipe manufacturers must be members of, or affiliated with, a quality control or

certification authority relevant to the pipes or fittings proposed for incorporation in the
works. ISO 9001 certification is required for pipe/fittings manufacturers.
The following specifications are referenced as applicable:
Reference Description
BS EN 14364:2006 +A1:2008
BS EN 1796:2006 +A1:2008 Plastics piping systems for drainage and

sewerage with or without pressure. Glass-
reinforced thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Specifications
for pipes, fittings and joints
Plastics piping systems for water supply with or

without pressure. Glass-reinforced thermosetting
plastics (GRP) based on unsaturated polyester
resin (UP)
ASTM D3262:2004 Specification for fibreglass sewer pipes for use in

gravity flow systems for conveying sanitary
sewage
ASTM D3754:2004 Specification for fibreglass sewer and industrial

pressure pipes for use in pressure systems for
conveying sanitary sewerage and industrial
wastes
ASTM D3517:2004 Specification for fibreglass pressure pipes for

conveying water system.
AWWA C950:2001 Standard for fibreglass pressure pipes
AWWA M45 Fibreglass pipe design manual
The GRP pipes & fittings shall be certified in accordance to BS EN 14364, BS EN

1796, ASTM D-3262 & D 3754 (Certificate to be submitted for Engineer’s approval).
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Certification must include the diameters of pipe to be supplied. Evidence of diameter

range is necessary.
GRP Pipe and fittings shall be manufactured in accordance with BS EN 14364, BS

EN 1796 and ASTM D-3262 for gravity application and BS EN 14364, BS EN 1796
and ASTM D-3754 for pressure application. GRP pipe and fittings shall be at least
adequate to achieve a minimum working life of 50 years under all applicable loading,
local environmental and installation conditions.
The pipes and fittings shall be designed to withstand up to 5% long term deflection in
the installed conditions.
Both gravity & Pressure Pipes shall have a 50 years strain corrosion design
performance as per the latest editions of ASTM D3262/ASTM D 3754, AWWA C 950
for sewer pipes, but the mean value of the regression line at 50 years shall not be
less than 1 % strain. Evidence of third party approved regression test date must be
submitted.
The GRP pipes used for gravity applications shall comply with the minimum
requirements for 6 Bar pressure pipes as the pipe lines may be intended to operate
under surcharged conditions and not as gravity pipe lines.
The pipe shall also comply with the additional requirements to suit the prevailing
Local temperature and corrosive environment conditions specified.
4.4.2.1 Materials Specification
a) Resin
The resin used for the internal liner of the pipes and fittings shall be of an epoxy
based vinyl ester resin complying with BS EN 14364 and BS EN 1796 and shall have
a minimum elongation to break of 5% when fully cured.
The resin in the structural wall of the pipes and fittings shall be of unsaturated
Isophtalic polyester type incorporating styrene as the monomer and meeting the
requirements of BS 3532 Type B. The use of vinyl ester resin in the structural layer is
also permitted.
* No pigments in the liner or structure shall be added.
b) Glass
The internal and external layer shall be of "C" glass veil produced from a chemically
resistant glass durable in both acid and alkaline environment and shall have a surface
treatment compatible with the resin. All fibre reinforcement used shall be of high acid
resistant type "ECR/Advantex" ' comply with BS EN 14364 and BS EN 1796 and shall
have a surface treatment compatible with the resin. The reinforcements shall
generally comply with the standards listed below as appropriate.
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References Description
BS 3691 Glass fibre roving for the reinforcement of polyester resin systems".
BS 3496 Glass fibre chopped strand mat for the reinforcement of polyester
resin systems".
BS 3396 Woven glass fibre fabrics for plastic reinforcement".
BS 3749 Woven glass fibre roving fabrics for the reinforcement of polyester
resin systems".
Glass rovings used in the structural wall shall not exceed 2400 Tex.
c) Aggregates and Fillers
Aggregates if used, shall be minimum 98% pure Silica Sand as defined in BS EN

14364, BS EN 1796 and AWWA C950 and shall contain no impurities. The
aggregates shall only be used in the stiffening layer of the pipe wall, where it is
designed as part of the composite structure.
The final product shall meet the requirements of the specifications.
Silica sand aggregates as defined in BS EN 14364 and BS EN 1796 shall contain no

impurities. Fillers as defined in BS EN 14364 and BS EN 1796 shall not be used. The
silica sand content in the pipe wall shall not exceed 50% for the gravity pipes and
30% for the pressure pipes.
The resin shall be cured to reach hardness not less than 90% of the resin
manufacturer's recommended hardness.
A manufacturer's tolerance of ± 1 % shall be allowed on the nominal diameter of the

pipe. The pipes shall be supplied in standard lengths of 3, 6, 10 or 12 metres with a
tolerance of ± 25 mm. The deviation from straightness of the bore of the pipe shall not
exceed 0.3% of the effective length or 15.00 mm whichever is smaller and shall apply
when measured on site. Up to 10% of the pipes will be allowed in random lengths.
The ellipticity of any pipe when measured resting freely on the ground shall not be
more than 2% of the mean diameter at any point. No pipe known to have undergone
a deflection greater than 7% shall be incorporated into the Works.
The stiffness shall be minimum 5000 N/m2 for all pipes but for pipes to be used in
Pumping Station and valve chambers and for Irrigation &Water application the
stiffness shall be minimum 10,000 N/m2 and pipes for use in microtunnelling or similar
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jacking operations the stiffness shall be minimum 50,000 N/m2 unless surrounded in
concrete. Please refer to Section 12 for the production of GRP pipes in jacking
operations.
GRP Pipes shall also be used in place of A.C. Pipes wherever applicable in storm
water drainage and Irrigation Pipes. The pipe laying procedures & the deflection
checks at Site etc. shall be the same as for sewer pipe. Pipe installation & Pipe
surround material shall be the same as specified for GRP Pipes & Fittings. The
minimum / maximum burial depth shall be as recommended by the Pipe
manufacturer. Supporting design calculation shall be provided to the Engineer to
satisfy the installation condition.
The specific tangential initial stiffness shall be demonstrated by application of the

following equation:
Stiffness of the pipe = is defined as EI/D3
(STIS)
Where: E = bending modulus of pipe wall circumferentially (in N/m2).
I = second moment of area of pipe wall per Unit length (in m4/m)
D = mean diameter of the pipe in metres
4.4.3 Compulsory Requirements Particular to Pipes, Couplers and Joints
a) The Inner Layer
All pipes and fittings shall have a resin- rich liner internal to protect the glass in
structural laminate from long term degradation having a minimum thickness of 1.5mm
and maximum thickness of 2.5mm consisting of an inner most 0.25mm surface layer
reinforced with chemical resistant "C" glass impregnated with 90% resin. The
remainder of the 1.25 mm backup barrier layer shall consist of acid resistant (ECR/
ADVANTEX) chopped glass strands or powder bound chop strand mat and having a
glass content between 25 and 30% by weight. The lining materials selected should
provide a good impact and corrosion resistance.
b) The Structural Layer
The structural wall of the pipe shall be reinforced with closely spaced continuous fibre
glass (ECR/ADVANTEX) filament winding, chopped roving, Silica Sand all
impregnated with Isophtalic polyester resin. No dark pigments or resin fillers such as
Calcium Carbonate shall be used in the pipes or fittings. Fine silica sand containing
no impurities and complying with the requirements of BS EN 14364 and BS EN 1796
may be added in a core layer sandwich, between the pipe structural layers.
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c) The Exterior Layer
The exterior resin rich layer of the pipe shall have a maximum thickness of 1 mm
reinforced with corrosion resistant glass (ECR/ ADVANTEX) and "C" glass veil
impregnated with isophthalic resin/vinyl ester resin. For protection against ultra violet
light degradation a translucent "UV" inhibitor should be included in the resin mix.
A black colouring pigment to suit the service identification of Storm water drain pipe
shall be added on external resin rich layer as instructed by Dubai Municipality.
d) Fittings
All fittings such as bends, tees, junctions, reducers and the like shall conform to BS
EN 14364 and BS EN 1796. The construction of bends shall be swept or mitered. The
laminated joints used in the fabrication of fittings shall meet or exceed the required
design requirements of the piping system. All hand laminations or windings shall
utilize only one type of resin throughout.
e) Flanges
GRP flanges shall be flat faced and drilled to BS EN 1092 PN 10 or PN 16 drilling

pattern. Flanges shall be filament wound up to 1800mm and may be contact moulded
for larger sizes. GRP flange gasket shall be of a design, material and thickness as
recommended by the GRP fitting manufacturer. The use of epoxy resin in a flange
manufacture is permitted.
f) Joints (For buried pipes)
Except where otherwise detailed on the drawings, all pipes and joints shall be of
flexible type. Joints shall be of loose GRP machine made coupling having two rubber
rings gaskets. All joints shall be capable of withstanding the various tests specified for
the appropriate class of pipe.
Joints shall withstand while maintaining the specified test pressure at a deflection of
not less than the values specified in the BS EN 14364/ BS EN 1796/ ASTM D3262/
ASTM D4161.
Pipes used for adjustment and short length shall be ordered from the manufacturer.
Cutting and rejoining is only allowed when butt joints are used or a calibration
machine is available and approved by the manufacturer. No cutting on site is allowed
without manufacturer’s recommendation. The Rubber rings shall be meeting
kitemarked the requirements of the appropriate parts of BS EN 681-1 and be of the
EPDM formulation.
g) Joint Lubricants
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For lubricants, use only a vegetable based soap available from the pipe
manufacturer. Never use petroleum product or automotive oils to lubricate the joint,
as they will damage the rubber rings.
Pipes shall have a resistance to longitudinal tensile force per unit circumference as
under:
Nominal Diameter (mm) Initial Ultimate Resistance

(N/mm)
Up to 700 100
700 to 1,000 120
1, 000 to 1, 600 160
1,600 to 2,400 250
2,400 to 4,000 300
When subjected to a parallel plate loading test no evidence of crazing or cracking and
no structural failure with the deflection levels specified in AWWA C 950-Table 9. The
deflection criteria presented are based on a Maximum installed long term deflection of
5%. If the pipe sample fails to meet either or both requirements, the long term
allowable deflection must be reduced proportionally for the pipes represented by the
sample.
The jointing system shall be an approved coupling system. Where the system
involves separate reinforced plastic couplings of sockets formed by a lay-up process
subsequent to pipe production, the resins used shall be clear and non-pigmented to
permit visual examination within the laminate.
Where GRP laminate is cut, exposed ends shall be sealed with a suitable resin and
approved prior to incorporation into the Works. Where such cutting and sealing takes
place at site the resins used and the methods of storage, mixing, application and
curing shall be strictly to the manufacturer's recommendation. Before any such work
takes place the manufacturer's representative shall visit the site to demonstrate and
give clear procedural advice to the Contractor in the presence of the Engineer.
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GRP pipe and fittings shall be as uniform as commercially practicable in colour,

opacity, density, and other physical properties.
GRP pipe and fittings shall be smooth and both the internal and external surfaces
shall be clean and free from delaminations, cracks, bubbles, pinholes, pits, blisters,
foreign inclusions and resin-starved areas that due to their nature, degree or extent
detrimentally affects the strength and serviceability of the pipe.
Unless authorized by the Engineer, repair will not be permitted on any pipes with
defects, as listed below and such pipes shall not be incorporated into the works:
(i) A scratch of greater depth than 0.30 mm.
(ii) Cracks of any type on the inside of the pipe.
(iii) Cracks on the outside, longer than 200 mm circumferentially or 6mm

longitudinally.
(iv) Delaminations.
(v) Damaged ends including bubbles, cracks, voids, exposed reinforcement or

extraneous matter.
(vi) Internal protruding fibres.
(vii) More than 25% of the external area with protrusions of any sort.
(viii) Air voids and blisters exceeding 5 mm diameter or 1 mm in depth, greater

in area than 0.50% of internal or 1.00% of external surfaces.
(ix) Pitting to more than 5% of the internal or 10% of the external surface area
and individual pits more than 1 mm diameter or 0.5 mm in depth.
(x) Wrinkles more than 3% of the surface area and individual wrinkles more
than 2 mm deep.
4.4.4 Type Test for GRP Pipes and Joints
DM approved, NAMAS accredited independent third party laboratory witnessed Type

tests shall be carried out compulsory, on locally produced representative pipe
products in accordance with Table 4-2 to pre-qualify the products and to verify the
design input data given in the design calculations.
Table 4-2 Pre-qualification Tests

Sr. Qualification or Type Test Method Minimum Requirements
Tests
1 Long term (10,000 hrs) BS EN 14364 AND Extrapolated predicted

Chemical test ( strain BS EN 1796 OR failure strain at 50 yrs.
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Sr. Qualification or Type Test Method Minimum Requirements

Tests
corrosion resistance) ASTM D3681 shall not be less than 1%.
2 Long term hydrostatic or ASTM D2992 / OR Hydrostatic strain at 50

pressure design basis BS EN 14364 AND yrs. shall not be less than
10,000 hrs test. (for BS EN 1796 0.66%
Pressure Pipe)
3 Long term specific ring BS EN 14364 AND 50 years-extrapolated

stiffness (creep factor) BS EN 1796 stiffness value shall not
under ring deflection Appendix L be lower than 70% of the
(10,000 hrs test) initial stiffness.
4 Long term ring bending ASTM D 5365 50 years strain shall not
strain (sb) be less than 1.35%.
5 Impact resistance BS EN 14364 AND As specified in relevant

BS EN 1796 standard.
Appendix J
6 Joint water tightness. ASTM 4161/BS EN Requirements as

14364 AND BS EN specified in relevant
1796 standard.
7 UV exposure on GRP Manufacturers Not to show surface

Pipe (1 Year). Recommended test Deterioration due to UV
Method. effect.
8 Short time Hydraulic ASTM D 1598 / D (a) Withstand 3.5 times

failure pressure of pipes 1599 the rated working
and fittings (After the first pressure with no sign of
production). leakage or weep. (b)
Determine the failure
pressure by pipe bursting.
Note: (1) The above tests are to be repeated on locally made pipes when the
material type & compositions are changed during the production from the original type
test of the product.
Quality control tests on raw materials and final products shall be carried out as listed
below:
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4.4.4.1 Quality Control Tests & Records
The manufacturer shall have maintained a record of all quality control tests for a
period of not less than 2 years and if requested, shall submit the data to the Engineer.
a) General Requirements
The pipe manufacturer must demonstrate the capability to produce pipes of

consistent properties and quality meeting the requirements of these specifications. A
detailed quality control/quality assurance program must be implemented at the
manufacturing facilities and all necessary test equipment to be operated by skilled
technicians. Calibration of test equipment shall be performed at least once a year.
Details of the pipe manufacturers QC/QA program, testing equipment, testing
program shall be presented to the Engineer for review and approval prior to
commencement of pipe manufacture. The manufacturer's quality control scheme
shall be certified by a recognized independent authority to meet the requirements of
ISO 9001.
b) Reconfirmation of Strain Corrosion Regression Line
When a GRP piping product has an existing strain corrosion regression line, any
change in material, manufacturing process, construction or liner will necessitate a
Screening evaluation as described in CL 10.2, 10.3, 10.4, 10.6 & 11 of ASTM
D3681:96. The pipe samples for screening test shall be selected by the Engineer’s
representatives from locally produced pipes only.
Table 4-3 Minimum Design Parameters, Installation Conditions and the

Mandatory Requirements for GRP Pipe Intended to Carry Septic Sewage/ Sea
Water
Details Requirements
Minimum working pressure class of pipe 6 Bar

for gravity applications.
Ground water table level (assumed). Minimum 1 M below ground surface.
Minimum working Pressure class pipe 10 Bar

Category for Pressure applications.
Service operating temperature 50 °C
Installation depth ('H' Min. & 'H' Max.) H min : Not less than 1.5 m
H max : As shown on the drgs.
Stiffness Class Pipe (for gravity & Minimum 5000 N/m² for gravity & 10000
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Details Requirements
pressure) N/m2 for Pressure pipes
50 Years extrapolated stiffness retention (a) Not less than 3500 N/m² for 5000
value (end stiffness) of pipe. STIS class pipe (b) Not less than 7000
N/m² for 10,000 STIS class pipe.
50 Years extrapolated strain value Minimum 1 %

established by long-term strain corrosion
type test conducted on local made pipe Safety factor = 1.5
(G & P) and witnessed by 3rd party
independent lab.
Required minimum strain value by 1000 Strain percentage achieved shall not be
hrs control test on local made production lower than the type test result of GRP.
pipe.
50 Yrs extrapolated 'HDB' value Minimum 0.66%

established by long term type test
conducted on local made pipe (G& P) Safety factor = 1.8
and witnessed by 3rd party independent
lab.
Permitted maximum long-term deflection Not greater than 5%

at 50 years service life of pipe.
Shape factor input data (Df) for pipe Minimum 4.5 as given in AWWA M45
design manual for pipe zone embedment
material as gravel with compaction
moderate to light.
Back fill modulus E'b for pipe zone Minimum 20.7 MPa as given in AWWA
embedment. M45.manual.Crushed rock as pipe zone
embedment with moderate proctor
Live load assumption to use in pipe Four-lane road with truck centred in each
design. 3.7m wide lane as given in AWW A M45
manual.
Impact factor to use in pipe design As per A WW A M45 manual

recommendation.
Water hammer calculation Ditto
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Materials in Pipe Laminate Structure
A Type of glass throughout the pipe ECR/ Advantex only

wall
B Type of resin to be used in Isophthalic polyester Resin type ‘B’

structural wall having minimum 3.0% elongation
property
C Type of resin to be used on resin- Epoxy based vinyl ester resin having
rich liner internal & external of pipe minimum 5% resin elongation property
wall
D Aggregate & fillers Silica sand SiO2 > 98%
E C' Glass (for the internal liner and Chemical resistant ECR Type only
liner external of pipe)
Corrosion Resistant Lining inside the Pipe Wall
a Surface layer internal Nominal thickness 0.25mm
Glass content up to 10%
b Barrier layer behind the surface Minimum thickness 1.25mm

layer of pipe
Maximum thickness 2.25mm
Epoxy based V.E.Resin 60- 80%
ECR / Advantex Glass 20-40%
c Overall liner thickness internal Minimum 1.5mm
Maximum 2.5 mm
d Overall liner thickness external Minimum 0.5mm
Maximum 1.00 mm
e Sand content minimum/max Sand content in gravity pipe wall shall not
limitations be greater than 50% and 30% in pressure
pipe.
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f Chopped Rovings Chopped rovings in pipe wall

minimum/max limitations minimum 7%.
The manufacturer shall carry out the quality control test listed below using the pipe
production sample selected and witnessed by the Engineer at the frequency stated.
The manufacturer shall maintain records of all tests and inspections and two copies
of all test certificates and reports shall be forwarded to the Engineer.
c) Raw Materials
Checks shall be made on all raw materials to ensure that they comply with the
manufacturers stated values. All deliveries of resin shall be checked for consistency
of Viscosity and reactivity. Any resin deviation from the manufacturers published
figures shall not be used. Glass samples shall be checked for yield/tex, moisture and
size content. All deliveries of aggregate shall be checked for consistency of grading,
moisture content and purity. The pipe manufacturer should provide a copy of the
materials certificate of analysis for the material supplied together with in-house Q.C.
test reports stating that the material used in the pipe wall construction is conforming
in all respects to the relevant specification.
Table 4-4 Quality Control Tests on Final Product

1 Pipes & Fittings Test Method Minimum
Requirements
Hydrostatic – Pressure Test BS EN 14364/ BS

(Pressure & Gravity) EN 1796 / ASTM
D 3262 / ASTM
3754 / AWWA C
950
(1) 100% of pipes and (1) 2 x Rated

couplers. working pressure for 5
minutes.
(2) 1% of the pipes and (2) 2 x Rated

couplers working pressure for 4
hours.
2 Stiffness (for Gravity &

Pressure) 1 in every 100 pipes
manufactured (minimum)
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(a) At 5% deflection ASTM D2412 / BS a) 5000 / 10000

EN 14364/ BS EN N/m2 (minimum).
1796 ASTM
D3262 / D3754
(b) At level “A” (12% / 9%) b) No liner crack
Deflection. For 5000 / 10000

STIS pipe.
(c) At level “B” (20% / c) No structural

15% ) Deflection for 5000 / failure
10000 STIS pipe.
(d) After level “A”. d) Continue to

deflect to the point of
liner cracking and
record.
3 Wall Thickness ASTM D3567 Manufactures

minimum quoted
(On 100% Pipes, Couplers and thickness given in the
Fittings) calculation for the pipe
design.
4 Hardness (On 100% of pipes, BS 4549: PI Minimum 90% of the

Couplers and fittings) using Appendix A or hardness value
Barcol impressor 934 – 1, on ASTM D2583 declared by the resin
liner manufacturer but not
less than 33 barcol
readings using barcol
impressor 934 – 1.
5 Loss on Ignition (1 in every 100 ASTM D2584 + / -5% of

pipes) manufactures specified
resin / glass sand ratio.
6 Hoop Tensile Strength (1 in 100 ASTM D2290 / BS Requirements

pipes) EN 14364/ BS EN specified in table 10 of
1796 ASTM D 3754 as
appropriate for the
pressure class or
AWWA C950 Table 10
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7 Longitudinal Tensile Strength (1 BS EN 14364/ BS BS EN 1796 Table 13 /

in 100 pipes) in axial direction EN 1796 Table 13 of ASTM
Appendix A D3754
8 Fittings
(a) Visual inspection ASTM D2563 (a) Every

items
(b) Dimension ASTM D3567
(b) Every
(c) Pressure tests BS EN 14364 BS items
EN 1796 / AWWA
(d) Barcol hardness (Resin C 950 (c) 1 in
cure) 10flanged
ASTM D2583 items 2 x
WP for 60s.
(d) Every
item
minimum.
(a) Every items
(b) Every items
(c) 1 in 10flanged
items 2 x WP for 60s.
(d) Every item

minimum. Barcol
reading 33
9 Chemical Control Tests ASTM D3681 Strain level shall be

above 1%.
(100 & 1000 hours tests) on ASTM D3262
samples of manufactured pipes
during pipes supply for each BS EN 14364 BS
contract. EN 1796
Evidence from the manufacturer shall be provided of the satisfactory completion of

the ‘Strain Corrosion Control test’ on samples of pipe representative of those to be
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supplied together with an assurance that the test result are in full compliance with the
requirements stated in Table 4.9 Item (9) above.
d) Visual Inspection
Each pipe and fittings shall be subjected to a complete schedule of inspection before
shipment and after offloading at site. All pipes and fittings shall be commercially free
of defects such as delaminations, bubbles, exposed or protruding fibre, cracks, air
voids, pits, or resin-starved areas that due to their nature, degree of extent
detrimentally affects the strength and serviceability of the pipe. The maximum
allowable visual defects of GRP pipe laminate parts shall be classified to type and
level as given in ASTM D2563: Table 1. The acceptable quality level for the pipes
internal and external shall be the level 2 as specified in CL. 3.3 of the above
standard. Visual inspection report of the pipes, couplers and fittings in accordance
with the above standard are to be provided by the manufacturer. Joints surface shall
be free of dent and other surface irregularities that will affect the integrity of the joints.
Any repairs at site if approved by the Engineer shall be carried out by qualified and
skilled staff of the pipe manufacturer.
e) Design Calculations
The manufacturer shall design the pipes for a life of not less than 50 years and shall
submit calculations for initial and long term deflection with truck loads, buckling,
vacuum, pressure, class, and strain in accordance AWWA M45. (Chapter V).
For the purpose of design calculations only the bedding and back fill for pipes shall be
considered as crushed stones/gravel with slight compaction and the modulus of soil
reaction value shall be 20.7 Mpa as given in Table 5.5 of AWAWA M45. The
maximum calculated long term deflection shall not exceed 5%. Copies of the design
calculations shall be submitted to the Engineer for review and approval at the time of
material submission.
f) Shape Factor
The shape factor input data to be used in the design calculation shall be based on
dumped gravel with slight compaction and its appropriate value shall choose as given
in Table 5.1 of AWWA M45 Manual.
g) Safety Factor
The following safety factor shall apply:
AWWA M 45 Design Procedure
Pressure Rating > = 1.8
Ring Bending Strain or stress > = 1.5
Combined Strain or stress > = 1.5 and 1.8

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Buckling> = 2.5
h) Inspection and Testing
(i) The manufacturer shall take adequate measures in the production of

products covered by this specification to assure compliance with the
requirements herein. An inspection and testing plan should be forwarded to
the Engineer for approval prior to start of manufacturer.
(ii) Production and testing notice: When plant inspection is required by the
Engineer the manufacturer shall provide adequate advance notice of when
and where production and testing of ordered products will commence.
(iii) The Engineer shall have free access with reasonable advance notice to the
manufacturer's plant areas that are necessary to assure that the products
comply with all requirements herein.
i) Workmanship
GRP Pipes, fittings and joints shall be free from delaminations, bubbles and pinholes,
pits, blisters, dry spots, pimples, resin pockets, deep scratches, wormholes and deep
wrinkles.
All GRP Fittings shall be fabricated in the factory to ensure quality control (under no
circumstances fabrication of fittings be allowed on site by the contractor). Complex
fittings arrangements may be pre-assembled by the pipe manufacturer on the factory
such that the field joints are kept to a minimum.
j) Marking
Each pipe and fittings shall be legibly marked with the following information:
- Manufacturers name or trademark

- Manufacturing date and the applicable standard
- Manufacturing number
- Nominal diameter in mm
- Operating pressure in bar
- Pipe stiffness class
- Nominal laying length (for pipe only)
- Manufacturer's inspection mark
- Contract name and number
- Identification mark & the colour distinguishing the gravity & pressure pipe.
k) Submittal/Drawings
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The following information shall be submitted to the engineer by the manufacturer.
(i) Resin, Glass reinforcement, aggregate, joint and gasket data, with material
manufacturer’s certificate of analysis.
(ii) Pipe supply specifications & installation manuals.
(iii) GRP manufacturers Pre-qualification
(iv) GRP Manufacturers Quality Control and Assurance Manual.
(v) GRP pipe data sheet in the standard format shown below.
In addition to the above information, the following information shall be submitted

during the mobilisation period.
(i) Detailed Manufacturing process for pipe, joints and fittings.
(ii) Detailed drawing of pipe end and couplers including pipe spigot OD, home
line length, allowable tolerance, and allowable gap between pipes.
(iii) Complete design calculations and design requirements including pressure

class from HDB, working pressure and surge pressure using pressure class,
calculation of allowable deflection from ring bending, external loads, WC &
WL based on burial depth, predicted deflection, buckling etc.
(iv) Quality procedure
(v) Type test results and reports specified
(vi) Safety factor
(vii) Proposed inspection and testing programme.
Prior to start production the manufacturer shall submit to the Engineer dimensional
drawings of each fittings required for approval. The Engineer may require design
calculations, and samples for approval at no extra cost.
GRP PIPE DATA SHEET (FOR EACH DIAMETER / PRESSURE/SERVICE)
(To be provided to the engineer prior to start of pipe manufacturing)
Attributes Units
Design parameters :
Service (sewer/storm water) :
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Nominal Diameter (DN) :
Pipe Manufacturing process :
Installation service :
(minimum/maximum depth
adopted)
Rated working pressure :

(PN)
Joint type :
Maximum allowable vacuum :
Factory hydrotest pressure :
Length of each pipe :
Pipe Wall Structure
Nominal Wall Thickness :
a) Liner thickness :
b) Structure Wall thickness :
c) Outer Layer thickness :

Resin /glass type
Mechanical Properties
Design specific Tangential :

initial stiffness (STIS)
Design initial Longitudinal :

tensile strength
Design initial hoop tensile :

strength
Internal Pressure & External :

Load
Flexural Modulus :
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Allowance design stress :
Calculation Method
Internal Pressure & External :

Load
4.4.5 GRP Pipes and Fittings for Pumping Stations and Valve Chambers
The design of GRP pipe and fittings for pumping stations and valve chambers shall
incorporate all the requirements of these specifications except for the following over-
riding or supplemental stipulations.
GRP pipe and fittings inside pumping stations and chambers shall be designed for
use above ground with no thrust blocks and shall have sufficient axial strength to
resist end thrust, temperature and bending stresses.
GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m2 and a
minimum wall thickness of 10 mm.
The design working pressure for pipes and fittings shall be minimum 12 bar unless
otherwise specified and the service temperature shall be 50°C. A minimum surge
allowance of 40% above the working pressure shall be included in the design of pipes
and fittings. Copies of the design calculations shall be submitted to the Engineer for
approval. The basis of design shall be checked by conducting 'type' tests on
representative sample(s) of manufactured materials, in accordance with the
requirements of BS EN 14364 and BS EN 1796 or ASTM D-2992.
The wall of the pipes and fittings shall be made up of:
a) A resin-rich inner liner of 1.5 mm minimum thickness, consisting of ‘C’ glass veil,
and 'ECR/ADVANTEX' glass and impregnated with vinyl ester or epoxy resin.
b) The structural layer consisting of ‘ECR/ADVANTEX’ glass reinforcements

impregnated with vinyl ester or epoxy resin. Silica sand shall not be used.
c) An exterior resin-rich layer of 1.0 mm minimum thickness, reinforced with a ‘C’

glass veil and impregnated with vinyl ester or epoxy resin.
No dark pigments, sand or aggregate fillers shall be used for pipes and fittings. Ultra
Violet stabilizers shall be incorporated in the pipe and fitting construction.
GRP pipe and fittings for pumping station and valve chamber pipework shall have a
suitably designed restrained joint capable of withstanding the design operating
pressure with no leaks and without the use of thrust blocks.
The acceptable jointing system shall be GRP flanges. GRP flanges shall be machine
filament wound using 'ECR/ADVANTEX' glass fibre reinforcements and vinyl ester or
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epoxy resin. Hand layed up flanges shall not be permitted. Flanges shall be drilled to
BS EN 1092 (metric units) type PN 10.
4.4.5.2 Factory Testing
The following tests shall be carried out on manufactured GRP pipe and fittings at the
intervals specified. Test methods shall be in accordance with BS EN 14364 and BS
EN 1796 or ASTM equivalent. Witnessing of factory testing by the Engineer’s
Representative will be required prior to delivery of the material. Copies of the
Manufacturer's test reports shall be submitted to the Engineer after each
consignment of pipe or fittings delivered to the site.
All GRP standard pipe and pipe used for fitting fabrication shall be factory pressure
tested to 24 bar for pressure pipes and 12 bar for non-pressure pipes.
The following tests shall be conducted on all GRP pipe and fittings:
- Dimension measurements (Wall thickness, Diameter, Length)

- Visual inspection
- Barcol Hardness (Resin Cure)
Stiffness and resistance to structural damage as per Tensile strength by strip for GRP
pipes as per BS EN 14364 and BS EN 1796: App: #, 1990.
Mechanical property testing shall be conducted on 1% of GRP pipe and fittings

produced.
Other tests for quality assurance shall be carried out on representative sample(s) as
required by BS EN 14364 and BS EN 1796 or ASTM equivalent.
In addition to factory testing, the following tests shall be re-checked in Dubai Central
Laboratory and compare with manufacturer’s test results. The cost involved in this
test shall be paid by the contractor.
- Initial longitudinal unit tensile strength by a tensile strip test as per BS5480
Appendix A.
- Initial specific stiffness under ring deflection BS EN 14364 and BS EN 1796
Appendix H.
GRP pipe and fittings shall be installed in accordance with the manufacturer's written
instruction. A field representative of the manufacturer shall be made available as and
when required during the installation of the GRP pipe and fittings. All flanges shall be
tightened in accordance with the Manufacturer's written instructions using a torque
wrench.
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4.4.6 GRP Pipes and Fittings for Irrigation and Potable Water Distribution &
Transmission
4.4.6.1 Scope
This specification covers the minimum requirements for the GRP piping for
aboveground and underground installations, intended to be used for potable and raw
water applications.
The Manufacturer's design shall satisfy the minimum requirements set herein. This
specification includes the minimum requirements for design, manufacture,
workmanship, testing, inspection and installation of standard GRP pipe systems.
4.4.6.2 Manufacturers Pre-Qualification
All Pipes and fittings shall be certified in accordance with BS EN 14364 and BS EN
1796 / ASTM D3517. For the diameters intended for the supply, evidence of the
certified range to be submitted.
GRP pipe and fittings shall be manufactured by an established pipe Manufacturer in a

purpose-built facility for the production of such materials. The Manufacturer shall
have an approved Quality Management System complying with ISO 9001 for all
activities being undertaken during pipe design, manufacture and supply.
Manufacturer's Scope of Work
The GRP pipe system Manufacturer will be responsible for the following:
a) Manufacture and Supply of the GRP pipe, fittings, flanges, saddles for
instrumentation tapping and pipe closing (make-up) pieces. Manufacturer to also
supply the gaskets for use in flange connections and provide general
recommendations on associated equipment such as valves, expansion bellows,
nuts and bolts and other accessories.
b) Design of the GRP pipe system including Stress Analysis (Surge and Flexibility),
Support Location / Function Analysis and the Conceptual Support Design for the
given design and routing for all above ground applications. These Engineering /
Design analysis are to be implemented by the pipe manufacturer.
c) Inspection and testing at the Manufacturer's works in accordance with specified

requirements herein.
d) Marking of pipe for identification shall be as per Clause 4.4.4.1 .
e) Provision of a Site Staff (s) to assist during pipe installation.
Applicable Codes and Standards
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The following internationally accepted standards are the minimum requirements for
the manufacture of GRP Pipe Systems and should be referenced throughout the
Project Specification where appropriate.
AWWA C950 Glass Fibre Reinforced Thermosetting Resin Pressure (Latest

Edition)
AWWA M45 Fibreglass Pipe Design
BS EN 14364 and Plastics piping systems for drainage and sewerage with or
BS EN 1796 without pressure - Glass-reinforced thermosetting plastics (GRP)
Plastics piping systems for water supply with or without pressure

- Glass-reinforced thermosetting plastics (GRP)
ASTM D3517 Specification for Glass Fibre Reinforced Thermosetting Resin

Pressure Pipe for conveying water system
4.4.6.3 Product Description
a) General
Pipe shall be designed and manufactured by the glass filament winding process as
described by AWWA M45, ASTM D3517, BS EN 14364 and BS EN 1796. Accepted
manufacturing processes are the continuous filament winding or the helical filament
winding process. The filament wound pipe shall be made using a straight steel
mandrel.
The pipe shall be constructed so as to include internal and external corrosion barriers
of a composition suitable to resist the corrosive effects of the contained and
surrounding environments.
The inside diameter (ID) of the finished pipe is fixed by the mandrel outside diameter.
The outside diameter (OD) of the finished pipe is determined by the amount of
material that is wound on the mandrel.
The pipe shall be produced in one continuous piece with no joints.
The resins to be used shall be:
Polyester: Isophthalic Acid Grade (at least equal to the requirements of BS 3532
Type ‘B’).
(i) Liner
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Pipe and Fittings shall have a smooth resin rich internal liner of 1 mm thickness with a
resin to glass ratio of 70: 30. This liner will be reinforced with "C" Glass.
No dark pigment or resin fillers, such as calcium carbonate shall be used.
(ii) Structural Wall
The structural wall of the pipe shall be reinforced with closely spaced continuous
fibreglass filament winding, chopped roving, all impregnated in thermosetting resin.
No dark pigments or resin fillers such as calcium carbonate shall be used.
For underground applications, where stiffness is a critical factor for the GRP pipe
system, fine silica sand, complying with BS EN 14364 and BS EN 1796 requirements,
may be included.
(iii) External Layer
A resin-rich post-coat, identically constructed as the inner liner, must be applied to the
external surfaces of all of the GRP pipes. All external surfaces shall be able to resist
the anticipated corrosion imposed by the service and ambient conditions.
Approximate thickness of the external surface, shall be 0.5 mm.
No dark pigments or resin fillers such as calcium carbonate shall be used.
(iv) Reinforcing ribs
Where stiffener ribs are used to structurally reinforce the pipe wall, they must be
protected in the same manner as specified for the external surface, above.
b) Raw Materials
All materials and the manner and degree to which they are used during the
construction of all components required for the GRP pipe system described by this
specification shall be selected so they will resist the corrosive effects of both the
contained and surrounding environments.
All structural materials shall be new and free from all deleterious defects and
imperfections and only be used for production after having been controlled and
approved by the Manufacturer's Quality Department.
Testing and controlling shall be done according to the relevant methods, as described
in Clause 4.4.4.1.h) (Inspection and Testing) of this specification.
Glass Reinforcements shall be compatible with the impregnating resin used and
should be suitable for the service intended.
Resins used shall be a commercial high grade thermosetting isophtalic, resin as

specified under Clause 4.4.6.3.
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No dark pigments shall be used in the GRP pipe or joints. No additives shall be used
except when required for viscosity control.
Fine silica sand can be used for underground applications of GRP pipes.
Pipes used for Potable Water Service: All GRP pipes and fittings conveying potable
water shall be certified and listed for potable water use by the Water Regulations
Advisory Scheme "WRAS" United Kingdom, in accordance with BS 6920.
4.4.6.4 Requirements
a) Wall Thickness
The wall thickness required for each size/pressure class shall be established by the
manufacturer to meet the design requirements but in no case shall the wall thickness
be less than (0.010 x DN); where DN is the nominal pipe inside diameter. For ribbed
pipe, the minimum shell wall thickness shall be (0.005 x DN); where DN is the
nominal pipe inside diameter. The pipe working pressure class shall be based on the
Hydrostatic design basis (HDB) of the pipe with a design (service) factor of 0.5.
b) Length
GRP pipe shall be manufactured in standard laying lengths of not greater than 12
meters. Random short lengths, if supplied, shall not exceed 5% of the quantity
supplied of each size. The tolerance on the Manufacturer's declared laying length
shall not exceed ± 25 mm.
c) Diameters
Pipe shall be manufactured in standard metric sizes based on the pipe nominal
diameter in sizes 25 mm and larger. The actual inside diameter shall not vary from
the nominal inside diameter by, more than 1 % or 4 mm whichever is greater.
d) Stiffness
The pipe stiffness shall be determined by the Manufacturer to meet the design
requirement with particular regard to installation method, burial depths, deflection
limits, buckling and vacuum requirements, in accordance with AWWA M45. The pipe
initial specific stiffness (EI/D3) shall, in no case, be less than 10,000 N/m2, when
tested in accordance with ASTM D2412 or BS EN 14364 and BS EN 1796.
e) Beam Strength
GRP pipe shall meet the minimum longitudinal tensile strength requirements specified
in AWWA C950 for the appropriate operating pressure class.
The above requirements are intended to provide adequate strength for normal
handling and underground conditions. Pipe intended to withstand the end load
resulting from internal pressure at changes of direction or the beam load resulting
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from above ground installation shall require higher longitudinal strengths and a
suitably designed, fully restrained, jointing system.
f) Hoop Tensile Strength
GRP pipe systems shall meet the minimum hoop tensile strength requirements
specified in AWWA C950 standard for the appropriate operating pressure class.
However, the structural wall hoop tensile stress for pressure pipe shall not be less
than 120,000 kN/m2 when tested in accordance with AWWA C950 or BS EN 14364
AND BS EN 1796.
g) Hardness - Barcol (ASTM D 2583)
The laminated surface shall have Barcol hardness of at least 90% of resin
manufacturer's minimum specified hardness for the cured resin.
h) Joints
(i) Flexible Joints
Standard buried pipe with unrestrained joints shall be filament wound GRP coupling,
with confined rubber ring gaskets. Rubber rings shall be of natural rubber conforming
to BSEN 681–1 or ASTM F 477 for seawater service, and synthetic rubber for other
services. Neoprene rubber shall be used for oil contaminated services. Joints shall
allow for at least 0.75° deviation while remaining watertight at 1.5 times the pipe
operating pressure. The rubber rings shall be the sole element depended upon for
water tightness. This system will require thrust blocks at changes in direction to
accommodate thrust loads,
(ii) Rigid Joints
Flanges: GRP flanges where used shall be machine filament wound up to 1800mmø.
Contact moulded flanges may be used for sizes 2000mm and larger. Flanges shall be
manufactured with epoxy or vinyl ester resin. Flanges shall be flat faced with full or '0'
Ring type gaskets. Gasket material and design shall be as per the Manufacturer's
recommendations. The pipe Manufacturer shall provide the torqueing sequence and
maximum tightening torque as appropriate for each flange size and design and
should at least be present in a supervisory role during the torqueing of all flange
connections. Washers shall be used under all nuts and bolts heads with special
spacers to be used at flange to valve connections as required.
Flange drilling and rating shall be as specified on the drawings. Flanged joints shall
be tensile resistant for above ground service.
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(iii) Reinforced Overlay Joints (butt & wrap)
Butt & Wrap joint where used only for site modification or repair shall consist of layers
of Glass fibre reinforcement impregnated with resin. The wall thickness, tensile and
axial strength of the reinforced overlay shall meet or exceed the design strength of
the adjoining pipe sections.
Butt & Wrap joints on site shall be performed only by or under the supervision of the
pipe Manufacturer.
All of the joint types given in Clause 4.4.6.4 h) shall be designed to remain watertight
when tested after installation to 1.5 times the pipe line pressure for a minimum of one
(1) hour.
i) Workmanship
GRP pipe, fittings and joints shall be free from de-laminations, cracks, bubbles,
pinholes, pits, blisters, foreign inclusions and resin-starved areas that due to their
nature, degree or extent detrimentally affects the strength and serviceability of the
pipe. No glass fibre reinforcements shall penetrate the interior surface of the pipe
wall.
Joint sealing surfaces shall be free of dents, gouges, de-laminations, or other surface
irregularities that will affect the integrity of the joints.
GRP pipe, fittings and joints shall be as uniform as commercially practicable in colour,
capacity, density and other physical properties.
j) Fittings
GRP fittings such as bends, tees, junctions and reducers shall be equal or superior in
performance to the GRP pipe of the same diameter and pressure. All fittings shall
have a smooth internal surface with similar wall construction.
Standard fittings shall be filament wound or mode by mitered construction from

filament wound GRP pipes.
For GRP fittings, the deviation from the stated value of the angle of change of
direction of a bend, tee, junction etc. shall not exceed 1 degree.
The tolerance on the Manufacturer's declared length of fitting shall be 10 mm taken

from the point of intersection to the end of the fitting or 10 mm on straight fittings.
All GRP fittings shall be fabricated in the factory, by the pipe manufacturer, to ensure
Quality Control (Under no circumstance shall fabrication of fittings be allowed on site
by Contractor). Complex fittings arrangements may be pre-assembled by the pipe
Manufacturer in the factory such that field joints are kept to a minimum.
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4.4.6.5 Design Parameters
Pipe shall meet the following minimum design requirements:
Operating Pressure (Pw) Minimum 12 bar or as specified
Surge Pressure (Ps) 40% of ‘Pw' unless otherwise specified.
Vacuum (Pv) As specified.
Minimum Earth Cover 1 .0 m or as shown on drawings for

buried pipe.
Initial Installed Deflection for buried pipe 2.0% Min
Long term Installed Deflection for Buried 5.0% Max. (3.0% max for ribbed pipe
Pipe and 5% for solid wall pipe).
Service temperature As specified
Safety Factors > = 1.8
Pressure Rating > = 1.5
Ring Bending Strain (stress) > = 1.5
Combined Strain (stress) Buckling > = 2.5
The Contractor shall be responsible for implementing / installing the correct design for
each GRP pipe system.
Buried GRP pipe design shall be established in accordance with A WW A M45.

Support requirements for complex above ground piping systems shall be based on
computer flexibility analysis (static and dynamic) of the piping systems. Pipe
manufacturer’s Design calculations shall be submitted to the Engineer for review and
approval.
4.4.6.6 Inspection & Testing
The Manufacturer shall take adequate measures in the production of the products
covered by this specification to assure compliance with the requirements herein. An
Inspection and Testing plan (ITP) should be forwarded to the Engineer for approval.
Plant inspection by the Contractor’s or Engineers qualified personnel or the omission
of such inspections shall not relieve the Manufacturer of the responsibility to furnish
products complying with the requirements of the minimum manufacturing
requirements given herein.
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Production and Testing Notice - When plant inspection is required by the Contractor
or Client the Manufacturer shall provide adequate advance notice of when and where
production and testing of ordered products will commence.
The Contractor and / or Client Inspector (s) shall have free access with reasonable
advance notice to the Manufacturer's plant areas that are necessary to assure that
products comply with all requirements herein.
As a minimum the following tests shall be performed at the indicated intervals unless
otherwise agreed-upon, and shall form a part of the Manufacturers overall quality
control program.
The following test shall be conducted on every pipe;
- Visual Inspection
- Dimension Measurements
- Resin cure (Barcol Hardness)
The following tests shall be conducted on pipe samples at a frequency of not less
than one per 50 pipes (one lot) of the same Diameter and Pressure.
- Stiffness
- Hoop Tensile Strength
- Longitudinal Tensile Strength
- Loss on ignition (composition)
However, this sampling is not applicable for GRP pipe manufactured thru helical
winding process. The determination of strength properties may be treated as
qualification testing, provided the manufacturer declares the winding angle and
submits qualification test reports duly authenticated by third party.
Pipe hydrostatic pressure test shall be carried out on 100% of Pipes.
Test methods shall be in accordance with AWWA C950 and BS EN 14364 AND BS
EN 1796.
Copies of all test reports shall be submitted to the Client for each lot delivered to Site.
4.4.6.7 Marking
Each pipe and fitting shall be indelibly marked with the following information.
- Manufacturers Name or trademark

- Manufacturing date
- Manufacturing number
- Nominal diameter in mm
- Operating pressure in bar
- Nominal laying length in meter (for pipe only)
- Manufacturers Inspection mark
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- Applicable standard complying the product.
4.4.6.8 Submittals
The following information shall be submitted by the manufacturer.
a) Pipe Data Sheet (s)
b) Detailed Resin Data
c) Detailed Glass Reinforcement Data
d) Detailed Pipe Aggregate Data
e) Detailed Joint & Gasket Data
f) GRP Pipe Manufacturer's Pre-Qualification
g) Manufacturer's ISO 9001 Certification
In addition to the above information, the following shall be submitted during the
mobilization period:
a) Detailed manufacturing process for pipe, joints and fittings.
b) Detailed drawings for pipe ends, joints and fittings.
c) Complete pipe design calculations for each Diameter/Pressure.
d) Friction loss factors of pipes and fittings
e) Manufacturers Quality Control and Assurance Manual.
f) Proposed Inspection and Testing Program (ITP).
g) Pipe Manufacturers written handling, storage and installation instructions.
h) Proposed Hydrotest method statement
i) Proposed pipe transport procedures.
j) Qualification (Type) Test results and report for:
- Long term stiffness (Aging factors); for buried pipe only

- Long term hydrostatic Design Basis (HDB); for pressure pipe only
4.4.6.9 Installation (General Requirements)
- The Contractor shall submit the pipe Manufacturer's Installation Manual and
associated Data for engineer’s review. A site meeting to include the engineer,
the Contractor and Manufacturer is to occur within two weeks from Contract
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Award to clarify any outstanding issues / questions on the given installation

procedures.
- GRP pipe shall be handled, stored, transported and installed in strict
accordance to the Manufacturer written instructions.
- The pipe installation procedures and practices chosen shall meet the design
requirements specified.
- No stacking of pipe larger than 1.8 m in diameter shall be allowed on site or
during transport.
- Reinforced concrete thrust blocks shall be used at all changes in direction,
size reduction / expansion, and other thrust locations underground for
unrestrained pressure systems. Thrust blocks shall encase the entire GRP
fitting at the directional change and should be constructed to fully absorb all
thrust loads. Thrust block sizes may be reduced or eliminated by using an
axially restrained piping system utilising high axial strength GRP pipe and
fittings and a suitable restrained pipe joint design.
- Pipe deflection readings shall be taken and recorded on all buried pipe at
three meter intervals. Initial deflections shall not show a reduction in internal
vertical diameter as mentioned in Clause 4.7.13 of the specification.
- The Contractor shall employ on a full-time basis the services of field
representatives from the pipe manufacturer throughout the pipe off loading,
storage, installation and testing period.
- For standard buried unrestrained pipeline sections, a flexibly jointed short pipe
shall be incorporated outside rigid structures to provide pipeline flexibility
against differential settlement. A minimum of two (2) flexible joints on either
side of a rigid structure is required. The length of the short pipe shall be in
accordance with the manufacturer’s recommendation.
4.4.6.10 Onshore Buoyancy Considerations
Where the pipe is to be installed on-shore within water table level, proper
considerations have to be taken to prevent pipe flotation. In general, a minimum soil
cover equal to one pipe diameter should be kept above the, pipe crown to prevent
flotation.
GRP PIPE DATA SHEET (FOR EACH DIAMETER/PRESSURE/SERVICE)
(To be provided prior to start of pipe manufacturing)
Design Units
Parameters
Nominal : mm
Diameter
Pipe :
Manufacturing
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Process
Service
Rated : Barg
Working
Pressure
Joint Type :
Maximum : Barg
Allowable
Vacuum
Laying Length : m
Pipe Wall
structure
Nominal Wall : mm
Thickness
Inner Layer : mm
Thickness
Resin Type
Glass Type
Structural Thickness mm
Wall Resin
Type
Glass
Type
Outer Liner Thickness mm
Resin
Type
Glass
Type
Mechanical
Properties
Design Pa
Specific
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Tangential
Initial
Stiffness
Design Initial MPa

Longitudinal
Tensile
Strength
Design Initial MPa

Hoop Tensile
Strength
4.5 STORAGE AND HANDLING OF PIPES
4.5.1 General
Method Statements must be approved for the transportation, handling and storage of
pipes before any pipes are delivered to site. All pipes shall be handled and stored in
compliance with the manufacturer's recommendations subject to the following
limitations: - Pipes shall be transported, handled and stored with such packing and in
such a manner that damage does not occur and that contact is avoided with sharp
edges which may cause damage. During transit, pipes and fittings shall be well
secured and adequately supported along their length. At every point of loading or
unloading, all pipes or castings must be handled by approved lifting tackle unless
specified elsewhere. Unloading by rolling down planks or any other form of inclined
ramp will not be allowed. Pipes shall not be tipped or dropped. Pliable straps, slings
or rope shall be used to lift pipes, and steel cables or chains will not be used without
written permission. Nesting of pipes for transportation will be permitted provided
method statements demonstrate that effective precautions will be taken to protect
inner surfaces from damage. All pipes and fittings shall be thoroughly inspected on
arrival at site after off-loading and prior to installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other
damages, proposals for repairs shall be submitted in writing for the Engineer's
approval. If in the Engineer's opinion the nature of any damage is such that the
condition of a pipe has been impaired and cannot be repaired, the pipe concerned
shall not be incorporated in the Works. Suitably smooth and level storage areas
shall be provided at or near the site and made secure to prevent unauthorised
access. Pipes of different sizes and thickness shall be stocked separately.
4.5.2 Glass Reinforced Plastic Pipes (GRP)
When pipes are transported or stacked they shall be supported on cradles at least
100 mm wide, conforming to the shape of the pipe placed at not more than 3 metres
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centres. Pipes must on no account be stacked directly on the ground but if individual
pipes are placed on the ground prior to laying care shall be taken to remove all rocks
and any potentially damaging debris. The number of layers in a stack shall not
exceed the following:
Internal Diameter of Pipes (mm) Maximum Number of Layers
Up to 500 5
500 to 700 3
The end pipes in each row shall be strapped to the battens. Pipes shall not rest on
their sockets.
4.5.3 Thermoplastic Pipes (uPVC)
Pipes and fittings of plastic materials smaller than 300 mm diameter may be handled
manually and those equal or larger than 300 mm diameter shall be lifted using a
single fabric or large diameter rope sling. There shall be enough slack in the sling to
keep the hook at least 600 mm over the pipe. Use of wire rope chains and forklifts
shall not be permitted. Care shall be taken to prevent distortion of the pipes during
transportation, handling and storage. They shall be stacked either on bearing timbers
on a level surface staked to prevent movement, or in suitable racks. Not more than
two layers shall rest on the bottom layer, and for spigot and socket pipes, sockets
shall be at alternate ends so that no pressure comes on a socket. Bearing timbers
shall be spaced at not more than 1 metre and shall be wide enough to prevent
denting of the pipe wall. Sharp edges (e.g. of metal) shall be avoided. Similar care
shall be taken with pipes in transit. Where shaped battens are used, they shall be at
least 100 mm wide and not more than 1.5 meters apart. The end pipes in each row
shall be strapped to the battens. The pipe shall not be stacked any higher than five
(5) layers. All thermoplastic pipes shall be shaded/protected from direct sunlight
during handling, transportation, storage and laying. The Contractor shall ensure that
thermoplastic pipes do not come into contact with bituminous or other hydrocarbon
based materials.
4.5.4 Reinforced Concrete Pipes (RCP)
Store pipes and fittings on a flat level area and raise above the ground on timber
bearers so that the lowest point of any pipe or fitting is not less than 150mm above
the ground. Provide timber bearers at spacing recommended by the pipe
manufacturer.
All coated pipes must be protected from UV exposure during storage.
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Store rubber joint rings in a well ventilated place, free from exposure to sunlight and
in their original packing until they are needed.
4.5.5 HDPE Pipes
Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or crated,
remain on the pallets or in their crates until required.
- Stack non-crated pipes to the approval of the Engineer.

- Stack pipes of different sizes and thickness separately.
Do not allow stacked pipes to exceed 2m in height or as recommended by the

supplier whichever is the lesser.
Scratching or scoring of pipe surface to a depth greater or equal to 10% of wall

thickness shall constitute an automatic rejection of that pipe section.
4.6 GRANULAR MATERIAL FOR PIPE BEDDING AND SURROUND
Granular material for pipe bedding & Surround shall be free-draining, hard, clean,
chemically stable gravel or crushed stone and shall be graded in accordance with the
following table:-
Table 4.3a Grading of Granular Material for Pipe Bedding and Surround
Test sieve (mm) Percentage by Weight Passing Sieve
For pipe diameters up to For pipe diameters

600mm 400mm and above
63 - -
37.5 - -
20 - -
14 100 85-100
10 85-100 0-50
5 0-25 0-10
2.36 0-5 -
Notes:
a) For pipes 400 mm to 600 mm diameter, either grading is acceptable.
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b) Total acid soluble content of the material when tested in accordance with BS1377
shall not exceed 0.3 percent by weight of sulphate expressed as SO3 (sulphur
trioxide).
c) The material shall have a Compaction Fraction value not exceeding 0.10.
d) For uPVC pipes only rounded aggregates will be permitted but for all other pipe
materials crushed aggregates may also be used.
4.6.2 Stone for Land Drains
Stone for land drains shall be nominal single size 20 mm in accordance with the
following table or the manufacturer’s recommendations if different, and placed as
shown on the drawings.
Table 4.3b Grading of Stone for Land Drains
Test sieve (mm) Percentage by Weight

Passing Sieve
75 -
63 -
37.5 100
20 85-100
14 -
10 0-25
5 0-5
2.36 -
4.6.3 Compaction Fraction Test
The compaction fraction test shall be carried out in accordance with BS EN 752 APP:
D.
For testing pipe bedding material, a representative sample of about 40 kg shall be

heaped onto a clean surface and quartered to obtain approximately 10 kg. The
moisture content of the sample should not differ materially from that of the main body
of material, at the time of use in the trench. A 150 mm internal diameter open ended
cylinder 250 mm high, shall be placed on a firm flat surface and loosely filled, without
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tamping, from the 10 kg sample. Any surplus material shall be struck off level with the
top of the cylinder. The area around the filled cylinder shall be cleared of all surplus
material and the cylinder then lifted clear of its contents and placed alongside the
material. Approximately one quarter of the material shall then be replaced into the
cylinder and compacted by tamping vigorously with a 40 mm diameter metal rammer
weighing about 1 kg until no further compaction can be obtained. This operation shall
then be repeated for each of the remaining quarters, tamping the final surface as
level as possible. The distance from the top of the cylinder to the surface of final
layer shall then be measured and this value, divided by the height of the cylinder,
shall be taken as the Compaction Fraction.
4.7 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION
4.7.1 General
This section applies to conventional open-trench pipe works.
4.7.2 Nominal Trench Width for Flexible Group ‘B’ Pipes
Nominal trench widths for single pipelines shall be defined as 1.50 times the diameter
plus 500 mm, subject to a minimum trench width of 750 mm.
Nominal trench widths for two or more pipes in the same trench (laid in parallel with
similar invert levels) shall be defined as the sum of the internal diameters plus 450
mm between the pipes, plus 750 mm. Any excavation from the bottom of the trench
to 300 mm above the level of the crown of the pipe which exceeds the nominal widths
defined above shall be filled with concrete or the specified bedding materials as
directed on site. A detailed method statement shall be submitted by the Contractor
for agreement by the Engineer to demonstrate an understanding of the correct
method of laying GRP and other pipes.
4.7.3 Pipelines in Wide Trenches
No wide unsupported trenches shall be permitted, in general, within the area of the
Works and therefore all trenches should conform to the minimum trench widths stated
above and shall be supported with the use of approved trench sheeting or sheet
piles. However in exceptional circumstances wide trenches may be approved by the
Engineer in which cases the following shall apply: -
- Wide trenches shall be constructed to not less than the defined widths for
those categories of Group B flexible pipelines in granular bedding defined
below.
- Prior to commencing trench excavation in an area an assessment of the
Modulus of Deformation (E's) shall be made of the soils likely to be
encountered at springing level of the pipes. In non-cohesive soils, approved
static cone penetrometer tests shall be carried out prior to excavation. In
cohesive soils other approved methods shall be used to determine E's.
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Alternatively, standard SPT & CPT tests may be required by the Engineer
prior to excavation to suite pipe manufacturer’s standard method of deflection
and trench widths. Tests shall be carried out in accordance with BS 5930 at
intervals to be determined on site which in variable ground conditions may be
to every pipe length and its cost shall be inclusive of trench excavation without
any extra cost.
- If the value of E’s determined from the results of such tests is greater than 2.5
MN/m2 then trench width is not critical. If less than 2.5 MN/m2 then trench
widths shall be constructed to the widths defined in the following table unless
alternative means of increasing the passive resistance of the trench sides are
detailed or are proposed in method statements where economic or
environmental restrictions make wide trenches undesirable.
Table 4.4 Wide Trench Widths for Non-Cohesive Soils
Static Cone Modulus of Deformation Wide Trench Widths

Penetrometer Test E’s (MN/m2) (mm)
(kg/cm²)
8.5-7.7 2.50-2.25 2.5 x dia
7.7 - 6.1 2.25 - 1.80 3.0* dia.
6.1 – 3.1 1.80 - 0.90 4.0* dia.
3.1 0.90 5.0* dia.
Alternative solutions to wide trench conditions may be adopted including permanent

sheeting increasing stiffness of the pipes used or encasing with reinforced concrete
as agreed by the Engineer subject to Pipe manufacturer’s recommendations.
4.7.4 Pipe Laying and Jointing
Pipes and fittings shall be laid and jointed in accordance with all relevant
recommendations of the manufacturer. Any variations between the manufacturer’s
recommendations and this specification shall be highlighted in the Contractor’s
Method Statements and a ruling will be given with the Engineer’s agreement.
Pipes and fittings shall be checked for soundness and be thoroughly cleaned out
immediately prior to laying and jointing. The setting of the pipeline to the required
levels and alignment shall be carried out by approved procedure such as boning
between sight rails or the use of laser systems. Sight rails, if used, shall be at a
suitable height vertically above the line of pipes or immediately adjacent thereto, and
there shall, at no time, be less than three sight rails in position on each length of
pipelines under construction to any one gradient. Large diameter pipes, 1000 mm
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diameter or greater, shall be individually set to level and line by instrument. For
pipelines laid in trenches and headings the permissible tolerances in line and level
unless otherwise specified shall be ± 3 mm in level and ± 12 mm from centerline
between manholes or access points. Also where a gravity pipeline or sewer is shown
as a straight line between manholes it will not be accepted as having passed the final
test unless a full circular light can be sighted through the bore of the pipe for the
length concerned.
For pipeline jointing systems incorporating flexible jointing rings pipes shall be laid
with a gap between the end of the spigot and the base of the socket, or between
spigots. This gap shall be not less than 6 mm or greater than one third of the straight
draw test dimension specified in CL. 4.1.2.1 for the pipe joint or as recommended by
the pipe manufacturer, and it shall be achieved by approved means, such as marking
the outside of the pipe or using removable metal or hardwood feelers. The annular
space between the pipe and the socket at a flexible joint shall be sealed with an
approved joint sealant to prevent the ingress of loose material or concrete. Sealing
shall be done on completion of a satisfactory preliminary testing prior to concreting or
backfilling, but not prior to the test. For uPVC pipes solvent welded joints with parallel
sockets shall not be permitted unless made in the manufacturer's workshop.
Where flexible jointed pipes are laid to curves the angular displacement at any joint
as laid shall not exceed three quarters of the maximum recommended by the
manufacturer. Flanged pipes shall incorporate an annular gasket at the joints. The
gaskets shall cover the full face of the flange and shall have holes cut in the
corresponding to the bolt holes in the flanges. However, in pipes fixed vertically a
plain ring covering the flange between the bolt circle and the bore of the pipe may be
used. Gaskets shall be manufactured as specified in Clause 4.1.2.2. When flanged
joints are to be made the Contractor shall follow manufacturer’s guidelines for the
tightening of nuts and bolts. The Contractor shall make sure that all joints are made
strictly in accordance with the manufacturer’s instructions. Pressure pipelines shall
be secured at all changes in direction by concrete anchor blocks or other means of
restraint approved in advance by the Engineer. After laying a length of pipeline but
before preliminary testing is carried out, the pipeline shall be checked for level and
gradient on top of the pipes. If a pipe is not at the correct level, it shall be un-jointed
and removed, the bed shall be adjusted and the pipe shall be re-laid and rechecked
for line and level. After the joint has been made and the preliminary testing completed
the annular gap at a socket or collar outside the flexible jointing ring shall be closed
with fine grained clayey soil or cotton waste to prevent the entry of granular material.
Pipelines shall be temporarily capped when pipe laying ceases to prevent the ingress
of foreign matter. The Contractor shall ensure that the pipes remain clean and free
from obstructions, and if required by the Engineer, the pipelines shall be cleaned out
using approved methods and equipment which do not damage the internal lining of
the pipes and manholes.
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4.7.5 Pipelines in Concrete Cradles and Surrounds
Where pipes are to be laid with a concrete cradle or surround they shall be supported
initially above the trench bottom on concrete setting blocks. The blocks shall either be
laid accurately to level and covered with damp-proof sheeting beneath the pipe barrel
or shall be provided with two hardwood wedges each to an approved pattern to
enable the pipe level to be adjusted. The blocks and wedges shall be of sufficient
size and strength to prevent settlement of the pipes during laying and at least two
concrete blocks shall be provided for each pipe. Concrete cradles and surrounds
shall be RCC with Class C40/20 SRC Concrete. The concrete shall be poured on one
side of the pipe until it can be worked under the pipe along its full length to ensure
that no voids develop. The concrete shall then be brought up equally on both sides of
the pipe until the required level is reached. The length of pipeline laid in any one
operation before concreting the pipeline shall be that which in the opinion of the
Engineer permits accurate laying of the pipeline and concreting in an efficient and
proper manner. Approved measures appropriate to the pipe material shall be
provided to prevent flotation or other movement during placement or curing of the
concrete. Concrete cradles to pipes of all diameters and surrounds to pipes of one
metre diameter or less shall be poured in a single lift. Concrete surrounds to pipes
over one metre diameter shall normally be poured in two lifts, with a horizontal joint
not more than 100 mm below the crown of the pipe. Concrete cradles and surrounds
shall be interrupted over their full cross sectional area at each pipe joint, by shaped
expansion joint filler. The thickness of filler shall be 18 mm for pipe diameter less than
450, 36 mm for pipe diameter 450 to 1200 and 54 mm for pipe diameters greater than
1200. In spigot and socket pipelines the joints in the bed shall be at the face of each
socket. In all flexible joints the annulus of the pipe socket shall be sealed with an
approved sealant to prevent the concrete from entering the pipe joint. When support
to excavations is provided, building paper or an approved material shall be placed
against that support before concreting to facilitate withdrawal of the support.
4.7.6 Pipelines on Granular Beds
Where granular beddings to pipelines are detailed the minimum thickness of bedding
material beneath the pipe shall be:
- 150 mm (minimum 100 mm under sockets) for pipes not exceeding 300 mm
internal diameter.
- 200 mm (minimum 100 mm under sockets) for pipes exceeding 300 mm
internal diameter.
The time interval between placing bedding material on the trench formation and
commencing pipelaying shall be as short as is practicable. The bedding material
shall extend to the full width of the trench and shall be compacted in layers not
exceeding 200 mm. The bedding material shall be carefully compacted using a plate
vibrator or other approved equivalent mechanical method. Sufficient passes of a plate
vibrator or other approved mechanical method are required to achieve positive
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deflection of flexible pipes to ensure that final deflections are within the specified
limits. Hand tamping or punning will only be permitted where insufficient space is
available to allow the use of mechanical plant.
Recesses shall be formed in the bedding to accommodate pipe joints while ensuring
continuous even support along the pipe length. Bedding material shall be prevented
form entering pipe joints. After the joint has been made bedding material shall be
carefully placed and hand compacted beneath the joint barrel to close any void left by
the recess.
Where the formation of the trench is of silt or soft clay and is below the natural water
table a 150 mm thick layer of cement stabilised road base material shall be
substituted after removal of soft material directly above formation and carefully
compacted to 95% of its MDD/ OMC if directed on site. The specified bedding
material shall be used above the road base layer.
4.7.7 Placing Surrounds to Pipelines
In narrow trenches and where the Contractor's method of working involves the use of
trench sheets or other forms of trench support it is imperative that the trench supports
are carefully withdrawn to a point above the crown of the pipe as the backfill material
is placed to ensure that voids between surround and trench side will be eliminated.
Where the Contractor is instructed to leave trench supports in place, the tops shall be
burned or cut off.
4.7.8 Group A Rigid Pipes Bedding, Surround Materials and the Trench Width
Except where concrete surrounds are specified or shown on the drawings, either
granular bedding material or approved selected excavated granular material shall be
introduced at bed, surround the pipe and compacted until it has been brought up to at
least 100 - 150 mm above the crown of the pipe.
The nominal trench width for the pipelines of single, twin or multiple pipes in the same
trench shall be as shown in the drawing. The methods of selecting excavated
materials may include seiving either in bulk or above the trench. Wherever
practicable the placing and compaction of the surround material shall be carried out in
sequence with the removal of the trench supports. In particular trench sheets or
boards shall be raised clear of each layer prior to its compaction. The granular
material shall be enclosed in approved filter fabrics to prevent the migration of native
soil.
4.7.9 Group B Pipe Materials
Except where concrete surrounds are detailed Group B flexible pipelines shall be laid
with granular bedding and surround, as specified, to at least 300 mm above the
crown of the pipe.
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4.7.10 Compaction of Pipe Surrounds
The granular material shall be carefully laid and compacted at the sides of pipes
according to one of the following methods for alternative types of compaction plant as
agreed with or directed by the Engineer.
Table 4.5 Alternative Methods for Compaction of Pipe Surrounds
Surround Max. Alternative Methods (Minimum Number of Passes of

Material Layer Compaction Plant)
Thickness
Hand Rammer Vibrating Plate 100 kg Power
Rammer
Gravel 200 2 2 2
Sand 150 3 4 4
The Contractor must demonstrate that alternative methods of compaction will provide
positive deflection of flexible pipes during installation.
4.7.11 Pipelines below Permanent Groundwater Level
For Group A and B pipelines located beneath the permanent groundwater level and
for all slotted pipes any granular bedding material or approved selected excavated
granular material forming granular bedding and surround shall be laid on and
enclosed within a geotextile filter fabric membrane.
4.7.12 Backfilling of Trenches - Pipelines/Structures
After completion of placement and compaction of the surrounds to the pipelines

backfilling of trenches for pipelines shall proceed using selected excavated materials
in accordance with the specifications for earthworks. The use of power rammers will
not be permitted over any pipe until the depth of fill above the crown of the pipe is at
least 300 mm. Services warning tapes shall be placed over the pipelines as specified
in Clause 4.7.20.5. The backfill requirements for trenches around structures shall be
the same as that for pipeline except that compaction by mechanical means shall
commence from the formation level (to the specified densities).
4.7.13 Deflection Measurements on Group B Pipelines
All Group B pipelines will be subjected to in-situ deflection measurements. Any

section of pipe failing to meet the deflection criteria shall have its surround material
recompacted, such procedure being repeated until the in-situ deflection is found to be
satisfactory. In the above paragraph deflection shall be considered as the maximum
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difference between the measured in-situ diameter and the stated non-deflected
diameter on any axis divided by the non-deflected diameter.
For all pipes the horizontal and vertical deflections shall be measured at each end at
points 100 mm and 1.5 m away from the joint and at 3.0 m intervals thereafter, or as
directed by the Engineer. For pipe lengths of less than 3.0 m these deflections shall
be measured at each end at a point 100 mm away from the joint and at the mid-point.
For pipelines smaller than 600 mm diameter deflections shall be checked by pulling
through an approved cylindrical plug dimensioned to suit the permissible minimum
deflected diameter of the pipe. Alternately, a deflectometer of a form that can be
drawn through the pipeline and be capable of measuring diametric dimensions both
vertically and horizontally may be used for deflection measurement of pipes of
diameter less than 600 mm. The deflectometer shall be calibrated for each diameter
regularly in the presence of the Engineer to maintain the accuracy of the instrument.
The device shall also provide a means of identifying where each deflection
measurement was taken along the length of a pipeline. This shall be in the form of
either a continuos printout or a visual display on a remote monitor. For pipes of 600
mm diameter and greater the device shall be in the form of a telescopic spring loaded
rod graduated for each diameter to show percentage deflections. The Contractor
shall tabulate the results of the measurements and copies shall be submitted to the
Engineer immediately after each set of measurements has been taken.
For pipeline of 1000 mm diameter and above the deflection measurements shall be
taken manually. Reading shall be taken at each pipe end on each side of a pipe joint,
at the quarter, mid and three quarter point of each pipe length and at any other joints
directed by the Engineer.
4.7.14 Deflection Measurements - GRP Pipes
The measurement shall be taken on at least three separate occasions:
a) After the pipe surround material has been placed and compacted to 300 mm
above the pipe crown.
b) On completion of all backfill material up to final ground level but before the
dewatering is removed. This measurement shall be taken at least two weeks
after the completion of backfilling.
c) Immediately prior to the issue of a Certificate of Completion. All pipes exposed

for recompaction and pipes replaced for any reason shall subsequently be subject
to the three deflection checks listed above. Deflection checks shall also be
carried out on adjacent pipes for 50 m either side of the recompacted or removed
pipes.
4.7.15 Deflection Measurements - uPVC and other Plastic Pipes
The measurement shall be taken on at least two separate occasions:
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a) As soon as a pipeline has been installed, tested and the trench backfilled, but
before the dewatering is removed.
b) Immediately prior to the issue of a Certificate of Completion. If any of these tests

indicate that the deflection may exceed the permitted values of the pipe or pipes
shall be replaced. Any pipe removed for this reason shall be taken from site and
not incorporated in the permanent works. All pipes replaced for any reason shall
subsequently be subject to deflection checks as described above. Deflection
checks shall also be carried out on adjacent pipes for 20 m either side of the
removed pipes.
4.7.16 Deflection Criteria on Group B Pipelines
Pipes will be regarded as damaged and shall be removed from the trench and
condemned of their in-situ deflection at any time exceeds the values stated in the
following Table:
Table 4. 6 Deflection Measurements on Group B Pipelines
Type of Pipe Deflection Criteria %
Material SDR After At least two Damaged and

Completion of weeks after not to be
Surround completing reused
Permissible the trench
range vertical backfill.
diameter Maximum
elongated only measured in
any plane
uPVC 10 - 15 0 – 1.0 1.0 2.25
uPVC 15 - 25 0 – 1.5 2.0 3.75
RP 30 - 40 0 – 1.5 2.0 4.50
RP 40 - 50 0 – 2.0 2.5 5.25
uPVC 25+ 0 – 2.0 2.5 5.0
RP 50+ 2.50 3.0 7.5
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PP 15+ 2.50 3.0 7.0
HDPE 10+ 2.50 3.0 7.0
‘SDR’ is the Standard Dimension Ratio, which is the ratio of pipe external diameter
divided by pipe wall thickness.
The deflection percentage shall be calculated as:
𝐴𝑐𝑡𝑢𝑎𝑙 𝐼𝐷 𝐼𝑛𝑠𝑎𝑡𝑙𝑙𝑒𝑑 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝐼𝐷 100 𝐴𝑐𝑡𝑢𝑎𝑙 𝐼𝐷
Actual ID may be determined by measuring the diameter of a pipe not installed laying
loose on a plane surface.
𝐴𝑐𝑡𝑢𝑎𝑙 𝐼𝐷 𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝐼𝐷 𝐻𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝐼𝐷 2
4.7.17 Stanks to Pipelines in Granular Bedding
Where pipes are laid on a granular bed or with a granular backfill, a stank, i.e. an
impermeable barrier, shall be provided across the full width of the trench and for the
complete depth of the bedding at intervals not exceeding 50 m, and generally mid-
way between manholes or chambers. The stank shall consist of:- Either a 300 mm
long plug of fine grained clayey soil or a 300 mm long plug of a mixture of sand and
bitumen consolidated in an approved manner. Or a mixture of sand and clay or the
local material known as sabkha compacted to form an impermeable barrier at least
one metre in length. Or a layer of thick polyethylene cut to fit around the pipe across
the full width of the trench and laid on the granular bedding material at its natural
repose angle. All methods must form an impermeable barrier. Bitumen shall not be
used for thermoplastic pipes.
4.7.18 Thrust and Anchor Blocks to Pressure Pipelines
Underground pressure pipelines shall be provided with concrete blocks as follows:-
Thrust/anchor blocks shall be provided at every installed bend, tee or angle branch.
Anchor/thrust blocks shall be provided on pipelines laid to gradients steeper than
1:20, up to 1:15 every third pipe shall be anchored, up to 1:10 every second pipe and
at 1:5 every pipe shall be anchored. Concrete shall extend to undisturbed ground on
thrust faces of thrust blocks and on both faces of anchor blocks. Where details are
not shown on the drawings the Contractor shall prepare proposals for thrust and
anchor blocks including calculations and submit them to the Engineer's
Representative for approval. Such approval shall not relieve the Contractor of his
responsibility for the adequacy of his proposals. Special details shall be shown on the
drawings or instructed at site where environmental or ground conditions dictate.
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4.7.19 Pipes Protruding from Structures, Concrete Surrounds and Anchor Blocks
Unless otherwise detailed a pipeline at or below ground level protruding from a

structure shall have two flexible joints adjacent to the structure. A band of an
approved concrete encasement rubber shall wrap around the pipe prior to placement
of any concrete such that the rubber protrudes 25 mm from the concrete. The pipe
shall be laid so the distance to first exposed flexible joint and the distance between
first and second joint are as follows:-
Table 4.7 Requirements for Flexible Joints for Protruding Pipes
Pipe Diameter Maximum Distance between first and second

(mm) distance to first joint (mm)
joint (mm)
Min Max
Up to 300 150 450 2.5* dia.
300 to 1000 300 1.5* dia. 2.5* dia.
above 1000 450 1.5* dia. 2.5* dia
In the case of Group B pipe materials, particular attention will be placed on elliptical
deflection conditions.
These joints will be required at surrounds and anchor blocks unless directed
otherwise on site.
a) Group A Pipe on Disturbed Ground
Between the structure and the first joint any disturbed ground below the pipe shall be
removed and replaced with Class C 40/20 concrete in the form of a cradle, all to the
direction of the Engineer. The cradle shall not extend beyond the first joint.
Beyond the first flexible joint within the excavated working space of the structure the
concrete fill shall be brought up 300 mm below the pipe invert only. Specified bedding
materials will then be used.
b) Group B Pipe on Disturbed Ground
Within the excavated working space for the structure disturbed ground below the pipe
shall be removed and replaced with Class C 40/20 concrete to within 300 mm of the
underside of the pipe. Specified bedding materials will then be used to support the
pipe. The width of the concrete backfill shall not be less than the nominal trench
widths except for any permanent shuttering against temporary trench supports to
facilitate removal of such trench supports after concreting. Where a flexible pipe
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passes through a rigid concrete face to a structure or surround the pipe shall be
protected from stress concentration and possible fracture of the pipe at the concrete
face. A 10 mm thick neoprene or other approved synthetic rubber strip complies to
BS 4255 Gr: L or ASTM C864 shall be wrapped around and cemented to the pipe
unless special wall protection units are used. The neoprene will normally extend
through the width of a wall to a dry chamber or structure but will be limited to 150 mm
or 100 mm is exposed to liquid (groundwater or liquid inside the structure) a sealant
groove shall be formed if detailed and filled with an appropriate, approved, joint
sealant.
The neoprene rubber properties shall be as described below:
Specific Gravity 1.5 gm/cc
Hardness 70+ / -5 shore – A
Tensile strength 35 kg / cm²
Elongation at break Min 250%
Abrasion resistance 450 mm³
Compression set 35%
Tear Resistance 12 kg/cm
Temperature range -20 / +100°C
Care shall be taken to ensure that the rubber strip is not displaced during concreting.
Where a pipeline protrudes from a concrete surround, no protection from stress
concentration will be required if the surround ends at a flexible joint leaving the next
pipe free. If the surround ends on a pipe barrel the specified protection will be
provided and, for pressure pipes only, the protruding pipe will be wrapped from the
edge of the neoprene strip along to the next flexible joint at which the concrete
surround is interrupted with an approved compressible material such as damp-proof
sheeting or building felt of minimum thickness 2 mm.
4.7.20 Protection of Pipelines and Pipeline Component
4.7.20.1 Pipelines
Protection of pipelines shall be in accordance with the manufacturer’s

recommendations which shall be included with submission details for agreement by
the Engineer. The minimum requirements are shown below:
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C 40/20 SRC concrete protection slabs as detailed on the drawing shall be provided
over the uPVC pipelines under roads when cover to pipe is equal or less than 1.2 m
for a gravity line; and for pressure line at any depth. In case of GRP pipe crossing
under the road RCC concrete surround shall be provided as per drawing if the depth
of cover is less than 1.5 m.
4.7.20.2 Pipeline Components
All buried valves, couplings, flange adaptors, and other metal components shall be
encased to guard against corrosion. Other pipe joints, valves and similar items on
both buried and exposed pipelines shall be encased where specified or shown on the
drawings.
The encasing shall be by one of the following methods, as detailed.
(i) Surrounding with Class C 40/20 concrete.
(ii) Enclosed by an approved hot-poured bitumen compound.
(iii) Wrapped with tape.
Method (ii) shall not be used with plastic pipes. The item to be encased shall first be
cleaned and its original surface treatment made good.
The surface shall be dry before encasing is carried out, which shall not be done
before the pipeline has been tested. The bitumen compound shall be cast in
purpose-built moulds in accordance with instructions issued by the supplier. The
protective wrapping tape shall be open-weave cotton or synthetic fibre or woven glass
fibre coated on both sides with an even coat of petrolatum (petroleum jelly) containing
a filler. The tape and paste shall be suitable for use in the prevailing climatic soils
pumped liquid and ground water conditions.
Before wrapping with tape the item to be encased shall be enclosed with an approved
mastic or inert putty-like filler which shall be moulded by hand so as to provide a
smooth surface for the tape. The tape shall be tightly spirally wrapped with 25 mm
overlaps so as to enclose the whole of the item and a minimum of 150 mm of pipe
length on each side. The enclosure shall be firmly pressed out to prevent air being
trapped under the wrapping.
4.7.20.3 Indicator Posts to Pressure Mains
Where pressure mains pass through open ground, not adjacent to roads, or where
the danger of accidental breakage by excavation is evident, the Engineer may instruct
the erection of indicator posts of an approved design. Details of the indicator post
construction and spacing shall be shown on the drawings or be directed by the
Engineer. The depth, location and size of the pressure main shall be detailed in
Arabic and English, to be an approved design, on an engraved plastic or non-
corrodible plate attached to the post. In addition at all air valve chambers, the
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Contractor shall erect indicator signs on posts, to an approved design, at locations

described to him by the Engineer.
The words ‘Warning Gas on Entry’ together with an appropriate pictorial

representation shall be detailed.
4.7.20.4 Enclosing Granular or Stone Surround with Geotextile Filter Fabric
The granular bedding and surround to all slotted pipes and pipes laid below the
permanent groundwater level shall be enclosed within a geotextile filter fabric.
Filter fabric used for subsurface drainage works shall consist of long-chain of
synthetic polymer fibres. They shall be formed into network such that the filaments or
yarns retain dimensional stability relative to each other, including selvages.
The Fabric stabilized against ultra-violet light, inert to commonly encounted chemicals
in the in-situ soil and water, and it shall confirm to the following requirements.
Table 4. 8 Requirements for Geotextile Fabric for Subsurface Drainage
Property Test Method Minimum required
CBR Puncture Resistance BS EN ISO 12236, DIN 1250 N (min average)

54307
Trapezoidal Tear ASTM D 4533 300 N

Resistance
Mean Flow Rate EN ISO 11058, BS EN 45 – 100 l/m2/s

ISO 12958
Apparent Opening Size EN ISO 12956, ASTM D 50 – 180 microns

4571
UV Degradation (Percent ASTM D 4355 70% strength retention

Retained Strength) after 150 hrs exposure
Mass Per unit Area BS EN ISO 9864 120 g/m2 (Minimum)
The fabric shall be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with surround to
the correct level the filter fabric shall be closed over the top of the surround by
forming a ‘lap’ of minimum width 500 mm. All membrane joints shall be overlapped a
minimum of 500mm.
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Care shall be taken not to puncture or damage the membrane in any way during
installation during backfilling of the trench. Any fabric damaged or displaced before or
during installation or during placement of overlaying aggregate material shall be
replaced or overlaid to the satisfaction of the Engineer at the Contractor’s expense.
During period of shipment and storage, the fabric shall be maintained wrapped in a
heavy-duty protective covering and protected from direct sunlight, ultra rays and
temperatures greater than 70°C.
4.7.20.5 Underground Services Warning Tapes
Service protection tapes shall be installed above all sewage, drainage irrigation,
water, DEWA, fire fighting and gas pipelines and pressure mains constructed or
exposed under this contract excluding individual service connections. For pipelines
with the top of the pipe barrel more than 900 mm below finished surface level the
tape shall be placed over the centreline of the pipeline at 600 mm below finished
surface level during backfilling and compaction operations. For pipelines with less
than 900 mm cover to the top of the pipe barrel the tape shall be placed over the
centreline of the pipe at 300 mm above the top of the pipe barrel during backfilling,
compaction and reinstatement operations. The tape shall be continuous over
pipelines and at joints between tapes from separate rolls the joint shall be lapped a
minimum of one metre.
Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions
at pH values of 2.5 to 11.0 inclusive. The tape shall be 150 mm wide and 250 micron
thick and produced as a strong 4 layer composite laminate consisting of: -
(i) 12 Micron polyester film top layer with reverse printing
(ii) 50 Micron pigmented polyethylene
(iii) 12 Micron detectable aluminium foil in between
(iv) 176 Micron bottom layer polyethylene.
(v) The thickness of the tape (250 micron / 1000 gauge) shall be measured in
accordance with BS 2782 : Part 6. Method 630 A.
The following properties shall be demonstrated by appropriate tests:
a) Physical properties (Average of 5 tests)
Tensile strength Longitudinal (MD):160 N (Minimum)
(BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)
Elongation (PE only)
(BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%

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Tear strength MD : 640 gram force
BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum
Dart Impact
BS 2782 : P3 : 352F : 1996 1000 grams minimum
b) Chemical resistance
The tape shall remain legible and colour fast in all soil conditions at PH 2.5 – 11.0,
inclusive. The tape shall not show any adverse effect when in contact with the
sulphates, chlorides and other minerals present in sub soil and water, oil, 5% Acetic
Acid, 5% NaOH and Alcohol mix, if any.
Chemicals Temperature Test Duration Test Method
Diesel Fuel 50°C 30 Days ANZ 4275.4:1995
pH –2.5 (1% H2SO4) 50°C 30 Days
pH –2.5 (with Hydrochloric 50°C 30 Days

Acid)
pH –11.0 (10% Conc. 50°C 30 Days

Sodium Hydroxide)
Saturated Sodium nitrate 50°C 30 Days

solution
Acid Soluble sulphate (with 22 ±2°C 30 Days

CaSO4)
Sea water 50°C 30 Days
Wastewater with hydrogen 22 ±2°C 7 Days

sulphide (30 ppm)
Ammonium Hydroxide (NH3) 50°C 15 Days
Ammonium Hydroxide (NH3) 22 ±2°C 30 Days
Note: After the chemical exposure of the supplied warning tape, the surface printing
should be intact without delamination and corrosion. Relevant independent lab test to
be conducted on supplied tape sample and comply with the requirements prior to the
use on site.
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Detectablility after installation and back filling Text in Arabic and English indicating
the protected services lying below the tape shall be permanent ink bonded to resist
prolonged chemical attack by corrosive acids and alkalis with the message repeated
at a maximum interval of two metres. Tapes shall be colour coded as follows, with
black text as indicated. The sign and styles of the text shall be approved by the
Engineer.
Sewers Blue
CAUTION Sea Pipeline below
Sewers Yellow
CAUTION Sewer below
Sewage pressure mains Yellow
CAUTION Sewerage pressure main below
Drains Yellow
CAUTION Drain below
Drainage pressure main Yellow
CAUTION Drainage pressure main below
Irrigation pressure mains Orange
CAUTION Irrigation pressure main below
Potable Water & As per DEWA Specification

electricity cable
Fire fighting As per Civil Defence Requirements
Gas Red Dangerous Sewer Gas
The Dubai Municipality logo shall be printed on the tape between the spaces of the
repeated messages. The Dubai Municipality logo and its colours shall be as shown
below.
CBR Puncture Resistance BS EN ISO 12236, 1250 N (min average)
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DIN 54307
Trapezoidal Tear ASTM D 4533 300 N

Resistance
Mean Flow Rate EN ISO 11058, BS 45 – 100 l/m²/s

EN ISO 12958
Apparent Opening Size EN ISO 12956, ASTM 50 – 180 microns

D 4571
UV Degradation (Percent ASTM D 4355 70% strength retention

Retained Strength) after 150 hrs exposure
Mass Per unit Area BS EN ISO 9864 120 g/m² (Minimum)
The fabric shall be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with surround to
the correct level the filter fabric shall be closed over the top of the surround by
forming a ‘lap’ of minimum width 500 mm. All membrane joints shall be overlapped a
minimum of 500mm.
Care shall be taken not to puncture or damage the membrane in any way during
installation during backfilling of the trench. Any fabric damaged or displaced before or
during installation or during placement of overlaying aggregate material shall be
replaced or overlaid to the satisfaction of the Engineer at the Contractor’s expense.
During period of shipment and storage, the fabric shall be maintained wrapped in a
heavy-duty protective covering and protected from direct sunlight, ultra rays and
temperatures greater than 70C.
a) Underground Services Warning Tapes
Service protection tapes shall be installed above all sewage, drainage irrigation,
water, DEWA, fire fighting and gas pipelines and pressure mains constructed or
exposed under this contract excluding individual service connections.
For pipelines with the top of the pipe barrel more than 900 mm below finished surface
level the tape shall be placed over the centreline of the pipeline at 600 mm below
finished surface level during backfilling and compaction operations. For pipelines
with less than 900 mm cover to the top of the pipe barrel the tape shall be placed
over the centreline of the pipe at 300 mm above the top of the pipe barrel during
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backfilling, compaction and reinstatement operations.
The tape shall be continuous over pipelines and at joints between tapes from
separate rolls the joint shall be lapped a minimum of one metre.
Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions
at pH values of 2.5 to 11.0 inclusive.
The tape shall be 150 mm wide and 250 micron thick and produced as a strong 4
layer composite laminate consisting of: -
(1) 12 Micron polyester film top layer with reverse printing

(2) 50 Micron pigmented polyethylene
(3) 12 Micron detectable aluminium foil in between
(4) 176 Micron bottom layer polyethylene.
(5) The thickness of the tape (250 micron / 1000 gauge) shall be measured
in accordance with BS 2782 : Part 6. Method 630 A.
The following properties shall be demonstrated by appropriate tests:
a) Physical properties (Average of 5 tests)
Tensile strength Longitudinal (MD):160 N (Minimum)
(BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)
Elongation (PE only)
(BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%
Tear strength MD : 640 gram force
BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum
Dart Impact
BS 2782 : P3 : 352F : 1996 1000 grams minimum
b) Chemical resistance
The tape shall remain legible and colour fast in all soil conditions at pH 2.5 – 11.0,
inclusive. The tape shall not show any adverse effect when in contact with the
sulphates, chlorides and other minerals present in sub soil and water, oil, 5%
Acetic Acid, 5% NaOH and Alcohol mix, if any.
Table 4. 1
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Chemicals Temperature Test Duration Test Method
Diesel Fuel 50oC 30 Days ANZ

4275.4:1995
PH –2.5 (1% H2SO4) 50oC 30 Days
PH –2.5(with Hydrochloric 50oC 30 Days

Acid)
PH –11.0(10% Conc. Sodium 50oC 30 Days

Hydroxide)
Saturated Sodium nitrate 50oC 30 Days

solution
Acid Soluble sulphate (with 22 2oC 30 Days

CaSO4)
Sea water 50oC 30 Days
Wastewater with hydrogen 22 2oC 7 Days

sulphide (30 ppm)
Ammonium Hydroxide (NH3) 50oC 15 Days
Ammonium Hydroxide (NH3) 22 2oC 30 Days
Note: After the chemical exposure of the supplied warning tape, the surface printing
should be intact without delamination and corrosion. Relevant independent lab test
to be conducted on supplied tape sample and comply with the requirements prior to
the use on site.
Detectablility after installation and back filling
Text in Arabic and English indicating the protected services lying below the tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive
acids and alkalis with the message repeated at a maximum interval of two metres.
Tapes shall be colour coded as follows, with black text as indicated. The sign and
styles of the text shall be approved by the Engineer.
Sewers : Blue
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CAUTION : Sea Pipeline below
Sewers : Yellow
CAUTION : Sewer below
Sewage pressure mains : Yellow

CAUTION : Sewerage pressure main below
Drains : Yellow
CAUTION : Drain below
Drainage pressure main : Yellow

CAUTION : Drainage pressure main below
Irrigation pressure mains : Orange

CAUTION : Irrigation pressure main below
Potable Water & electricity cable : As per DEWA Specification
Fire fighting : As per Civil Defence Requirements
Gas : Red
Dangerous Sewer Gas
The Dubai Municipality logo shall be printed on the tape between the spaces of the
repeated messages. The Dubai Municipality logo and its colours shall be as shown
below.
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Green
white
dark brown
brown
black
4.8 PIPEWORK WITHIN STRUCTURES
(i) Pipework shall be supplied to the general arrangements and limits indicated
on the Contract drawings and shall be supplied complete with all joint rings,
gaskets, washers to each side of a bolted joint, nuts, bolts, grease and any
other components necessary for the complete installation
(ii) The layout and design of the pipework shall be such as to facilitate its
erection and the dismantling of any section for maintenance of associated
plant by inclusion of approved mechanical coupling or flange adaptors.
(iii) Where a common delivery pipe is used, individual pump delivery branches
unless otherwise shown on the drawings shall be jointed to it in a horizontal
plane and angled to prevent sharp changes of flow direction.
(iv) Adequate supporting and anchoring arrangements for all pipes shall be
included which may take the form of straps, stays, tie bars or concrete
cradles. All pipe hangers and supports inside pumping stations and valve
chambers or other structures shall be of 320S17 stainless steel. All fixing
bolts shall be stainless steel grade 320S17.
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(v) GRP pipes shall be provided with puddle flanges where they pass through
the walls of underground or water retaining structures.
(vi) Small bore pipework for sump pumps, vents, etc., may be an approved
plastic material.
(vii) All pipes connected to pressure vessels, pumps, etc., shall have flanged
connections.
(viii) All pipes shall be checked for alignment and mating of flanges and
connections before secured. Pipes shall not be sprung into position.
4.9 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES
4.9.1 General
The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the drawings and
herein specified.
Manholes, chambers, and special structures shall conform in shape, size,

dimensions, materials, and other respects to the details indicated on the drawings or
as ordered by the Engineer.
4.9.2 Construction of Manholes, Chambers, and Special Structures
All manholes, chambers, and special structures shall have reinforced-concrete bases
as detailed on the drawings. Manhole bases for storm-sewers less than 600 mm and
bases for chambers may be precast or cast in place at the Contractor's option and as
approved by the Engineer. For precast reinforced concrete manhole bases, openings
for pipes shall be cast in the base at the required location during its manufacture.
Field cut openings will not be permitted. All other manhole and special structure
bases shall be cast in place as indicated on the drawings.
Manhole and chamber cover slabs shall be cast in place reinforced concrete as
marked on the drawings. The ductile iron frames and covers for manholes and
chambers shall be brought to grade by the number of courses of concrete blocks
shown on the drawings or as instructed by the Engineer and a reinforced concrete
frame into which the ductile iron frame is embedded.
Class C 40/20 concrete shall be cast to a minimum thickness of 150 mm around the
concrete blocks for rigidity or as detailed on the drawings.
The inverts shall conform accurately to the size of the adjoining pipes. Side inverts
shall be curved and main inverts (where direction changes) shall be laid out in
smooth curves of the longest possible radius which is tangential, within the manhole,
to the centerlines of adjoining pipelines all as indicated on the drawings and
instructed by the Engineer.
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The ductile iron frames, grates and covers shall be to the Dubai Municipality standard
frame, grate and cover as indicated on the drawings and hereinafter specified in
Clause.
All benching and channel shall be formed with C35/10 concrete unless shown
otherwise on the drawings. GRP laminate (7 mm minimum) shall be applied to
benching and channel.
Manhole walls shall be plain Class C 30/20 SRC concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to give a fair
faced finish.
Internal surfaces of manholes and structures shall be protected with a reinforced

plastic liner in accordance with Clause or with an approved coating in accordance
with Clause as and where shown on the drawing and the external (buried) surfaces
shall be protected in accordance with Clause either with water-proof membrane with
protection board or with a brush-applied bituminous emulsion as indicated in the
drawing.
Pipes entering and leaving manholes, chambers and special structures shall be laid
soffit to soffit unless otherwise shown on the drawings. Details of pipelines entering
and leaving manholes, chambers, etc., shall be as specified for pipes protruding from
structures in accordance with Clause 4.7.19.
All construction joints to manholes, chambers and special structures shall be perfectly
watertight. Waterstop across joints in structures as specified in Clause 3.9.5 shall be
provided where detailed on the drawings or as directed. Joints shall be fully
scabbled.
Manholes and chambers shall be completely constructed as the Works progress and
as each one is reached by the pipework. Frames and covers shall be placed
immediately after the completion of the manhole and chamber.
4.9.2.1 Road Gullies
Gullies shall comprise the gully grating and frame and the polypropylene gully pot, all
as shown on the drawing.
The gully pots shall be supplied with a fibre glass sand bucket with lifting handle, as
detailed on the drawing. The sand bucket shall have perforations in its upper part and
small holes 3 mm in diameter in its base. The total area of perforations shall not be
less than 20,000 sq. mm and the minimum diameter of each hole shall be 50 mm.
The depth of the bucket shall not be less than 750 mm.
The gully pot shall be surrounded by a minimum of 150 mm of concrete as shown on

the drawing.
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The connecting pipe between the gully pot and the drain/manhole shall be 160 mm
dia. uPVC.
The connection into the drain pipe shall be made by means of an oblique junction.
4.9.3 Access Covers, Frames, and Grates
4.9.3.1 General
The Contractor shall furnish all ductile iron frames, grates, and covers conforming to
the details shown on the drawings, and as specified in Table 4.23 and 4.24.
The Contractor shall submit for approval detailed shop and working drawings of all
castings before fabrication. Such drawings shall be obtained from the supplier(s) he
chooses to select from the approved list of Dubai Municipality.
The castings shall be of good quality, strong, tough, even-grained ductile iron,
smooth, free from scale, lumps, blisters, sand holes, and defects of every nature
which would render them unfit for the service for which they are intended. Covers and
frames contact surfaces shall be machined and the compatible frames and cover
carefully marked to ensure correct covers and frames are matched on site.
If required by the Engineer, the Contractor shall obtain from the supplier/
manufacturer a guarantee that replacement component parts will be available for a
minimum period of 10 years from the issue date of the Completion Certificate.
All covers, frames and grates shall be delivered to Dubai with a transit protective
packaging or wrapping. Any damage occurring to the approved coating system shall
be made good prior to installation.
One set of prising and lifting keys of approved design Tri –glide Cover lifting key and
MSG safety grid shall be supplied by the Contractor with each twenty manhole covers
and frames supplied.
Loop –handled & T – handled keys suitable to lift Type E600, D400, C250 and B125
covers shall also be supplied along with 20 covers.
4.9.3.2 Access Covers and Frames
All access covers and frames shall be of heavy duty construction complying with BS
EN124 and the requirements of the Dubai Municipality Standards. Access covers and
frames shall be sand tight (with the use of sealing plates where necessary) with
seating designed to be non-rocking unless detailed otherwise.
Double triangular and semi-circular covers must be loosely coupled by stainless steel
bolts with nuts provided with an approved method to render the nuts incapable of
both undue tightening or loosening.
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Holes provided in non-ventilating covers for lifting keys shall be appropriately shaped
pockets which shall not penetrate through and there may be no projections above
cover level.
Both sides of covers and frames shall be protected with an approved epoxy coating
system appropriate to the Dubai environment. The coating system may be applied at
the place of manufacture or in Dubai under controlled application conditions approved
by the Engineer.
Covers for sewerage manholes and chambers shall also be provided with a
reinforced plastic sealing plate. The design of cover, frame and sealing plate shall be
such that no load can be transferred from the cover to the sealing plate. Access
covers shall be as follows: -
a) Sewerage
(i) Manhole covers shall be 600 mm x 600 mm square clear opening double
triangular heavy duty, embossed with the word 'Sewerage' in Arabic and
English.
(ii) Inspection chamber covers shall be single seal 600 mm x 600 mm square
clear opening heavy or medium duty, embossed with the word 'Sewerage' in
Arabic and English. Alternately, 600 mm x 600 mm square clear opening
double triangular covers may be used subject to approval by the Engineer.
b) Storm/Land drainage Manhole covers shall be non-ventilated, 600 mm diameter

clear opening double semi-circular heavy duty with sealing plate, embossed with
the word 'Storm' in Arabic and English.
c) Fire Fighting
Manhole covers shall be 600 mm diameter clear opening, circular, embossed with the
word ‘FH’ in Arabic and English. They shall be heavy duty (11.50 tonne wheel load
or D400) where located in a road corridor. For other locations they shall be Type
C250 or B150.
d) Water Supply
Manhole and chamber covers shall be of clear opening as specified on the drawings,
embossed with the word ‘water’ in Arabic and English. They shall be heavy duty
(11.5 tonne wheel load or D400) where located in a road corridor, for other locations
they shall be Type C250 or B 150. Where air tight / gas tight covers are specified,
these shall be of bolted type (bolted down) with double seal.
e) Aluminium Covers
General
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Aluminium covers shall be of the clear opening as shown in the drawing, fabricated
from anodised aluminium alloy chequer plate of thickness as specified. The cover
shall be suitable for exposed locations (ambient conditions) and shall not distort due
to temperature variations. Hinges shall be of heavy duty with adjustments to provide
a proper vermin proof protection. Covers shall be provided with padlocking facility.
(a) Hinged Aluminium Floor Access Covers for Interior and Exterior Applications
Aluminium floor access covers shall be designed for interior and exterior applications
where water tightness is not required. The frame shall be with an angle frame
construction with an integral anchor flange designed to cast into concrete. The cover
panel shall be diamond plate required with a flush aluminium drop handle and an
automatic hold open arm with red vinyl grip.
Materials Aluminium cover and frame, stainless steel hinges and

hardware
Cover 6 mm thick aluminium diamond plate reinforced for live load of

800 kg/m2 and 1500 kg/m2.
Frame Angle iron frame fabricated from aluminium extrusion with an

integral (25 mm) wide anchor flange.
Hinge Stainless steel but hinges with tamproof stainless steel blots &
nuts.
Opening Device Automatic hold open arm with red vinyl grip allows door panel to
open 90 , locking door in open position and allowing easy
control when closing door panel.
Latch Flush aluminium drop handle with staple for padlock.
Finish Mill finish with optional specified coating with sprayed aluminium
Cover opening As shown in the drawing

size
Standard size 600 x 600 to 1500 x 1500 mm
(b) Non-Hinged Aluminium Floor Access Covers for Interior Applications
Aluminium floor access cover is designed for interior applications where water-
tightening is not required. The cover shall be flush diamond plate door secured to the
frame with flat head screws and is completely removable.
Cover size from 200 x 200 mm to 610 x 610 mm
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Material Aluminium
Cover 6 mm thick aluminium diamond plate reinforced for the live load
of 800 kg/cm2, recessed 3 mm for floor finish/concrete.
Frame 25 mm x 25 mm aluminium angle designed to be cast into

concrete. 40mm x 32 mm aluminium angle with mounting holes
in top flange.
Latch Door panel secured to frame with 32 x 25 mm flat head screws.
Finish Mill finish with optional specified coating with sprayed

aluminium.
f) Channel Grating
Standard channel grating shall be DI, D400, 225 mm x 750 mm in size single piece
with two bearer frames or extendable to cross the carriageway location where
required.
g) Pumping Stations & Associated Chambers where Specified
They shall be rectangular 600 mm x 750 mm or 600 mm x 900 mm or multiples of

these sizes, as detailed on the drawings with concrete infill and shall be heavy duty.
Where ventilated covers are detailed the total area of ventilation shall not be less than
5 % of the minimum clear opening area and the covers shall be provided with suitable
protective sand traps which shall seat in the access cover frame.
c) Reinforced Plastic Sealing Plates to Access Covers
Reinforced plastic sealing plates to access covers shall be designed to provide a

push-fit, gas-tight seal with the cover frame. The sealing plate shall be in the form of a
plug with a flange to prevent the plate passing into the manhole. The seal shall be
achieved by means of an approved integral synthetic rubber gasket mechanically
locked into the periphery of the plate.
The rubber gasket shall have the following physical properties:
Properties Specifications Test Method
Hardness (Shore A) 75 ± 5 ASTM D 2240
Tensile Strength (Mpa) 10.5 min. ASTM D 412
Elongation Break % 200 Min ASTM D 412
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Properties Specifications Test Method
Hardness Change 0 to + 10 ASTM D 573
Tensile change % 15 Max ASTM D 573
Elongation change % 40 Max ASTM D 573
Compression Set 22 hours 25% Max ASTM D 395

at 70°C
Low Temperature Should be flexible at -40°C ASTM D 2137

Flexibility
Ozone resistance 20% No cracks ASTM D 1149

stretch 40°C 100 PPM 96
hrs
Maximum working 140°C

temperature
The gasket shall be suitable for the service temperature range 0°C to 60°C and
possess good weathering and H2S resistance. Any lubricant used on the seal shall be
silicon based. The underside of the plate shall have a resin-rich finish and there shall
be no exposed fibres. Cut and/or drilled faces shall be sealed with resin.
The plate shall have a minimum thickness of 5 mm and be capable of withstanding a

static load of 150 kg applied centrally over a 150 cm square surface area with a
deflection, measured at the centre of the plate, not exceeding 25 mm.
A minimum of four number reinforced plastic lifting handles shall be provided per
plate. They shall be of the same materials as the plate securely laminated to the plate
or fixed by stainless steel blind rivets.
The complete sealing plate including gasket shall be resistant to 10% sulphuric acid
at 50°C for 100 days.
d) Road Gulley Gratings and Frames
Road gully gratings and frames shall be of ductile iron construction made to BS
EN124 and have a minimum waterway of 900 sq. cm. The grating and frame shall be
of a non-rocking construction and shall be dimensioned as detailed on the drawing.
Gully gratings shall be of the raised kerb type complete with sand seal, road retaining
bar and a removable GRP debris bucket. The weir depth shall be a minimum of 165
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mm and the frame and cover are to be protected with an approved epoxy coating
system applied in Dubai under controlled application conditions approved by the
Engineer. The clear opening size shall permit removal of the GRP grit sand bucket.
e) GRP Gulley Grating Over the GRP Bucket
Reinforced plastic gully grating shall be a rectangular perforated plate to the shape
shown on the drawing. The plate shall have a minimum thickness of 6mm and shall
be capable of withstanding a static load of 100kg applied centrally over a 150mm
square surface area without showing any breakage. The corners of the plate shall be
chamfered as shown on the drawing to fit in to the place. The grating shall be
manufactured by using Isophthalic resin and ‘E’ glass standard mat & woven rovings
for the of 6mm thick layers and top coating shall be with gel coat as per the
lamination requirements.
f) GRP Gully Pot With Bucket
GRP gully pot with bucket shall be manufactured by using Isopthalic resin reinforced
with ‘E’ glass chopped strand mat to a thickness of 4 mm as per Dubai Municipality
approved drawings.
g) GRP Toe Holes inside Deep Manholes
G.R.P Toe holes shall be manufactured using Epoxy based vinylester resin reinforced
with ‘ECR’ glass 7mm thick and two layers of ‘C’ Glass surface Tissue.
h) GRP Pre-fabricated Sleeve
The pre-fabricated GRP sleeves shall be as shown on the Drawing. The sleeves
materials and construction shall also be as specified in Clause 7.1.6.
4.10 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS
Table 4. 10 Standards for Covers and Gratings for Storm/Land Drainage
Requirements Manhole Gully Gratings
In Road Out of Road Flush Upstand Pumping

Kerb Kerb Station
Access
Cover
Shape Double Double Square - Rectangular

Semi- Semicircular
Circular
Size of clear 600 dia. 600 dia Width weir dpt 600 x 750
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Requirements Manhole Gully Gratings
In Road Out of Road Flush Upstand Pumping

Kerb Kerb Station
Access
Cover
opening Nom.450 165 600 x 900
Standard BS EN BS EN 124 BS EN 124 BS EN BS EN 124

124 124
Strength D400 C250 D400 D 400 D400
Material Ductile Ductile Iron Ductile Iron Ductile Ductile Iron

Iron Iron
Protective Epoxy Epoxy Epoxy Epoxy Epoxy

Coating
Ventilation No No - - No
Construction Solid Solid - - Concrete

Infill
Sealing Plate Yes Yes - - -
Inscriptions Storm Storm Storm Storm Storm
Tightness Yes Yes - - -
Rocking No No No - No
Locking No No No - Yes
Interchange- Yes Yes Yes Yes Yes

ability
Other - - - GRP Special Keys

GRID
Suppliers 1-6 1-6 1-6 1-6 1, 2, 4
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Table 4. 11 Standards for Covers and Gratings for Sewerage
Requirements Manhole House Pumping

connection station
In road Out of road chamber access
cover
Protective Coating Epoxy Epoxy Epoxy Epoxy
Ventilation No No No No
Construction Solid Solid Solid Concrete

Infill
Sealing Plate Yes Yes Yes -
Inscriptions Sewerage Sewerage Sewerage -
Tightness Yes Yes Yes -
Rocking No No No No
Locking No No No -
Interchangeability Yes Yes Yes Yes
Other - - - Special Keys
Suppliers 1–6 1-6 1-6 1, 2, 4
4.10.1 Repair Mortar for Metal Products
The cold applied mortar shall be a two component repair and rebuilding material on
metal products. It shall be based on ceramic and steel reinforced system (similar to
the product of Belzona) suitable to repair broken metal parts and the casting defects
etc.
This material shall be non-corrodable and be resistant to broad range of chemicals

including acids and alkalis.
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The mechanical strength of the cured product shall not be lower than the values given
below:
Compressive strength ASTM D 695 ≥800 kg/cm2
Flexural strength ASTM D 790 ≥575 kg/cm2
4.10.2 Approved List of Suppliers
1. ELKINGTON GATIC
2. PASSAVANT
3. PAM – SAINT – GOBAIN PIPE LINES
4. SELFOCK
5. GLYNWED BRICKHOUSE
6. HYDROTECH
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DEPARTMENT
SECTION 5
BRICKWORK AND BLOCKWORK
DM/SRPD Section 5 Brickwork and Blockwork Rev 00 June
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Dubai Municipality
DM/SRPD Section 5 Brickwork and Blockwork Rev 00 June Page i of iii
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SECTION 5
BRICKWORK AND BLOCKWORK
CONTENTS
5 BRICKWORK AND BLOCKWORK ................................................................................... 1
5.1 GENERAL...................................................................................................................... 1
5.1.1 Scope.................................................................................................................... 1
5.1.2 Standards ............................................................................................................. 1
5.2 SUBMITTALS ................................................................................................................ 1

5.2.1 Products And Materials Approval ......................................................................... 1
5.2.2 Method Statements ............................................................................................... 2
5.2.3 Drawings ............................................................................................................... 2
5.2.4 Samples ................................................................................................................ 2
5.2.5 Mock Up ................................................................................................................ 3
5.3 QUALITY CONTROL..................................................................................................... 3

5.4 DELIVERY, STORAGE AND HANDLING ..................................................................... 3
5.5 REGULATORY REQUIREMENTS ................................................................................ 4
5.6 MATERIALS .................................................................................................................. 4
5.6.1 Concrete Bricks and Blocks .................................................................................. 4
5.6.2 Bricks .................................................................................................................... 5
5.6.3 Sand for Mortar ..................................................................................................... 6
5.6.4 Lime for Mortar ..................................................................................................... 6
5.7 CONSTRUCTION .......................................................................................................... 6

5.7.1 General ................................................................................................................. 6
5.7.2 Engineering Brickwork .......................................................................................... 7
5.7.3 Blockwork ............................................................................................................. 7
5.7.4 Cement Mortar / Masonry Mortar .......................................................................... 7
5.7.5 Cement Lime Mortar ............................................................................................. 8
5.7.6 Cement Mortar Rendering .................................................................................... 8
5.7.7 Masonry Grout ...................................................................................................... 8
5.7.8 Metal Ties, Anchors and Joint Reinforcement ...................................................... 9
5.7.9 Accessories ........................................................................................................ 10
5.7.10 Lintels ................................................................................................................. 10
5.8 EXECUTION ................................................................................................................ 10

5.8.1 General ............................................................................................................... 10
5.8.2 Masonry Construction ......................................................................................... 12
5.8.3 Placing And Bonding .......................................................................................... 12
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5.8.4 Cavity Walls ........................................................................................................ 13

5.8.5 Reinforcement And Anchorage ........................................................................... 13
5.8.6 Grouting .............................................................................................................. 14
5.8.7 Joints .................................................................................................................. 16
5.8.8 Masonry Flashings .............................................................................................. 16
5.8.9 Lintels ................................................................................................................. 16
5.8.10 Built-In Work ....................................................................................................... 17
5.8.11 Cleaning .............................................................................................................. 17
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5 BRICKWORK AND BLOCKWORK
5.1 GENERAL
5.1.1 Scope
This section of the specification gives the requirements for concrete masonry.
5.1.2 Standards
All activities relating to this section of the specification shall comply with the following
or approved equal standards.
BS 6398 Specification for bitumen damp proof courses for masonry.
BS EN 480 Admixtures for concrete mortar and grout
BS EN 771-2 Specification for masonry units. Aggregate concrete masonry

units (dense and Light weight aggregates)
BS EN 772-1 Methods of tests for masonry units. Determination of compressive

strength
BS EN 13139 Aggregates for mortar.
ISO 11600 Building Construction Jointing Products Classification and

requirements for sealants
5.2 SUBMITTALS
5.2.1 Products And Materials Approval
a. In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Information to be submitted
shall comprise but not necessarily be limited to:
(i) Manufacturer’s/supplier’s name.
(ii) Product name/description.
(iii) Manufacturer’s technical data.
(iv) Manufacturer’s certificates of compliance with this section of the

specification.
(v) Storage instructions.
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(vi) Application instructions.
(vii) Mix design for mortar and grout.
5.2.2 Method Statements
a) The Contractor shall submit method statements to the Engineer for approval 4
weeks in advance of commencing the site activity. These shall comprise but not
necessarily be limited to:
Method of mortar mixing, block placement, reinforcing, tooling and grouting for all
masonry works
5.2.3 Drawings
a) The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity. These shall comprise but not necessarily be limited
to:
(i) Details of anchors, inserts, joints, connections to adjoining work or

materials. Also include elevations indicating setting out and placement of all
joints, openings, cut outs, etc.
(ii) In addition to above submit drawings for fabrication, bending and

placement of reinforcement for concrete masonry work. Show bar
schedules, diagrams of bent bars, stirrup spacing, lateral ties and other
arrangements and assemblies as required for fabrication and placement of
reinforcement for concrete masonry work.
5.2.4 Samples
a) Representative samples, as agreed with the Engineer, must be submitted for at

least the following items at the same time as the particulars are submitted.
(i) Hollow concrete blocks.
(ii) Solid concrete blocks.
(iii) Masonry reinforcement.
(iv) Masonry anchors.
(v) Lintels.
(vi) Damp proof course.
(vii) Flashings.
(viii) Joint fillers and sealants.
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5.2.5 Mock Up
a) Prior to the construction of concrete masonry work provide a sample wall mock-
up for all types of concrete masonry work.
b) Construct a masonry wall into a panel sized 2m long by 1m high, which includes
mortar and accessories, reinforcing, wall openings, flashings, wall insulation, air
barrier, vapour barrier and indicating the proposed range of colour, texture and
workmanship expected in the completed work.
c) Locate as directed by the Engineer.
d) Provide each sample wall panel using materials, together with bond and joint
tooling, shown or specified for final work.
e) Obtain acceptance of visual qualities of each sample panel before proceeding

with the final work.
f) Retain each sample panel mock-up during construction period as a standard for
judging completed masonry work. Do not alter, move or destroy mock-up until
work is completed.
g) Mock up may remain as part of the permanent work.
5.3 QUALITY CONTROL
a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery.
b) Products and materials shall be from a manufacturer/supplier that operates a

quality system which is registered to ISO 9000 series or approved equal.
c) To allow the Engineer to inspect the Works the Contractor shall give the Engineer
a minimum of 24 hours’ notice of carrying out the following activities on site.
(i) Commencement of masonry work.
5.4 DELIVERY, STORAGE AND HANDLING
a) Delivery, storage and handling of products and materials shall be in accordance

with the manufacturer’s recommendations:
(i) Delivery, storage and handling shall at all times be performed in a manner
to avoid product damage.
(ii) Products shall be stored at site in an. environment as recommended by the

manufacturer.
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(iii) Deliver concrete masonry materials, other than bulk materials, to site in
manufacturer’s unopened containers, bundles, pallets or other standard
packaging devices, fully identified with name, type, grade, colour and size.
(iv) Protect all concrete masonry materials during shipment, storage and
construction against wetting and contamination with earth or other types of
materials.
(v) Take all necessary precautions to prevent all masonry materials from
chipping, cracking or other damage during transportation, unloading and
storage on site.
(vi) The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.
1. Any products damaged during delivery, storage and handling shall be

marked by the Contractor and set aside.
2. Proposals for repair of any damaged products shall be submitted in

writing to the Engineer for approval.
3. Any damaged products deemed unsuitable for repair by the Engineer

shall be removed from site and replaced.
5.5 REGULATORY REQUIREMENTS
Requirements for fire-rated or lateral support conditions are to be regulated in

compliance with local building codes and are not necessarily fully defined on the
drawings. Whenever a fire rating is shown for a wall, use concrete masonry in that
wall complying with the requirements established by the local governing authorities.
5.6 MATERIALS
5.6.1 Concrete Bricks and Blocks
a) Concrete bricks and blocks shall be constructed from C 40/10 concrete but the
coarse aggregate shall be 10 mm to 5 mm. The blocks shall be cast in clean oiled
moulds.
b) They shall be free from cracks, uniform in size, true to shape; free from
deleterious matter, clean, hard, impervious with smooth faces in appearance
similar to normal Class 40/10 concrete and with well-defined arises. The
constituent parts comprising the concrete of the blocks shall conform, unless
otherwise stated, to Section 3 of this specification.
c) Bricks and blocks shall not be incorporated into the Works until they have
matured under suitable conditions for 28 days. All concrete blocks shall comply
with the requirements of DM Local Order No. 44/90.
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d) Do not use blocks which have chips, cracks, voids, streaks, iron spots or other
substances which might stain exposed finished surfaces.
e) Obtain blocks from one manufacturer, cured by one process and of uniform
texture and colour, for each type required, for each continuous area and visually
related areas.
f) Concrete blocks generally are to be in accordance with BS EN 771-3. They shall

be factory produced under strictly controlled conditions.
g) Blocks shall be made using ordinary Portland cement (OPC) unless otherwise
h) Blocks for external and load bearing walls where indicated on the drawings shall
be 100% solid blocks with an average compressive strength after 28 days of
10N/mm2
The blocks shall be of the following sizes:
390mm x 190mm x 190mm
390mm x 190mm x 140mm
390mm x 190mm x 90mm
i) Blocks for internal partition walls where indicated on the drawings shall be hollow
blocks with an average compressive strength after 28 days of 6N/mm2
The blocks shall be of the following sizes:
400mm x 200mm x 200mm.
390mm x 190mm x 140mm.
390mm x 190mm x 90mm
Provide special shapes wherever shown and wherever required to build corners,
lintels, jambs, control joints and expansion joints in order to provide a complete
installation in accordance with the highest standard of workmanship.
j) Ten blocks shall be taken from every designated block section in each
consignment and tested in accordance with BS EN 772-1.
5.6.2 Bricks
a) Engineering bricks and special purpose bricks such as radial bricks, weir bricks,
copings and bull nosed bricks shall have an average compressive strength of at
least 69 N/mm2 and an average absorption not exceeding 4.5 percent by weight
measured by a standard boiling or vacuum method.
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b) Faces of engineering bricks to be exposed to the weather or liquids shall not be

wire cut.
c) Bricks for arches and circular work of 1.5 metres and less in diameter shall be
purpose made radial bricks.
5.6.3 Sand for Mortar
a) Aggregates shall consist of natural sand or crushed sand complying with BS EN

13139 and approved by the Engineer.
b) Sand for mortar shall comply with the following table:
Sieve Size Percentage by mass passing sieve
Rendering Brickwork/General
Purposes
5.00 mm 100 100
2.36 mm 90 100 90 100
1.18 mm 70 100 70 100
600 microns 40 80 40 100
300 microns 5 40 5 70
150 microns 0 10 0 15
5.6.4 Lime for Mortar
a) Lime for cement-lime and lime-sand mortar shall be the hydrated type to the
approved standard.
5.7 CONSTRUCTION
5.7.1 General
a) Bricks and blocks shall be properly stacked on level hard standing. Broken blocks
shall be removed from the site.
b) Bricks shall be adequately protected from inclement weather.
c) During hot and dry weather bricks and blocks shall be wetted as necessary and
the tops of walls shall be wetted before a course is laid
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d) All faces of brickwork or block work will be kept clean and no rubbing down of
exposed faces will be permitted.
e) Vertical faces of all bricks shall be well buttered before being laid and the whole
well grouted at each course.
f) Brickwork and block work should be built in a uniform man¬ner. Corners and
other advanced work should be raked back and not raised above the general
level more than 1.0 m at one lift.
g) All blocks shall be laid on even full beds of mortar; vertical faces of all blocks shall
be well buttered before being laid and the whole well grouted at each course.
h) The overall dimensions of four blocks laid in mortar shall not exceed by more than
25 mm the overall dimensions of the same blocks laid dry.
5.7.2 Engineering Brickwork
a) Unless otherwise specified or ordered all engineering brickwork shall be built in

English bond.
b) In all engineering brickwork the overall dimensions of four bricks laid in mortar
shall not exceed by more than 25 mm the overall dimensions of the same bricks
laid dry.
c) When concrete is to be faced with brickwork, header bricks shall be built into
every fourth course and at intervals of 2 bricks horizontally so as to project 1/2
brick into the concrete. Headers in successive courses shall be staggered.
5.7.3 Blockwork
All block work shall be built level, plumb and true to line with all perpends in line
vertically. Blockwork shall be built in stretcher bond and alternate courses shall be
bonded in at all junctions. All block work shall be set in gauged mortar as described
to the lengths, heights and thicknesses shown on the drawings. Fair and fair-faced
work shall be kept perfectly clean and no rubbing down of block work will be allowed.
Blockwork to be plastered shall have joints struck off flush and left rough.
5.7.4 Cement Mortar / Masonry Mortar
a) Mortar for precast concrete units, brickwork and block work shall be gauged in the
proportions of one part of cement to three parts of sand. Lime shall only be added
if specifically ordered.
b) Cement mortar shall be mixed on a clean surface in small quantities sufficient

only for 30 minutes work and shall not be remixed or worked up again after
setting or hardening; any mortar that has become set or hard shall be rejected
and removed from the site.
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c) Ingredients shall be measured in proper boxes and shall be turned over and
thoroughly mixed on a wooden platform.
d) The ingredients shall be accurately measured and mixed in a mechanical mixer

with a sufficient amount of water added to produce a workable consistency
e) If only small quantities are required the Engineer may permit mixing together dry
on a clean wooden stage until the mix is homogeneous in colour. Water shall then
be added in sufficient quantity to give no more than stiff workability. The whole
shall then be turned until perfectly mixed.
f) Where admixtures are permitted they shall be in accordance with the

requirements of BS EN 480 and be used strictly in accordance with the
manufacturer’s instructions.
5.7.5 Cement Lime Mortar
Cement lime (gauged) mortar shall consist of one part Portland Cement, one part of
lime and six parts of sand by volume (1:1:6). All materials shall be accurately gauged
using gauge boxes and shall be thoroughly mechanically mixed. Mortar that has
begun to set shall not be revived or re-used.
5.7.6 Cement Mortar Rendering
a) Cement mortar rendering shall consist of two or more coats; the undercoat shall
be 13 mm thickness and scored to form a key for the final coat which shall be not
less than 6 mm in thickness. The finished coat shall be worked with proper metal
floats, and the face left with an even and polished surface. The mortar for the
undercoat of the rendering shall be gauged in the proportion of one part of
cement to three parts of sand, and the finished coat shall be in the proportion of
one part of cement to two parts of sand.
b) For at least 24 hours before rendering is applied the concrete or brickwork face or
previous coat of rendering shall be thoroughly soaked with water, and the finished
rendering shall be watered at least four times a day and kept damp for a period of
a least fourteen days after completion. Not more than three days shall elapse
between the application of one coat and its being covered up with a second or
finishing coat. All arises shall be sharp and linear.
c) When rendering is to be applied to brickwork, the joints shall be raked and

cleaned out to a depth of 13 mm.
5.7.7 Masonry Grout
a) Masonry grout shall consist of cement, sand and lime in the proportions given as
below
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Grout Type OPC Sand Lime
Coarse 1 1.5 Coarse 2.5 Fine 0.5
Fine 1 2.5 Fine 0.5
b) Aggregates shall consist of natural sand or crushed sand complying with BS EN

13139 and approved by the Engineer. Fine aggregate shall all pass a 9.5mm
sieve and coarse aggregate shall all pass a 12.5mm sieve. Aggregate grading
shall be to the approval of the Engineer.
c) All grouts shall have a minimum compressive strength of 20N/mm2 at 28 days
d) The ingredients shall be mixed in a mechanical mixer with a sufficient amount of

water added to produce a workable consistency. The Engineer may permit hand
mixing if the required quantity is small.
e) Method of measuring materials shall be such that the specified proportions of the
grout materials can be controlled and accurately maintained to the satisfaction of
the Engineer.
f) Where admixtures are permitted they shall be in accordance with the

requirements of BS EN 480 and be used strictly in accordance with the
manufacturer’s instructions
5.7.8 Metal Ties, Anchors and Joint Reinforcement
a) Provide anchoring devices such as bolts, straps, bars and rods of the type and
size shown fabricated from not less than 1.6mm sheet metal or 9mm diameter
bars unless otherwise shown on the drawings. Anchoring devices shall be
fabricated from stainless steel grade A316 unless otherwise approved by the
Engineer.
b) Lateral support for wall heads shall be fabricated from 30mm X 6mm thick
stainless steel grade A316, flat on both sides unless otherwise approved by the
Engineer.
c) Blocks shall be restrained at vertical interfaces with concrete using stainless steel
grade A316 wall starters with integral ties for building in.
d) Wall ties shall be fabricated from stainless steel grade A316 unless otherwise
e) Reinforcement shall be high strength deformed bars complying with Section

03200 of the specification.
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5.7.9 Accessories
a) Compressible joint filler shall be closed cell PVC, SBR or Neoprene, either solid
or tube type, of proper dimension to serve as back-up for joint sealant at face of
concrete masonry. Filler shall be an approved material meeting the required fire
rating if applicable.
b) Preformed control joints shall comprise solid rubber key section joint filler, 60 to
80 Shore A Durometer hardness, designed to maintain lateral stability in a
masonry wall. Corner and tee accessories shall be provided and the joints heat
fused.
c) Do not use control joint filler at building expansion joints.
d) Joint sealants shall be a one part, elastomeric, low modulus, silicone rubber
sealant. Joint sealant shall be an approved material meeting the required fire
rating if applicable.
e) Cavity vents shall have aluminium grilles and be insect resistant.
f) Flashings shall be manufactured from stainless steel grade A316 unless

otherwise approved by the Engineer.
g) Damp proof course shall comply with BS 6398.
h) Masonry work cleaning solution shall be non-acidic, not harmful to concrete

masonry work or adjacent materials.
5.7.10 Lintels
a) Concrete for lintels shall only be made from approved materials, in approved mix
proportions and at approved facilities.
b) Galvanised steel lintels may be used subject to the approval of the Engineer and
the sizes shall be as recommended by the manufacturer.
5.8 EXECUTION
5.8.1 General
a) Prior to the start of each major type of masonry work, meet at site and review the
installation procedures and co-ordination with other work. Meetings shall include
Contractor, Engineer and major material manufacturers as well as others whose
work must be co-ordinated with the masonry work.
b) Examine all parts of the supporting structure and the conditions under which the
masonry work is to be installed, and notify the Engineer in writing of any
conditions detrimental to the proper and timely completion of the work. Do not
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proceed with the installation of masonry work until satisfactory conditions have
been corrected in a manner acceptable to the Engineer.
c) Ensure co-ordination between masonry work and concrete work such that all
inserts and flashing reglets required for the proper installation of masonry work
are correctly pre-installed. Co-ordinate the masonry work with other building
works such as installation of window and door anchors.
d) Cutting of blocks shall be undertaken using a motor driven saw designed to cut
blocks with clean sharp corners.
e) Cut and fit for chases, pipes, conduit, sleeves and any other items. Co-ordinate
with other sections of work to provide correct size, shape and location.
f) Obtain approval prior to cutting or fitting masonry work not indicated or where
appearance or strength of masonry work may be impaired.
g) Take all necessary precautions to keep mortar, blocks and other materials cool
and in particular:
(i) Do not mix mortar or lay units while shade temperature is above 40oC on a
rising thermometer or above 43oC on a falling thermometer.
(ii) Do not allow temperature of fresh mixed mortar to exceed 32oC. Take
suitable measures to ensure this.
(iii) Do not lay masonry units having a film of water on their surfaces.
(iv) The Contractor will be deemed to have allowed for all steps necessary for
compliance with the above.
(v) Place a recording thermometer at each location of unit masonry work during
its construction.
h) Protection during progress of work.
(i) Protect masonry with polythene sheeting from direct exposure to the wind
and sun for 48 hours after construction.
(ii) Protect partially completed masonry walls against weather when work is not
in progress, by covering top of walls with strong, waterproof, non-staining
membrane. Extend membrane at least 600mm down both sides of walls and
anchor securely in place ensuring that there is free airflow sufficient to
prevent heat build-up.
(iii) Wet curing by direct application of water shall not be allowed.
i) Protection of completed work.
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Dubai Municipality
(i) Keep completed walls clean and protect from staining. Use suitable corner
guards to protect the corners of exposed masonry walls.
5.8.2 Masonry Construction
a) Comply with the manufacturer's printed instructions and recommendations for the
installation of each type of masonry product, unless otherwise shown or specified.
b) Form chases and recesses as shown and as may be required for the work of
other trades. In select instances the Contractor may be allowed to chase hollow
blocks if approved by the Engineer. Do not cut horizontal or diagonal chases in
load bearing work. Provide not less than 200mm of masonry between chase or
recess and jamb of openings and between adjacent chases and recesses.
c) Leave openings for equipment as shown or required to be installed at later date.

Complete masonry work after equipment is in place using materials identical with
those immediately adjacent to the opening.
d) Step back unfinished work for joining with new work, toothing will not be
permitted. Before new work is started clean exposed surfaces of set masonry, wet
units lightly and remove loose blocks and mortar prior to laying fresh masonry.
e) Do not build in concrete blocks until at least 28 days after manufacture and until
they are fully cured.
5.8.3 Placing And Bonding
a) All blocks shall be laid in stretcher bond solidly bedded and jointed in masonry
mortar number 2. All block work joints above damp-proof course level shall be
raked back to a depth of 10mm and shall be pointed up after completion unless
the wall face is to be rendered as specified herein. Pointing externally shall give a
slightly recessed joint by using a jointer having a diameter slightly larger than the
mortar joint width. Pointing internally shall be flush. All work below damp-proof
course level shall be finished flush as the work proceeds. Joints in block work to
receive plaster or rendering shall be raked back.
b) All joints shall be 10mm nominal thickness. Horizontal joints shall be level and
vertical joints shall be aligned with jambs and other features and plumbed as the
work proceeds.
c) Blockwork shall be carried up in a uniform manner no one portion being raised at

one time more than 1m above another. All perpends, quoins, reveals and the like
shall be kept strictly true and square and the whole properly bonded together.
d) Cut blocks shall only be used where required for bonding purposes or to facilitate
building in of other components.
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Dubai Municipality
e) During laying blocks an open joint not less than 15mm wide shall be left between
the ends of all concrete lintels whether precast or cast in situ and blocks adjacent
to these ends. These open joints shall be left as long as possible during
construction and not filled in until plastering or other works render such filling
necessary. All such joints shall be properly filled in before the completion of the
work.
f) Jambs of opening in hollow block walling shall be built in solid blocks.
g) The Contractor shall ensure that the finished walls are not damaged by
subsequent operations.
h) Where block work is to be constructed adjacent to concrete surfaces it shall be

tied to the concrete structure using stainless steel anchors shot fired or expansion
bolted to the concrete and built in every other course of block work.
5.8.4 Cavity Walls
a) Cavity shall be maintained at the width shown on the drawings or as specified.
b) Cavity shall be kept clean by efficient means throughout the construction of the
walls and any accidental mortar droppings shall be prevented from adhering to
cavity faces of walls, wall ties, cavity trays or insulation.
c) Wall ties shall be bedded a minimum of 50mm into each skin of walling and
spaced at 600mm vertically and 800mm horizontally. Additional ties shall be
provided within 200mm of sides of openings and at 400mm vertical centres. All
ties shall slope downwards and outwards.
d) Build inner skin ahead of outer skin to receive cavity insulation and air/vapour
barrier adhesive.
5.8.5 Reinforcement And Anchorage
a) Provide horizontal joint reinforcement and vertical reinforcement in all masonry

walls, unless specifically noted or specified to be omitted.
b) Vertical reinforcement shall comprise one 12mm diameter bar at 1m centres and
grouted full height. Bars shall be lapped by a minimum of 500mm.
c) Horizontal reinforcement shall be provided as follows:
(i) Spaced at 600mm centres for interior walls and 400mm centres for exterior
walls unless otherwise shown or specified.
(ii) Lap reinforcement a minimum of 150mm at ends and do not bridge control
and expansion joints with reinforcement except at wall openings.
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Dubai Municipality
(iii) Use matching prefabricated T and L sections of reinforcement at corners

and wall intersections to provide continuity.
(iv) Centre reinforcement in wall to provide a minimum mortar cover of 15mm to

reinforcement.
(v) Place masonry joint reinforcement in first and second horizontal joints
above and below openings. Extend minimum 400mm each side of opening.
(vi) Place joint reinforcement continuous in first and second joint below top of
walls.
(vii) Reinforce joint corners and intersections with strap anchors at 400mm
centres.
5.8.6 Grouting
a) Grout used for filling cavities shall conform to the requirements given in the
specifications.
b) Use fine grout for filling cavities less than 100mm in one direction and coarse
grout for filling cavities 100mm and greater in both directions. Mortar shall not be
used for filling cavities.
c) At the Contractor's option, use either low-lift or high-lift grouting techniques

subject to the following requirements.
(i) Place vertical reinforcing before grouting and either before or after laying
blocks, as required by job conditions.
(ii) Support vertical reinforcing at 1m centres.
(iii) Where individual bars are placed after laying masonry, place wire loops
extending into cells as masonry is laid and loosen before mortar sets.
(iv) After insertion of reinforcing bar, pull loops and bar to proper position and tie
free ends.
d) Prior to grouting, clean and inspect grout spaces and close cleanout holes.
(i) Remove dust, dirt, mortar droppings, loose pieces of masonry and other
foreign materials from grout spaces.
(ii) Clean reinforcing and adjust to proper position as required.
(iii) Clean top surface of structural members supporting masonry to ensure

bond.
(iv) After final cleaning and inspection, close cleanout holes and brace closures
as required to resist grout pressures.
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e) Do not place grout until entire height of masonry to be grouted has attained
sufficient strength to resist displacement of masonry units and breaking of mortar
bond. Install shores and bracing if required, before starting grouting operations.
f) Limit grout pours to sections which can be completed in one working day with not
more than one hour interruption of pouring operation.
(i) Place pour in lifts which do not exceed 1.2m.
(ii) Allow not less than 30 minutes and not more than one hour between lifts of
a given pour.
(iii) Rod or vibrate each grout lift during pouring operation.
g) When more than one pour is required to complete a given section of masonry,
extend reinforcing beyond masonry as required for splicing.
(i) Pour grout to within 40mm of top course of first pour.
(ii) After grouted masonry is cured, lay masonry units and place reinforcing for
second pour section before grouting.
(iii) Repeat sequence if more pours are required.
h) Low lift grouting.
(i) Place vertical reinforcing prior to laying of masonry. Extend above elevation
of maximum pour height as required to allow for splicing. Support in
position.
(ii) Lay masonry to maximum pour height. Do not exceed 1.2m in height.
(iii) Pour grout using container with spout or chute. Rod or vibrate grout during
placing. Place grout continuously and do not interrupt pouring of grout for
more than one hour. Terminate grout pours within 40mm of top course of
pour.
i) High lift grouting.
(i) Provide cleanout holes in first course at all vertical cells which are to be
filled with grout.
(ii) Use units with one face shell removed and provide temporary supports for
units above or use header units with concrete brick supports or cut
openings in one face shell.
(iii) Construct masonry to full height of maximum grout pour specified prior to
placing grout.
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Dubai Municipality
5.8.7 Joints
a) Control joints.
(i) Install control joints in masonry walls where shown on the drawings.
(ii) Rake out mortar in preparation for application of sealant.
b) Control joint spacing.
(i) If control joint locations are not shown, place joints vertically spaced at each
structural column or joint between bays of the building but in no case
spaced more than 9m.
(ii) Place vertical joints at points of natural weakness in the masonry work
including the following locations:
1. At locations where masonry wall height changes by more than 20%.
2. Above expansion or control joints in the supporting structure.
3. Where end of masonry wall butts against supporting structure.
c) Control joint construction.
(i) Form continuous control joints 10mm wide and build-in 40mm wide x
200mm long galvanised mild steel flats minimum 1.6mm thick at each
alternate course.
5.8.8 Masonry Flashings
a) Extend flashings horizontally at foundation walls, above ledge or shelf angles and
lintels, under parapet caps, at bottom of walls and where instructed.
b) Turn flashing up minimum 200mm and bed into mortar joint of masonry or seal to
concrete or otherwise as required.
c) Lap end joints minimum 150mm and seal watertight.
d) Turn flashing, fold, and seal at corners, bends, and interruptions.
5.8.9 Lintels
a) Provide masonry lintels wherever shown, and wherever openings in the masonry
of more than 300mm are shown without structural steel or other supporting lintels.
Provide reinforcement as shown on the drawings or as directed by the Engineer.
b) Provide minimum lintel bearing at each jamb of 100mm for openings which do not
exceed 1.8m width.
c) Precast lintels, or form lintels in place with adequate temporary support.
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Dubai Municipality
d) Cure precast lintels thoroughly before handling and installing.
e) Allow cast in place lintels to attain specified strength before removing temporary
supports.
5.8.10 Built-In Work
a) As work progresses, install built-in door and window frames, anchor bolts, plates,
and other built-in items.
b) Install built-in items plumb and level.
c) Do not build in organic materials subject to deterioration.
5.8.11 Cleaning
a) During the completion of masonry installation and the tooling of joints, enlarge
any voids or holes and completely fill with mortar. Point up all joints at corners,
openings and adjoining work to provide a uniform, neat appearance, properly
prepared for the application of sealant compounds and other work to follow.
b) All exposed work shall be cleaned without the use of acid. Cleaning shall not be
done until mortar is thoroughly set and hard.
(i) Before wetting wall, remove large particles of mortar by means of wood
scraper, or if necessary by means of chisel or wire brush.
(ii) Pre-soak the wall, saturating the masonry with clean water and flush off all
loose mortar and dirt.
(iii) Using a stiff fibre brush only, scrub down the wall with a solution of 0.25 litre
household detergent and 0.25 litre of tri-sodium phosphate dissolved in 4
litres of clean water.
(iv) Thoroughly wash off all cleaning solution, dirt and mortar crumbs using
clean pressurised water.
(v) If after this cleaning procedure is completed the wall or portion of the wall is
not clean in the judgment of the Engineer, clean with an acid solution by
means and methods acceptable to the Engineer. If cleaned with an acid
solution, metal lintels and other material shall be thoroughly protected.
c) Particular care shall be taken to prevent smearing mortar on surfaces of concrete

masonry. If mortar smearing occurs, it shall be removed while soft, when
possible, if dry and hard, it shall be removed by rubbing with a small piece of
concrete masonry. All mortar smears, drippings, etc., on exposed faces of
concrete masonry units shall be removed.
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 6
INSPECTION AND TESTING OF

PIPELINES AND STRUCTURES
DM/SRPD Section 6 Inspection and Testing of Pipelines and Rev 00 June

Structures
2016
OPEN DATA / ‫ﺑﻴﺎﻧﺎﺕ ﻣﻔﺘﻮﺣﺔ‬

Dubai Municipality
DM/SRPD Section 6 Inspection and Testing of Pipelines and Rev 00 June Page i of ii
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Dubai Municipality
SECTION 6
INSPECTION AND TESTING OF PIPELINES AND
STRUCTURES
CONTENTS
6 INSPECTION AND TESTING OF PIPELINES AND STRUCTURES ................................ 1
6.1 CLEANING AND INSPECTION OF PIPELINES ........................................................... 1
6.2 TESTING OF PIPELINES .............................................................................................. 1
6.2.1 General ................................................................................................................. 1
6.2.2 Testing of Non-Pressure/ Low Pressure Pipelines ............................................... 2
6.2.3 Testing of Pressure Pipelines ............................................................................... 4
6.3 TESTING OF VALVES .................................................................................................. 7

6.4 TESTING OF WATER RETAINING STRUCTURES ..................................................... 8
DM/SRPD Section 6 Inspection and Testing of Pipelines and Rev 00 June Page ii of ii
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6 INSPECTION AND TESTING OF PIPELINES AND STRUCTURES
6.1 CLEANING AND INSPECTION OF PIPELINES
a) The Contractor shall ensure during and after construction that the pipes remain
clean and free of all silt, mortar, debris and other obstructions, and if required by
the Engineer, the pipelines shall be cleaned out using approved methods and
equipment which do not damage the internal lining of the pipes and manholes.
When work is not in progress the open ends of the pipeline shall be securely
plugged with an approved watertight plug or stopper to prevent the ingress of
deleterious matter into pipelines.
b) After backfilling pipe trenches and completing chambers, hatch boxes, etc., and
before the trench surfaces are reinstated, the interior of pipelines shall be cleaned
of silt and debris by approved methods for inspection by the Engineer's
Representative as follows:
c) All newly constructed pipelines of 600 mm (nom.) internal diameter and smaller
shall have a loose plug passed through them to show that they are clear of
obstruction and free from deflection. The loose plug shall be dimensioned to suit
the permissible minimum deflected diameter of the pipe. Alternately, a
deflectometer capable of measuring diametric dimensions both vertically and
horizontally may be used.
d) All newly constructed pipelines greater than 600 mm (nom.) internal diameter will
after cleaning be inspected from the inside and the Contractor shall provide a
suitable trolley for this purpose.
e) All renovated or replaced pipeline shall after cleaning, be inspected from the
inside using CCTV inspection, as directed by the Engineer.
f) In addition gravity pipelines or sewers shown as straight lines between manholes

on the drawings shall be subjected to a light sighting test as detailed in the pipe
laying specification Clause.
g) Pipelines, manholes, chambers/structures will be inspected again before being

put in service or taking over (whichever is sooner) and if required by the
Engineer's Representative shall be cleaned again in whole or in part by suitable
means which may include, if directed, flushing with clean water.
6.2 TESTING OF PIPELINES
6.2.1 General
a) The Contractor shall make his own arrangements for the supply of water used for
testing and cleaning of pipelines which shall be obtained from a source approved
by the Engineer. All water required for testing and cleaning shall be provided by
the Contractor at his cost.
DM/SRPD Section 6 Inspection and Testing of Pipelines and Rev 00 June Page 1 of 9
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Dubai Municipality
b) Prior to commencement of flushing or testing, approval shall be obtained to the

methods and programme for testing and to the method of disposal of all fluids
used for flushing or testing purposes. Under no circumstances will permission be
given for the discharge of such fluids into the existing sewerage system.
c) If permission is given to use new or existing pipelines or culverts which are not
part of a live system, they shall be thoroughly cleaned of all silt and any resulting
damage made good after use.
d) If lagoons for the storage of such fluids are permitted, they must be suitably
protected with fencing and attended by day and night to prevent access by the
general public and will not be sited adjacent to buildings. Approved means of
preventing the formation of mosquito larvae on the surface of the lagoons shall be
employed.
e) Testing of pipelines shall in all cases be applied in the presence of the Engineer's
Representative. The Contractor shall notify the Engineer at least 48 hours in
advance of his intention to test a section of pipeline. The Contractor, at his own
expense, shall provide complete plant and all struts, thrust blocks, etc., as may be
necessary for effectively testing the pipelines to the specified pressures.
f) Pipelines shall be properly completed and supported before being put under test.
No testing will be permitted until seven days after thrust blocks and other holding
down works have been completed.
g) For both gravity and pressure pipelines only testing of new, renovated, or
replaced sections of pipelines and fittings will be required under the Contract, in
accordance with this Specification, unless detailed otherwise. Such testing will be
carried out before making final connections to the existing network. However
where tees or other fittings are inserted into existing pipelines and where lengths
of pipeline are replaced, no backfilling will be allowed at the tees or fittings or at
the joints between new and existing pipework until the pipeline has been returned
to service and a visual inspection of all such fittings and joints made at the
network pressure.
h) Should any inspection be unsatisfactory or any test fail the Contractor shall
replace defective pipes, leaking joints or otherwise reconstruct defective work as
instructed following which cleaning and testing will be repeated until the
Engineer's Representative certifies the pipeline to be satisfactory.
6.2.2 Testing of Non-Pressure/ Low Pressure Pipelines
a) Non pressure/ low pressure pipelines of all sizes shall be tested for joints by Air
test as specified in this section.
b) Non pressure/ low pressure pipelines of 900 mm nominal diameter or smaller

shall be given a preliminary air test when the pipeline is bedded and jointed
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Dubai Municipality
before backfilling and a final water test after backfilling in the presence and to the
c) Water tests will not normally be applied to non-pressure pipelines greater than
900 mm (nom.) internal diameter and acceptance of these pipelines will be
dependent on satisfactory visual test of the joint for infiltration of the pipes and
joints.
d) Unless otherwise instructed non-pressure pipelines shall be tested in sections

between manholes.
e) Air Test (Preliminary Test)
After a length of pipeline is bedded and jointed, and before backfilling, it shall be
given a preliminary test as detailed below:
1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.
2. Air shall be pumped in slowly to the pipe until a pressure of 100 mm

head of water is indicated on a manometer connected to the system.
3. After the internal pressure of 100 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.
4. Air may be added to restore the pressure to 100 mm.
5. During a further period of 5 minutes (without further pumping of air) the

pressure should not fall below 75 mm.
6. Release of the air pressure shall be carried out by removal of the

stopper at the end of the pipeline away from the manometer which will
remain connected. Failure to carry out the air pressure release in this
manner shall render the test invalid.
7. The Contractor will not be permitted to commence testing later than 4

hours after sunrise or earlier than 4 hours before sunset during the
summer period unless otherwise directed by the Engineer.
f) Water Test (Final Test)
After backfilling the length of pipeline under test, it shall be given the following final
test:
1. All branches and open ends shall be closed with suitable stoppers,
secured with longitudinal braces before testing commences.
2. Water shall be filled from the lowest point and air allowed to escape. No
entrapped air shall remain in the pipeline while testing.
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Dubai Municipality
3. An internal pressure equivalent to a head of water of depth to invert of

the pipeline plus 1.25 m, or 4 m head whichever is greater shall be
maintained for 30 minutes to allow for initial absorption of water.
4. After that, the test pressure shall be maintained for 60 minutes and
water added shall be measured.
5. Pipeline shall be treated as passed if water consumption in 60 minutes

does not exceed 7.5 litres per metre of diameter per 30 m of length of
pipeline under test.
g) Where in the opinion of the Engineer's Representative the above test is not
sufficiently indicative of water tightness by reason of high ground water levels the
test will not be applied. Acceptance of the pipelines will then depend on
satisfactory inspection or testing for infiltration as referred to below, and air test of
the pipeline in manhole lengths.
h) The Engineer may require any length of pipe suspected of being damaged to be
retested by the water test at any time during the contract period.
i) Infiltration Test
After completion of backfilling and restoration of normal subsoil conditions, all gravity
pipelines and manholes shall be examined for infiltration as follows:
1. All inlets to the system shall be closed sufficiently to prevent the

entrance of water.
2. Pumping of groundwater shall be discontinued for at least 3 days prior

to the test for infiltration.
3. The section of the pipeline under test, including manholes, shall be

accepted as satisfactory if the infiltration does not exceed 1.00 litre per
day per metre of pipeline per metre of nominal internal diameter.
j) Notwithstanding the satisfactory completion of the infiltration test, if there is any

discernible flow of water entering the pipeline at a point which can be located
either by visual or closed circuit television inspection, appropriate measures shall
be taken to stop such infiltration.
6.2.3 Testing of Pressure Pipelines
a) Pipelines shall be subjected to a preliminary air test as soon as a length of pipe

has been laid and before backfilling. Pressure pipelines shall then be given a
final test using water after they have been backfilled, cleaned and inspected.
b) Individual joint tests, by means of an approved joint testing apparatus, may be

used for pipes of 1200 mm diameter and above subject to the approval of the
Engineer.
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Dubai Municipality
c) Each joint shall be individually water tested by means of an approved joint testing
apparatus at a pressure of 100kN/m2. The test will not be considered satisfactory
if the loss of pressure during a test period of 30 minutes exceeds 10kN/m2 as
indicated by an approved pressure gauge having a range of 0 – 150 kN/m2.
d) Preliminary pressure testing of pipelines may be carried out if so required by the

Engineer with partial backfill only and exposed joints, but the stability and safety
of the Works must be ensured at all times.
e) Each test shall be restricted to pipes of one class. Pipelines shall be tested in
sections not exceeding 500 metres or between valve positions. In addition the
whole pipeline shall be tested upon completion. Particular care must be taken to
isolate air valves, etc., not to apply higher pressure than specified at any point on
the pipelines and to ensure that the pipelines are adequately anchored before any
test is carried out.
f) Gauges used for testing pressure pipelines shall be capable of reading

increments of 0.1 metre head. Before any pressure gauge is used, the Contractor
shall arrange for it to be checked independently and a dated certificate of its
accuracy shall be provided to the Engineer. Calibration of pressure gauges shall
be carried out at regular intervals as required by the Engineer
g) Air Test (Preliminary Test)
As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary test:
1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.
2. Air shall be pumped in slowly to the pipe until a pressure of 300 mm

head of water is indicated on a manometer connected to the system.
3. After the internal pressure of 300 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.
4. Air may be added to restore the pressure to 300 mm.
5. The test will not be satisfactory if the air pressure falls to less than 275
mm during a period of 5 minutes without further pumping of air.
h) Water Test (Final Test)
i) Pressure pipelines shall be given the following final test using water after they
have been backfilled, cleaned and inspected:
1. All the joints of the pipeline shall be left open for the purpose of
inspection for leakage if any, where practicable or instructed by the
Engineer.
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Dubai Municipality
2. Pipe ends shall be closed with suitable stoppers, secured with

longitudinal braces/thrust block, before testing commences.
3. Water shall be filled slowly from the lowest points and air allowed to
escape through an air vent fixed for the purpose at the highest points of
the pipeline section under test. No entrapped air shall remain in the
pipeline while testing.
4. Pressure in the pipeline shall then be raised steadily up to and

maintained at the rated pressure for a period of 30 minutes to allow for
absorption and achieve conditions as stable as possible for testing.
5. If no leakage has been observed, pumping shall then be resumed and

the pressure slowly raised to the specified test pressure.
6. Unless specified elsewhere or directed otherwise by the Engineer. The

minimum site test pressure shall be:
a. Reinforced Concrete Pipeline =1.5 x Maximum working pressure

of pipe line (or) 9 bar pressure whichever is higher
b. GRP Pipe lines =1.5 x Maximum working pressure

of pipe line (or) 9 bar pressure whichever is higher.
c. HDPE & P.P Pipe lines = 1.5 x maximum working pressure

of pipe line minus the deration factor above 25°C temperature at the
time of testing.
d. UPVC Pipe line =1.5 x maximum working pressure

of the pipe line minus the deration factor above 25°C temperature at
the time of testing.
e. Stainless steel Pipeline =1.5 x maximum working pressure

of the pipe line
f. D.I. Pipelines =1.5 x maximum working pressure

class of the pipe line
Note: (1) Below noted graph shall be used to calculate the derating factor.
(applicable only for thermoplastic pipes) . This shall be verified from the
manufacturer’s data.
(2) The maximum working pressure of the Pipeline shall be as specified. Pipes shall
be tested at site after installation at test pressure.
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Dubai Municipality
Figure 1: Graph of Derating Factor fT for Derating up to 45°C
7. Pressure in the pipeline shall be checked after a period of 60 minutes

and test pressure shall be restored by the use of the pump. The amount
of makeup water required to maintain the pressure shall be accurately
measured (to the nearest 1/8 litre).
8. Pipeline shall be deemed to have passed the test if all the following
conditions are satisfied:
a. No water is visible coming out of the pipe or joints at any point;
b. Amount of make-up water required does not exceed 1 litre per hour
per 100 mm diameter per kilometre of pipeline under test;
c. The loss of the pressure during the test period does not exceed
70KN per square metre.
6.3 TESTING OF VALVES
Valves and all pipelines appurtenances shall be hydraulically tested together with the
pipeline in which they are installed. Valves shall be tested for operation under working
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Dubai Municipality
pressure and shall be adjusted so that they operate smoothly, seat properly and are
installed to tolerances recommended by the manufacturer.
6.4 TESTING OF WATER RETAINING STRUCTURES
a) All water retaining structures shall be visually inspected to confirm that there is no
infiltration. Where it is required by the Engineer, water retaining structures shall
be tested for water tightness.
b) The Water test for liquid retaining structures shall be tested as described below.
(i) ‘For a test of liquid retention, the structure should be cleaned and initially
filled to the normal maximum level with the specified liquid (usually water) at
a uniform rate of not greater than 2 m in 24 h. When first filled, the liquid
level should be maintained by the addition of further liquid for a stabilizing
period while absorption and autogenous healing take place. The stabilizing
period may be 7 days for a maximum design crack width of 0.1 mm or 21
days for 0.2 mm or greater. After the stabilizing period the level of the liquid
surface should be recorded at 24 h intervals for a test period of 7 days.
During this 7-day test period the total permissible drop in level, after
allowing for evaporation and rainfall, should not exceed 1/500th of the
average water depth of the full tank, 10 mm or another specified amount.
Notwithstanding the satisfactory completion of the test, any evidence of
seepage of the liquid to the outside faces of the liquid-retaining walls should
be assessed against the requirements of the specification. Any necessary
remedial treatment of the concrete, cracks, or joints should, where
practicable, be carried out from the liquid face. When a remedial lining is
applied to inhibit leakage at a crack it should have adequate flexibility and
have no reaction with the stored liquid. Should the structure not satisfy the
7-day test, then after the completion of the remedial work it should be
refilled and if necessary left for a further stabilizing period; a further test of 7
days’ duration should then be undertaken in accordance with this clause.’
(ii) Or otherwise specified by the Engineer.
c) The roofs of the liquid retaining structures shall be tested & shall comply as
described below.
(i) ‘The roofs of liquid-retaining structures should be watertight and should,

where practicable, be tested on completion by flooding the roof with water to
a minimum depth of 25 mm for 24 h or longer if so specified. Where it is
impracticable, because of roof falls or otherwise, to contain a 25 mm depth
of water, the roof should have water applied by a continuous hose or
sprinkler system to provide a sheet flow of water over the entire area of the
roof for not less than 6 h. In either case the roof should be considered
satisfactory if no leaks or damp patches show on the soffit. Should the
structure not satisfy either of these tests, then after the completion of the
Structures
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Dubai Municipality
remedial work it should be retested in accordance with this clause. The roof
insulation and covering should be completed as soon as possible after
satisfactory testing.’
d) The test shall be carried out before any backfilling and before the application of
any internal and external concrete protection or roof membrane has taken place.
Any damages revealed as a result of such tests shall be made good to the
Structures
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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 7
CORROSION PROTECTION AND SURFACE COATING
DM/SRPD Section 7 Corrosion Protection and Surface Coating Rev 00 June
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Dubai Municipality
DM/SRPD Section 7 Corrosion Protection and Surface Coating Rev 00 June Page i of ii
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SECTION 7
CORROSION PROTECTION AND SURFACE COATING
CONTENTS
7 CORROSION PROTECTION AND SURFACE COATING ................................................ 1
7.1 MATERIALS .................................................................................................................. 1
7.1.1 Corrosive Environment and Corrosion Protection System ................................... 1
7.1.2 Paint...................................................................................................................... 2
7.1.3 Impervious Tanking Membrane ............................................................................ 2
7.1.4 PVC Sheet Lining Materials .................................................................................. 2
7.1.5 Glass Reinforced Plastic Liners ............................................................................ 3
7.1.6 In-situ GRP Laminations ....................................................................................... 6
7.1.7 Epoxy Mortar for Manholes ................................................................................. 20
7.1.8 Rubberised Bitumen Emulsion ........................................................................... 21
7.1.9 Waterproof Paper ............................................................................................... 22
7.1.10 Protective Materials for Wrapping Pipeline Components ................................... 22
7.1.11 High Density Polyethylene Protection Sheet ...................................................... 22
7.1.12 Protective Coating with Cementitious Water Proof Coating................................ 22
7.1.13 Approved Paint Suppliers ................................................................................... 24
7.1.14 In-situ GRP Lamination with Grit bonding on final finish coat ............................. 24
7.1.15 Epoxy Coating .................................................................................................... 24
7.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO

CONCRETE ................................................................................................................. 25
7.2.1 General ............................................................................................................... 25
7.2.2 Water Proof Membranes/Liners/Roof Waterproofing and Protective Coatings... 25
7.2.3 GRP Prefabricated benching unit for Sewer Inspection Chambers .................... 39
7.2.4 Cutting and Sealing of Reinforced Liners ........................................................... 39
7.2.5 Protective Coatings to Concrete Works .............................................................. 40
7.2.6 Coating System for Ferrous, Non Ferrous Metals and Plastics .......................... 47
DM/SRPD Section 7 Corrosion Protection and Surface Coating Rev 00 June Page ii of ii
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7 CORROSION PROTECTION AND SURFACE COATING
7.1 MATERIALS
7.1.1 Corrosive Environment and Corrosion Protection System
Corrosion protection systems and surface coatings shall in all cases be suitable for
exposure to their contact with environmental conditions which may include any or all
of the following:
a) The average climatic conditions prevailing in the project area with particular
emphasis on temperature variations, high surface temperatures and high humidity.
The following table presents the average climatic conditions exist in Dubai:
Table 7.1 – Average Climatic Conditions in Dubai
Maximum Ambient Temperature 52ºC
Minimum Ambient Temperature 1ºC
Max. incident light intensity (energy) 50ºC
Light intensity (measured under the sun) approximately 50,000 Lux
Maximum metal temperature under the sun 85ºC
Min. Barometric Pressure 998 mb
Max. Barometric Pressure 1030 mb
Average Barometric Pressure 1015mb
Max. Ambient Humidity 100%
Min. Ambient Humidity 20%
Design Ambient Humidity 80%
Max. Design Wind Velocity 160 km/hr
Average yearly Rainfall 80 mm
i. The climate of Dubai is relatively mild from November to April, and hot from May
to October with high relative humidity.
ii. Under certain combinations of the above climatic conditions considerable

condensation may take place.
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iii. A considerable amount of salt is contained in the atmosphere, which together

with the extremely high ambient humidity can produce severe corrosion problems.
iv. Distribution of rainfall is irregular, and the precipitation amounts are normally of
no significance, but attention should be paid to the fact that sudden heavy rain falls in
a very short period of time can occur.
v. The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr and sandstorms and dust-
storms occur in the summer months.
b) Sea water with a pH value of 7 to 9 and maximum salinity upto 40,000 ppm.
c) Saline groundwater with high chloride or sulphate contents both below the water
table and in soil zones above the water table where capillary action and the presence
of oxygen may cause extremely severe conditions.
d) Windblown chlorides
e) Windblown abrasive sands
7.1.2 Paint
a) Protective and decorative paint systems including primers and undercoats shall
be obtained ready mixed for use. All containers of paints and other coating systems
shall show date of manufacture, shelf life and pot life where applicable. Paint shall be
applied as per Clauses in section 7.2.
b) The Contractor shall only be allowed to use paints which are delivered to the site
in sealed cans or drums bearing the name of the manufacturer and properly labelled.
c) Tints and shades of final coats shall be advised by the Engineer or his
Representative.
7.1.3 Impervious Tanking Membrane
Membrane used for tanking to concrete structures shall be impervious, self-adhesive

and covered with a release agent.
7.1.4 PVC Sheet Lining Materials
a) PVC sheet materials to be used for lining concrete structures and pipelines
internally shall be manufactured from polyvinyl chloride, plasticisers and pigments to
make permanently flexible sheets.
b) The colour of the sheet shall be approved on site.
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c) The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed
by extrusion to have on one side locking keys or ribs of either 'T' or diamond section
at centres not greater than 75 mm. It shall be capable of forming a continuous 100%
effective seal with the use of welding strips or other approved method and shall be
supplied with all materials and tools for making the joints.
d) The tensile strength of the material shall not be less than 17,000 kN/m2.
e) All weld strips, patches and other sheets used in the permanent fixing of the
ribbed sheet shall be of a material having the same composition as the ribbed sheet.
7.1.5 Glass Reinforced Plastic Liners
a) Glass Reinforced plastic liners to be used for lining water retaining structures,
pumping stations and manholes shall be manufactured to the dimensions given on
the Drawings, within the following tolerances:
1. The work size, which is defined as internal diameter as specified by the

manufacturer, shall be declared and shall not differ from the normal diameter by more
than ±1%.
A manufacturing tolerance on the work size of 10 mm will be allowed provided

that a tight fit is achieved between the liner and the slab liner.
2. Liners shall be supplied in lengths to suit requirements with a resin ¬rich finish to
internal surfaces.
3. Maximum thickness shall be 7 mm for required works as specified. Liners larger

than 2000 mm in diameter shall have a minimum wall thickness of 9 mm.
4. The out of squareness shall not be greater than 10 mm.
5. The deviation from straightness of the bore of the liner shall not exceed 20 mm.
b) Although the liners are not designed to be structural, they shall have a sufficient
stiffness to withstand:
1. Buckling or distortion in transit or storage.
2. A hydrostatic head of 8 metres without distortion damage, leakage or

permeation.
3. Grouting pressures.
c) Prior to grouting of the manhole liner at least 24 hours shall be allowed for
temperature equalization between the manhole structure and the reinforced plastic
liner.
d) The manufacturer shall provide shop drawings of the proposed top slab liners
prior to manufacture for approval.
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e) The manufacturer shall stipulate the maximum deflection of the slab liner
permitted without causing surface cracking to the gel coat. The Contractor must take
care not to exceed this limit, and any surface cracking that occurs will be repaired.
f) The construction methods employed shall be so as to ensure that a completely

water and gas tight seal is made preventing any exposure of the concrete surround to
the corrosive liquids and gases present, in the sewage.
g) In particular:
1. Glass Reinforced plastic liners shall be handled in the same manner as glass
reinforced plastic pipes. In addition, extra care shall be taken to avoid damage to the
liners which are not designed to carry loads.
2. The manufacturer shall visit the site to demonstrate to the Contractor in the
presence of the Engineer's Representative the methods of handling and lifting,
including formation of the joints between the chamber liners.
3. The Contractor is reminded that these liners are not designed to withstand
pressure exerted by the concrete during construction.
4. The design of GRP liners to provide a permanent internal shutter, to the concrete
structures shall be the responsibility of the liner manufacturer. The design should
however incorporate all the requirements of these Specifications.
5. The liner shall be designed to provide protection for concrete for 50 years from
the corrosive effects of raw sewage/ sea water or other liquid in temperature up to
50°C. The GRP liners shall be machine made filament wound and of similar material
(except sand filler) construction and manufacturing process as for the GRP pipe.
h) Chemical Requirements
The liner design shall qualify the chemical requirements specified in ASTM D3753.
1. Testing shall be performed in accordance with the chemical test method.
2. The log percentage property retention versus log of time data graph should be
extrapolated by a linear plot beyond the 12 months result to 10,000 hours. The
extrapolated data must assure retention of at least 50% of the initial properties.
i) Chemical Test Method
Testing procedures for measuring chemical resistance shall conform to ASTM C581
with the exceptions as noted below:
1. Test Laminate Construction: The basic test coupon shall be cut from a laminate
made in a manner consistent in every way with manhole construction.
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2. Test Intervals: Coupons shall be drawn and tested after 1 month, 3 months, 6
months, and 12 months immersion in each test medium. It may be advisable to
include extra coupons at the time of the initial immersion in the event it is necessary
to extend the test interval beyond 1 year to 10,000 hours.
3. Test Media: The test media shall represent as completely as equal to the actual
environment in the manhole service. In that respect, test medium shall be the material
as specified for chemical resistance for sewer manholes.
4. Test Temperature: The test temperature of test medium used in corrosion

resistance verification of manhole containing that medium (normally this shall be
50ºC).
5. Interpretation of Results: Laminate properties to be determined initially and after

each test period are flexural strength, flexural modulus (both as per ASTM D790) and
the Barcol hardness as per ASTM D2583) of both interior and exterior lamination. The
laminate should be fully cured before initial properties are obtained. Any effect up on
the immersion medium or laminate observed during visual inspection shall be noted.
The log percentage retention after immersion testing (verses initial) is to be plotted
against the log of immersion time in hours.
j) Quality Control Testing
The following test shall be carried out as detailed below:
1. Composition Test: A loss on ignition test shall be carried out once every 100m of
shaft produced. Conduct the test as per ASTM D2584 and determine the glass/resin
ratio. Controls on glass and resin content must be maintained for all manufacturing
process and for each portion of manhole fabrication. Record shall be maintained of
these control checks.
2. Barcol Hardness: Each manhole component part shall be tested in accordance

with ASTM D2583, standard method of test for Indentation Hardness of plastics by
means of a Barcol Impressor. The minimum acceptable value of cure shall not be
less than 90 percent of the resin manufacturers’ minimum value for the cured resin.
3. Thickness: Wall thickness of each manhole component part shall be checked

with a micrometer caliper gauge, or other suitable instrument to establish the actual
thickness.
4. Appearance (Interior and Exterior Surfaces): The following defects are not
permitted.
(a) Crazing (b) Delamination (c) Blisters (d) Fiber show (e) Surface pits and voids
directly beneath the surface of the laminate and on the surfaces (f) Dry spots (g)
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Pimples (h) Pit or pinhole (i) Resin pocket (j) Deep scratches (k) Impact cracks (l)
Fish eye (m) Worm holes (n) Deep wrinkles.
k) Certification
When requested, a certification shall be made on the basis of acceptance. This shall
consist of manufacturers test report accompanied by copy of test results, which the
GRP liner has been sampled, tested and inspected, in accordance with the previsions
of this specification and meets all requirements. Each certification shall be signed by
the manufacturer.
l) Cutting and Sealing of Reinforced Liners
1. Where the Contractor is required for any reason to cut reinforced plastic liners,
he shall seal the exposed ends with an approved resin before incorporating the cut
reinforced plastic in the work. No cut reinforced plastic shall be used until the resin
has cured.
2. The resin shall be as recommended by the manufacturer of the reinforced plastic

item and shall be pigmented so that the areas where it has been applied are easily
identifiable.
3. It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labeled as to its content and shelf life.
4. For flexible pipe materials a rubber protection strip shall be inserted between the
pipe barrel and the steel band.
7.1.6 In-situ GRP Laminations
a) General
This Clause shall cover all in-situ GRP lamination work to be carried out under the
Contract as corrosion protection. It shall include site work related to jointing of
prefabricated reinforced plastic components e.g. manhole liners, GRP pipe sleeves,
lamination work to benchings and channels, sealing of pipe entries, lamination work
to internal concrete faces of major concrete structures, pumping stations, valve
chambers, air valves and washout chambers etc as shown in the approved drawings.
b) Site Operatives for GRP Work
1. The In-situ GRP lamination work shall be carried out only by the DM approved
laminators. All lamination work must be carried out by skilled operators under the
supervision of a worker with a minimum of 10 years experience in in-situ lamination.
2. The Contractor shall only employ personnel who have received suitable training
and possess relevant experience in the execution of any in-situ GRP work, including
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lamination work and the cutting, sealing and jointing of reinforced plastic. Site
operatives for employment on this work shall be certified in writing by the supplier or
Contractor as trained to a satisfactory standard in application techniques.
3. Such personnel will be subject to approval by the Engineer prior to the

commencement of such work. Approval will include site trials to demonstrate
competence to undertake the work.
4. GRP Applicator’s Special Requirements
The company doing the GRP lamination work should have:
i. A Safety Manual ‘For Guide to Making a Laminate, Planning and Maintaining the
Work area’
ii. An automatic master and batch mixer with agitator
iii. A mobile storage (fire-proof) vehicle with steel container having AC, exhaust fan
inside for storing the resin and glass and the master batch resin mixer.
iv. Automatic resin discharge pump system and spray facilities to feed the resin
from master batch mixer into the laminated work area to achieve a uniform resin
mixing and dispensing during lamination period.
v. In-situ testing apparatus to carry out the following quality control tests.
– Barcol impressor Nr. 934-1 with sufficient numbers of calibrating shim.
– Digital elcometer thickness gauge with calibration shim
– Pull off adhesion tester with sufficient numbers of dolly.
– Holiday detection spark tester recommended by the resin manufacturer
– Relevant hammer for hammer test
vi. Safety arrangements to keep inflammable catalysts with fire hydrant in working
condition.
vii. Services of an efficient technician at site to mix the resin in desired proportion to
suit the variable working temperature condition at site.
viii. AC room facilities for bulk storage of resin drums and glass mat rolls in an
isolated place.
ix. first aid facilities and the services of a safety engineer at site.
x. Sufficient numbers of powerful exhaust fan at working area to clear out the
styrene gas.
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xi. Breathable air inlet facilities for the workers at site
xii. Safety harness for each labourer working on site.
c) Method Statement
1. All in-situ lamination must be carried out in accordance with an approved

detailed method statement. This shall include details of all materials to be used
together with the manufacturers’ names, addresses and specification sheets.
Particular details of procedures relative to separate categories of work as given
above shall be itemised separately.
2. If materials are to be stored on site then details shall be provided of the store in
which the materials are to be kept, the environmental controls which will be used to
ensure materials are stored in accordance with manufacturers’ recommendations and
the control and security arrangements necessary to prevent unauthorised tampering
with materials.
3. If materials are to be brought to site on a daily basis from the supplier’s central
store in site containers then details shall be provided of the type, size and
identification markings on each container to be used for this purpose. The Contractor
shall indicate the controls to be set-up to ensure that different resins and materials
are clearly identifiable at site. The method statement shall include forms to be
submitted to the Engineer which will be necessary to record the decanting of
materials from manufacturers containers to site.
d) Materials in GRP Lamination
Table 7.2 – Materials in GRP Lamination
1 Type of resin to prime Epoxy based vinyl ester resin having minimum 8%
the concrete surface elongation property
2 Type of glass (csm) Powder bound ECR/Advantex fiber glass ‘csm’
throughout the having excellent corrosion resistance to acids
lamination
3 Type of ‘C’ glass tissue ‘C’ glass of ECR type having excellent corrosion
for final layer resistant to acids
4 Recommended catalysts 1. BUTANOX LPT
to prepare resin at site 2. MEKP LA 3
5 Type of resin throughout Epoxy based vinyl ester
the lamination
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Table 7.3 Typical Room Temperature Clear Casting properties of VE Resin
Tests Epoxy Resin Epoxy Resin Method of Analysis

Primer
Tensile Strength MPa 81 70 ASTM D-638

Tensile elongation at 5 8 ,, D-638
yield%
Tensile modulus GPa 3.3 3.1 ,, D-638
Flexural strength MPa 124 135 ,, D-790
Flexural modulus GPa 3.1 3.2 ,, D-790
Compressive Strength 114 86 ,, D-695
MPa
Compressive Modulus 2.4 2.2 ,, D-695
GPa
Compressive deformation 6 6 ,, D-695
at yield%
Specific Gravity 1.12 1.13
Average coefficient of 65 70
expansion between 25
and 100ºC X10-6 cm
cmºC
Izod impact J/m 22 250 ,, D-256
Heat distortion temp ºC 102 80 ,, D-648
Barcol Hardness 35 40 Barcol impresser
model 934 -
Table 7.4 Typical Properties of Liquid Resins
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Property Epoxy Resin Epoxy Resin Primer
Styrene Level % 45 40
Brook field Viscosity MPa 500 350
at 25ºC
Flash point ºC Tag open 34 32
cup
Specific Gravity uncured at 1.04 1.04
25ºC
Acid number maximum 8.5 10
Storage stability (months) 6 3
Table 7.5 Physical Properties of ECR / Advantex Glass Fibres
Property Test Method Unit ECR/Advantex

Density ASTM D1505 g/cc 2.62
Refractive index Oil Immersion 1.560-1.562
Thermal linear ASTM D696 Ppm/C 6
expansion 0 -
300ºC
Softening point ASTM C338 ºC 916
Annealing point Parallel Plate ºC 736
Viscometry
Strain point Parallel Plate ºC 691
Viscometry
Table 7.6 ECR/Advantex Single Filament Tensile Properties
Property Test Method Unit ECR/Advantex

Tensile Strength ASTM D2101 MPa Kpsi 3100-3800 450-550
@23ºC
Elastic Modulus Sonic Method GPa MPsi 80-81 11.6 – 11.8
Elongation at the ASTM D2101 % 4.6
Breaking Load
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4. The method statement shall also provide details of the material build up or layup.
It shall state the number and type of layers of glass fibre reinforcement together with
the resin used to impregnate it. Proposed layup shall be not less than the
requirements detailed in this Clause.
5. The method statement shall also detail the Contractor’s safety proposals with
respect to this work to demonstrate compliance with his obligations under the
Contract, for each type of work location.
6. Surface preparation
i. The concrete surface must be fully cured and older than 4 weeks.
ii. Before commencing work surfaces must be cleaned down, suitably prepared and
allowed to dry. Under no circumstances must the laminate be applied in dirty, damp
or wet conditions.
iii. Once dry, no water should be allowed into the structure except that required for
safety reasons.
iv. Concrete surfaces must be clean, sound, dry and dust free. Any surface
laitance, loose or unsound concrete etc shall be removed. Surfaces must be entirely
free of oil, grease, paint, detergents, rust, biological or other surface contaminants.
Surfaces shall preferably be prepared by high pressure water jetting, pneumatic
scabbling, grinding or steel grit blasting, followed by thorough brushing with a clean
paint brush (used only for this purpose) or by washing to remove dust and remaining
particles and to provide an exposed aggregate finish to ensure a mechanical key to
the laminate. Diesel, oil and grease contaminants shall be removed and rinsed
thoroughly with water by steam cleaning, detergent scrubbing or the use of
proprietary degreaser. Effectiveness of decontamination may, on the instructions of
the Engineer, require to be assessed by a pull-off test. The hardened condition of the
concrete substrate is to be subjected to hammer test by tapping on concrete and
make sure any hollow sound is not produced. The defective concrete is to be
removed and make good and allow the surface to dry condition.
v. Prior to application, all active hydrostatic leaks must be stopped by the use of an
appropriate approved material specifically formulated to stop the ingress of water.
vi. Where the laminate will be in contact with the surface or edges of uPVC pipes or
existing GRP laminates, liners, pipe or fittings the contact surface shall first be
roughened by grinding or wire brushing. The contact surface for benching
lamination extending within GRP pipes shall be accurately feather ground from 0 to 7
mm over a length of 150 mm. All dust shall be removed as above.
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vii. Grinding shall be carried out to limits neatly defined by masking tape or other
approved means. Measures shall be taken to prevent damage to surfaces outside
such limits by the use of appropriate masking devices etc.
viii. On concrete surfaces of major structures, base slab wall and roof slab: -
ix. After completed two layers of GRP lamination work, SS 316 grade hilty nails are
to be shot into the concrete by the help of a shotgun at 60 cm intervals to achieve a
proper key in interlock between the concrete surface and the GRP lamination work.
Further layers of lamination work shall be continued after the nail fixing.
x. Particular care is needed in preparation to ensure that the correct laminate

thickness will be maintained over nosings to the arris between horizontal and vertical
parts of the benching, including removal of concrete as necessary.
xi. Following after obtaining engineer’s approval for the GRP materials a trial
lamination work to a size of 1.2M x 1.2M shall be carried out on concrete surfaces of
any one of the structures and conduct the followings Pre qualification test. These
trials shall be carried out using the approved type of materials, mixing procedures and
applications as will be used on the Contract.
Table 7.7 Trial Sample and Pre qualification Test on GRP Lamination Work
Sr. Test Test method Minimum Test Requirements

1 100 days acid ASTM C581 Test sample shall not show
immersion test @10% any defects as mentioned in
concentrated sulfuric relevant standard
acid at 50ºC
2 Flexural strength of ASTM D790 193 MPa
GRP laminate sample
3 Tensile strength of GRP ASTM D639 138 MPa
laminate sample
4 Pull off adhesion ASTM D 4541 Pulling strength shall be
strength of lamination greater than concrete
5 Resin / Glass ratio ASTM D 2584 60:40
6 Resin cure Barcol Impressor Minimum : 33 Barcol reading
934-1 in accordance with the
manufacturer’s test
procedure specified.
7 Thickness of Lamination Digital Elcometer Not less than the specified
thickness
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8 Holiday Detection Test 105 DC high voltage Air bubble / voids free
0-10 to 20 kV surface on final lamination
Holiday Detector
9 Surface Quality ASTM D 2563 Quality level ‘2’ as specified
in relevant standard
10 Acetone Sensitivity test Resin Tack free surface on GRP
manufacturer’s lamination
recommended test
11 Hollow sound detection Hammer test No hollow sound on
completed lamination work.
Note:
1. All relevant samples of GRP lamination test coupons are to be taken from the
test patch area and identified by the Engineer.
2. The tests are to be witnessed by the Engineer.
3. Testing apparatus required for in-situ tests is to be provided by the GRP
applicator.
xii. The acid immersion test will take 100 days duration and hence the applicator
shall provide a guarantee for the work until they get the relevant test results for the
GRP lamination work. The lamination work shall start at site on written confirmation
with the guarantee.
Table 7.8 Minimum Quality Control Test on Final GRP Lamination work
Sr. Test Test method Minimum Test Requirements

1 Barcol Hardness Resin Average 33 reading on
manufacturer’s Barcol Impressor @ 100% of
recommended test laminate area in accordance
method with test procedure specified
2 Thickness Digital elcometer Min. 3 tests on each
structure and shall achieve
the minimum thickness
specified.
3 Alarm type Spark test As stated in Spark Full surface area of each
tester catalogue structure. Locate the
defects if any & repair in
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good condition
4 Pull off adhesion test Pull off test in Minimum one test on each
accordance with major structure. Pull off
ASTM D4541 strength shall be greater
than the concrete strength
5 Resin glass ratio ASTM D 2584 One test on a sample taken
from any one of the
structure. The proportion
shall be 5% of the
specified value
6 Visual inspection ADTM D 2563 100% of the GRP laminated
area. Required Level-2 as
specified in the standard.
e) Test Procedure for Barcol Hardness Test Recommended by the Resin

Manufacturer
– Use Barcol impresser apparatus Nr. 934-1
– Take 10 – 12 readings on test patch area
– Reject the highest and lowest readings
– Take the average of the remaining 10 readings to get the barcol hardness value
1. Final approval for the GRP lamination work will be given by the Engineer only
after comply with the pre-qualification test specified.
2. Final approval for GRP work to proceed on site shall be subject to satisfactory
compliance test results observed at site.
3. Site Lamination
i. The following details of lamination apply to all work required under the Contract.
ii. Application shall be carried out in the cooler times of the day i.e. early morning or
late evening. Application shall not be carried out to surfaces exposed to direct
sunlight and high surface temperatures. Shade structures shall be provided as
necessary. Application shall not be carried out in conditions of windblown dust and
sand or during periods of high humidity.
iii. Before entering any chamber or standing on any surface which is to receive
lamination workers shall check their footwear to ensure that it is clean and will not
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transfer contamination. Care shall be taken when passing materials down into
chambers etc. to avoid entry of contaminating materials.
iv. Upon completion of mixing, materials shall be used immediately. During

lamination, work must cease immediately if the resin starts to gel and the work
completed to that point shall be allowed to cure before restarting.
v. No standing on or application of pressure to uncured laminates will be permitted

as this will result in squeezing out of resin producing defective areas of laminate
where the glass has not been fully wetted out.
vi. All surfaces to receive lamination shall be prepared as detailed above.

Lamination shall not be carried out to concrete surfaces until they have cured for at
least the minimum number of days recommended by the resin manufacturer since
casting of the concrete.
vii. All lamination to surfaces of prefabricated components shall be gradually

feathered away to a defined limit using masking tape or similar so that the final
appearance is neat without a sudden change in thickness or of appearance to the
completed job.
4. Lamination Build-up
i. A Primer coat of 75 to 125 micron catalysed vinyl ester resin shall be painted
over the area to be laminated. Whilst still wet one layer of ECR/Advantex glass shall
be applied over the area. Where it is necessary to make a joint in the reinforcement
then the reinforcement must overlap by a minimum of 25 mm. The reinforcement
shall then be rolled with a metal roller and then wet out with further resin until fully
wet. It shall then be carefully finally rolled with a metal roller to remove all air and
consolidate the laminate.
ii. Successive layers of ECR/Advantex glass shall be added and fully wetted-out
with epoxy based vinyl ester resin. Between applying each layer the laminate shall
be fully rolled using the metal roller to ensure that all the air is removed from all the
layers.
iii. Joints in reinforcement layers shall not lie directly above joints in layers below.
iv. This layer shall be allowed to fully cure. When fully dry the whole surface shall be
lightly abraded using a grinder with a 120 grit disc.
v. A coat of vinyl ester resin shall be applied over the area. Whilst still wet one layer
of ECR/Advantex glass chopped strand mat shall be applied. Further layers of ECR/
Advantex glass chopped strand mat shall be applied and fully wet out with epoxy
based vinyl ester resin and rolled with a metal roller.
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vi. The final two layers of 'c' glass tissue shall then be applied and wet out with vinyl
ester resin. These layers shall not be rolled with a metal roller.
vii. When the last layer has dried it shall be lightly sanded using 120 grade wet and
dry abrasive paper to remove any lumps or loose fibres. Any resin runs shall also be
removed making sure not to de-laminate the previous layers.
viii. A final layer of epoxy based vinyl ester resin incorporating a sealing agent
(paraffin wax) to ensure final and full cure shall then be applied over the whole
laminate and allowed to dry.
ix. In situ GRP lamination to concrete surfaces shall have the following composition,
as a minimum requirement.
Final finished GRP surface Finished GRP Surface with Paraffinated vinyl ester
resin flowcoat
2 x ECR, ‘C’ glass tissue impregnated with Epoxy

based vinyl ester resin
300 g/m2 ECR glass CSM impregnated with Epoxy
Minimum 7 mm thick GRP 600 g/m2 ECR glass CSM impregnated with Epoxy
Laminated Composite based vinyl ester resin
Concrete surface Vinyl ester Resin Prime Surface coat
x. In situ GRP lamination to the internal faces of brickwork corbelling shall have a
lesser composition as a minimum requirement as follows.
Final finished GRP surface Finished GRP Surface with Paraffinated

vinyl ester resin flowcoat
2 x ECR, ‘C’ glass tissue CSM impregnated

with Epoxy based vinyl ester resin
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Dubai Municipality
Minimum 3 mm thick GRP 300 g/m2 ECR glass CSM impregnated with
Laminated Composite Epoxy based vinyl ester resin


Vinyl ester Resin Prime Surface coat
Concrete surface Concrete surface
5. Pipe Entries
i. The position of the centre of the required hole shall be accurately marked. This
includes holes to liners only where a boxout has been provided through the structural
wall. The prefabricated component and/or concrete wall shall be neatly cut by means
of a hole saw or diamond drill coring machine. The radius of the hole shall be not less
than the outer pipe radius plus 5 mm nor more than the outer pipe radius plus 15 mm.
ii. The surface of the liner shall be abraded to a distance of 100 mm from the cut
hole. The pipe to be fitted shall have its end and final 75 mm of barrel prepared to
receive lamination.
iii. The pipe shall be-fitted and securely fixed in position in accordance with an
approved Method Statement. It shall protrude at least 50 mm and not more than 100
mm past the face of the liner. The annular gap shall be filled with vinyl ester putty
which shall be neatly trimmed and allowed to cure.
iv. Lamination shall then be carried out to seal the pipe entry to the liner using ECR'
glass build-up to a minimum of 7 mm thickness but using vinyl ester resin only
throughout. Lamination shall be turned over the pipe end.
v. These requirements apply to all pipe entries including house connections, cable
ducts, air release pipework from pump casings, sump pump discharges, penstock
spindle sleeves, etc.
vi. These requirements apply to pipes built through both walls above benching level
and to pipes through walls into the benching. Sealing requirements where the pipes
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Dubai Municipality
penetrate the main structural wall are identical in both cases irrespective of whether
the pipe will later be covered by benching concrete.
vii. Should the material of the pipe built through the walls into the benching be
incompatible with in situ GRP lamination materials then the joint between the pipe
and liner shall incorporate a prefabricated GRP pipe sleeve which shall be bonded to
the pipe outer diameter with a solvent free epoxy adhesive putty. In-situ GRP
benching lamination shall be bonded to the inner faces of the GRP pipe sleeve in
accordance with the above.
6. Cutting and Sealing of Reinforced Plastic
i. Where the manufacturer or Contractor is required for any reason to cut or drill
prefabricated reinforced plastic (GRP), including pipes, he shall completely seal the
exposed ends and edges with a coat of approved vinyl ester resin, before
incorporating the cut reinforced plastic into the Works. No cut reinforced plastic shall
be used until the sealing resin has fully cured.
ii. Resin used for sealing shall be delivered to site in sealed containers bearing the
name of the manufacturer and properly labeled as to its contents, storage
requirements and shelf life.
7. Safety Precautions
i. Proper ventilation and/or breathing apparatus shall be provided and all

necessary precautions shall be taken to ensure the safety of workers when in situ
GRP lamination materials are being used.
ii. Applicators shall also be made aware of the health risks involved in working with
these materials. Skin and eye contact should be prevented by the use of plastic or
rubber gloves, barrier creams, eye protection and protective clothing. Smoking will
not be permitted.
iii. Nothing in this Clause shall be deemed to limit the Contractor's more general
obligations under the Contract.
f) In-Situ GRP Lamination Requirements
Following Lamination Procedures and tests are to be conducted by the G.R.P

applicator.
1. To reduce air bubbles in the laminate relevant catalysts recommended by the

resin manufacturers only to be used. Catalyst manufacturer's technical catalogue to
be provided along with the material submission.
2. Samples of all materials to be used on sites are to be provided prior to start of

lamination work on site.
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Dubai Municipality
3. Resin and glass mat brought to the site are to be supplied in manufacturers
sealed drums, in packets with manufacturing date, compliance certificate and the
allowable pot life.
4. Details of each constituent material and proof of supply throughout the work
period on site from the manufacturer is to be provided. Also provide test certificates
from the relevant material manufacturers for the materials used on site.
5. The lamination work is to be guaranteed for material and workmanship for a

period of 10 years from completion by the applicator and countersigned by the
manufacturer.
6. A Trial lamination is to be carried out in the presence of Engineer's

Representatives using proposed materials and the procedure, as specified, on a
concrete surface and arrange to conduct an initial pull off test, barcol hardness,
thickness and resin/glass ratio tests.
7. Lining of a concrete surface is to be carried out as per the manufacturers

recommended procedure.
8. Care must be exercised to ensure the correct balance of catalyst and accelerator
for optimum curing. Checking for complete cure to be carried out as per the
procedure recommended by the manufacturer.
9. The resin/glass ratio in the laminate, type of resin and glass and the sequence of
layers proposed are to be reported.
10. Final laminate thickness, loss on ignition, pull off adhesion, hardness tests etc are
to be conducted to prove compliance of the laminate with the contract requirement
and specification.
11. 100 days acid immersion test in 10 percent concentrated sulphuric acid solution
at 50 degree centigrade using final laminate samples ¬selected by the Consultant is
to be carried out. In-situ tests on the resin will be conducted during lamination work.
12. 2 layers of 'c' glass tissue of ECR type to be used on the final laminate.
13. Final wax topcoat resin formulation to be as per the procedure recommended by
the manufacturer.
14. Provide full details of safety measures that will be instituted during lamination
works for separate approval before starting any in-situ work. A full time supervisor
from the applicator's side must be on site.
15. Provide technical catalogue for all the type of resin, glass and surface tissue
proposed.
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16. Minimum thickness of lamination shall be 7 mm and use only ECR glass epoxy
based vinyl ester resin approved by the Engineer.
17. No hollow sound on final laminate will be permitted.
18. Lamination work is to be carried out in layer by layer and not to apply more than 3
layers in a day and allow the styrene gas to come out and enough curing time for
curing each layer.
19. Final approval shall be given following the acceptance of quality of the finished
works.
Material samples, safety procedures, material details, guarantee letter, name of

skilled workers and supervisors etc. are to be provided prior to starting the lamination
work on site.
7.1.7 Epoxy Mortar for Manholes
a) Where indicated on the drawings or specified to use epoxy mortar for benching
and channels in any manhole or any other structure such as chambers, pump station
wet-well, etc., they shall be formed to have a min. of 10 mm thickness of an approved
epoxy-resin mortar system.
b) The epoxy mortar system shall be a trowellable, two component epoxy resin
system consisting of a prefilled base and unfilled reactor which when mixed shall
produce a high strength, impermeable and chemically resistant mortar.
c) The epoxy mortar system shall have excellent chemical resistance to sodium
chloride and sulphuric acid (shall pass the relevant chemical resistance test), and
shall have high impact resistance. Typical properties are given in the following table:
Table 7.9 Properties of Two Component Epoxy Mortar
Property Test Method Limit

Sag at 10 mm thickness - None
Working Time ASTM C308 > 90 min. at 25°C
Full Cure at 25°C - 3 to 7 days
Setting Time at 25°C - 30 to 45 min.
Water Absorption ASTM C413 < 0.07 %
Compressive Strength BS 6319:Part 2 > 40 N/mm² at 25°C, 7
days cure
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Flexural Strength BS 6319:Part 3 > 3 N/mm² at 25°C, 7

days cure
Tensile Strength BS 6319:Part 7 > 8 N/mm²
Bond Strength BS 6319:Part 4 > 30 N/mm²
Density BS 6319:Part 1 1750 kg/m³
d) When placed on a concrete substrate the epoxy mortar system shall have an
adhesive strength of not less than the internal cohesive strength of concrete.
e) To achieve the necessary adhesion to the substrate an epoxy primer compatible

for use with the mortar and the substrate shall be applied.
f) The epoxy mortar or the primer where required, shall be suitable for application
onto a substrate with moisture content of 4% or less as measured by the "wet-check"
Moisture Meter or other instruments approved by the Engineer.
g) The pot-life of the mixed mortar shall not be less than one hour at the
temperature at the place of application at the time of mixing. The Engineer may
restrict application to such time as the ambient temperature is sufficiently low for the
specified pot-life to be ensured.
h) There shall be strict control of surface cleanliness between primer and epoxy
mortar and between coats of the same. Vacuum removal of dust and sand shall be
employed and water soluble contamination shall be removed as specified above.
Where dirt or dust has become trapped in the primed surface it shall be removed with
suitable abrasive paper. The surface being primed shall be free of visible moisture
throughout these operations.
i) The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a
maximum tolerance of +4 hours. Where this is exceeded the surfaces to be re-coated
shall be suitably abraded to remove gloss.
j) Mixing of the components shall be strictly in accordance with the Manufacturer's

recommendations and care shall be taken to avoid the entrainment of air in the
mixes.
k) Wet thickness gauge shall be used by the mortar applicators continually to check
that sufficient mortar is being applied to achieve the required dry thickness.
7.1.8 Rubberised Bitumen Emulsion
a) The bitumen emulsion shall be a cold applied thixotropic coating incorporating

liquid latex in the bitumen emulsion conforming to BS 8102. The latex content will be
a minimum 10% on the dried film and the solid content Min. 60%.
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b) The coating shall be applied in two coats with a priming coat which will be made
by diluting the bitumen emulsion with max. 10% clean potable water or as
manufacturer’s recommendations.
c) Two undiluted coats of the bitumen paint shall be applied @ 1.1 lit/m2 in two
coats. The total dry film thickness of the coating shall be Min. 0.50 mm.
d) The second coat will be applied at right angles of the first coat and only after the
coat has dried completely.
e) For concrete haunching at manhole and chamber covers and for 300 mm height
of concrete of structures above ground level, two coats of rubberised bituminous
emulsion system shall be applied. The second coat shall not be the same colour as
with the first.
f) The brush applied bituminous emulsion shall be used on location as given in the
approved drawings. The surface shall first be wire brushed and all dust and loose
scale removed. Both methods of protection shall totally enclose the substructure
within a water proof membrane of either polyethylene sheet or a waterproof building
paper as applicable to the limits shown on the drawings.
7.1.9 Waterproof Paper
Waterproof building paper shall be to the approved standard. For road works it shall
be Class ‘B’.
7.1.10 Protective Materials for Wrapping Pipeline Components
The protective materials for wrapping pipeline components shall comprise a rust
inhibiting compound for the bolts, a mastic or comparable filler which will not harden
for moulding over the assembly, and a waterproof tape for wrapping.
7.1.11 High Density Polyethylene Protection Sheet
The polyethylene sheet shall be of 1000 gauge (heavy duty) minimum thickness 250
microns.
7.1.12 Protective Coating with Cementitious Water Proof Coating
Concrete surface shall be protected with an approved elastomeric cementitious

waterproof coating as follows and where indicated on the drawings.
a) On the concrete blinding below perimeter and dividing wall base slabs.
b) The materials are required to provide excellent waterproofing and crack-bridging

properties, whilst providing protection against water abrasion.
c) The system shall be a high performance, elastomeric, cementitious coating

system specifically formulated to provide excellent resistance against aggressive
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Dubai Municipality
elements whilst retaining its chemical and physical properties through long term water
immersion.
d) The coating shall exhibit the following typical properties.
Table 7.10 Typical Properties of Coatings
% Elongation Minimum 120%
Water vapour diffusion resistance SD 0.11 m @ 200 microns dft
Resistance to positive water pressure 7 bar DIN BSEN 12390
Resistance to negative water pressure 3 bar – Ditto-
Reduction in chloride ion penetration >99% (no penetration after 10 months

continuous testing)
Dynamic crack accommodation 1.8 mm
Abrasive resistance Wear index
e) The mixing and application of the elastomeric cementitious coating shall be

strictly in accordance with the manufacturer's instructions.
f) In preparation for the fairing coat and protective coating all existing surfaces shall
be free from existing coatings, oil, grease, loose particles, decayed matter, moss or
algae growth and general curing compounds. All surface contamination and surface
laitance must be removed through the use of high pressure water jetting or sweep
blasting.
g) Blow holes, prepared surface cracks and areas of substantial pitting shall' then
be filled with a proprietary polymer modified cementitious fairing coat as
recommended by the coating manufacturer.
h) The protective coating system shall be spray applied by a specialised applicator

approved and recommended by the coating manufacturer.
i) Where required by the Engineer, trial areas not exposed in the finished work
shall first be treated using the selected materials. These trial areas shall be carried
out using the type of materials, mixing procedures and applications as will be used on
the contract. These shall be approved by the Engineer before the Contractor
commences with the general work.
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7.1.13 Approved Paint Suppliers
All paint suppliers shall be subject to approval. Suppliers shall demonstrate that their
paint systems have been successfully used in sewage environments similar to
conditions experienced and / or anticipated in Dubai.
7.1.14 In-situ GRP Lamination with Grit bonding on final finish coat
This clause will cover all in-situ GRP Lamination work as specified in CL 7.1.6 and an
additional resin coat to be applied as final finish top coat sprinkled with non-metalic
mineral abrasive grit or sand to achieve a non-slip, non-abrasive surface finish.
7.1.15 Epoxy Coating
This clause will cover all in-situ Epoxy coating for the concrete surfaces as specified
such as water retaining structures, external surfaces of RC pipes and on the external
surfaces of Concrete Encased GRP Jacking pipes.
a) Epoxy coatings shall be solvent free, two component high build epoxies meeting
the requirements of Table below.
Table 7.11 Epoxy Coating Requirements
Property Requirement
Volume of solids 100%
Number of coats Minimum of 2
Dry film thickness Minimum of 250 microns per coat
Adhesion to concrete Minimum of 1.0 N/mm2
Colour Light grey or off white or as accepted by

the Engineer.
b) Coal tar epoxies shall not be used
c) Coating system shall have a proven track record of not less than 5 years in
Dubai or in similar environmental conditions prevailing in Dubai with regard to pot life,
useable life of freshly mixed components and curing.
d) Intermediate coats shall be tinted to facilitate inspection of coverage for each

coat.
e) UV resistant overcoating for external applications shall be as recommended by

the manufacturer.
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7.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE
7.2.1 General
Concrete structures shall be protected both internally and externally where indicated
on the Drawings and by the methods detailed.
7.2.2 Water Proof Membranes/Liners/Roof Waterproofing and Protective Coatings
a) All the protection systems shall be applied strictly in accordance with the
manufacturer’s instructions, two copies of which shall be included with the
Contractor’s application for the approval of the material, and when approved will be
deemed to be part of this specification unless stated otherwise.
b) The permissible rate of permeation of all protection systems shall not exceed
0.0027 per inch (ASTM, 1 per inch = 1 gramme of water per hour per square foot
(0.0929 m2) per mil (0.00254 mm) of thickness for a 1 inch (25.4 mm) difference in
Hg vapour pressure on each side of a membrane.
c) Coating shall not be applied at expansion, contraction or construction joints

which incorporate a sealant.
d) External and Internal Exposed Surfaces -
Where exposed surfaces of concrete structures are not protected by reinforced

plastic liners, the following systems given in the ‘Schedule of Tanking Membranes
and Protective Coating’ or as indicated on the drawings, where applicable, shall be
applied.
Table 7.12 Schedule of External Tanking Membrane on Concrete Surfaces of

underground Structures up to the Existing Finished Ground Level
System Description & Generic Type of Material
T1 Single coat solvented bitumen primer as

recommended by the tanking membrane
manufacturer
T2 Pre-fabricated self-adhesive SBS

modified bitumen membrane 1.5 mm thick
sandwiched between two layers of silicon
film having the specified properties
T3 Impervious self adhesive bituminous

water proofing membrane 2 mm thick
tropical grade, non-perforated, cross
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laminated white polythene sheet top film

with high impact and puncture and UV
resistance having the specified properties.
T4 Self-adhesive type 6 mm thick Asphaltic

protection board impregnated with tough
layer fibre glass reinforcement inside to
use under all raft foundation floor slab on
top of blinding layer.
T5 Self-adhesive type 3 mm thick bituminous

protection board with ‘UV’ resistant, 400
gm/m2 polyester fabric layer external
having specified properties.
T6 Termination end details of self-adhesive

membrane 2 mm thick + 3mm thick self-
adhesive protection board as shown in the
approved drawing
T7 Termination end details of composite 1.5

mm thick SBS modified membrane + 2mm
thick cross laminated membrane + 6 mm
thick self adhesive protection board as
shown in the approved drawing
T8 Termination details of membrane over

protruded built in pipes from the structure
as shown in the approved drawing.
T9 Termination details of membrane at

internal and external corners as shown in
the drawing
T10 Termination details of bitumen emulsion +

P.E. sheet as shown in the drawing.
Or alternatively
T11 3 mm thick two component spray in place

flexible 100% solid content Thermoplastic
(Tpu) Polyurathene / Polyurea Coating
System
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Note: The Contractor can choose either the

tanking membrane system T1 – T10 or
the 3mm thick polyurea coating without
any extra cost variation.
7.2.2.1 External Buried Surfaces
The external surfaces of major and minor concrete substructures shall be protected
or ‘tanked’ by the following methods which will be indicated on the Drawings.
a) External Waterproofing for Major Buried Structures
1. Water proofing for major structures shall be a three layer application.
i. Prime the concrete surface with solvent based bitumen primer as recommended
by the membrane manufacturer.
ii. The first layer shall be a 1.5 mm thick prefabricated layer of SBS modified
bitumen sandwiched between two layers of silicon film. The layer shall have 1200 %
elongation. The overlaps should be 15cm and should have 100% bitumen to bitumen
adhesion to ensure a seamless layer of rubberized bitumen. The layer should have
no reinforcements or top films which would affect the elongation and overlap
adhesion.
iii. The second layer shall be 2 mm thick an impervious bituminous waterproofing

membrane.
2. The membrane shall be tropical grade, non- perforated cross-laminated top film
with high strength, puncture and impact resistance and shall be chemically resistant
for protection against aggressive soils and contaminated ground water. The
membrane shall be white in colour to reduce the effect of UV and for easy
identification of damages if any on the membrane.
3. The cross laminated self-adhesive membrane shall comply with the following:
Table 7. 13 – Properties of Self-adhesive Membrane
Properties Test Method Typical Results
Tensile strength of ASTM D 638

membrane
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Dubai Municipality
Longitudinal 3.8 N/mm width
Transverse 3.8 N/mm width
Top Surface High

Density Cross
Laminated PE Film
White
Tensile strength ASTM D 882

(Film)
Longitudinal 38 N/mm2
Transverse 38 N/mm2
Elongation of ASTM D 638

membrane
Longitudinal 230%
Transverse 180%
Tear Resistance ASTM D 1004

(film)
Longitudinal 280N/mm thickness
Transverse 280N/mm thickness
Puncture ASTM E154 220N /60mm deflection

Resistance
Adhesion to primed ASTM D 1000 2 N/mm width

substrate
-Ditto- self 2.4 N/mm width
Water absorption ASTM D 570
After 24 hours 0.14%
After 35 days 0.95%
Crack bridging Min 1 mm
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Dubai Municipality
ability
Water resistance of BSEN 12390
Membrane 5 bar pressure No penetration
Cross laminated 5 bar pressure No penetration

Film (solvent
extracted from
membrane)
Self-adhesive ASTM D 36 102 C

softening point
4. The membrane shall be laid on the twin stick surface of the SBS bitumen layer
with the sticky side downwards and laid strictly in accordance with the manufacturer’s
instructions. The minimum overlap should be 150 mm side and end. The top silicon
release film of the twin stick membrane to be removed before the application of the
subsequent layer.
5. The corners and pipe joints shall be sealed with a 1.5 mm thick two side
adhesive bitumen tape. The tape shall comprise of a non-reinforced SBS modified
bitumen layer sandwiched between two layers of plastic release film. The bitumen
tape should have a minimum ultimate elongation of 1200%. The tape should be a
minimum of 300 mm width. The silicon release film on the top side should be
removed at the time of laying the waterproofing membrane. In the event adhesive
side of the tape gets contaminated with dust or other debris, the tape should be
removed with a heated scraper. The surface should then be primed again and the
tape re-applied. If the contamination is very minor and localised, the tape can be
repaired with heating it up with a hot air gun. A 40 mm x 40 mm corner fillet with
polysulphide sealant shall be made for all corners around the pipes to allow
movement.
6. Protection Board (6 mm & 3 mm thick)
The membrane has to be protected as the third layer with a 6 mm thick self-adhesive
asphaltic protection board impregnated with a tough layer of fibre glass and to be
used under all the raft foundation and 3 mm thick protection board for walls and sides
of raft foundation. The board should be weather, water and rot proof and should be
completely devoid of organic material. The edges of the protection board to be
sealed with a 50 mm self adhesive bitumen strips in order to avoid any back fill
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material from entering into the system. The protection board shall comply with the
following properties.
Table 7.14 Properties of Protection Board
Thickness 6 mm & 3 mm
Chisel test BS 1142 pass
Heat resistance Ueatc Min 80C
All products in the waterproofing system to be sourced from the same manufacturer
who operates a certified ISO quality system. The membrane shall be applied strictly
in accordance with the manufacturer’s method statements.
Termination of the system shall be done at a height of 100 mm from the ground level.
A 40mm x 40mm groove to be cut and the membrane neatly tucked into the groove.
The groove shall be sealed with a polysulphide sealant. The self-adhesive protection
board should extend at least 50 mm above the groove and be sealed to the substrate
with an epoxy adhesive or a suitable system recommended by the membrane
manufacturer and approved by the Engineer. The cost of membrane is inclusive of
fixing and termination with approved sealant.
b) External Waterproofing for Minor Buried Structures such as Manholes,

Inspection Chambers etc.
1. The external surfaces of minor concrete substructures shall be protected or

tanked by the following method. The water proofing system shall be two layer
application. The 1st layer waterproofing membrane shall be a 2 mm thick bitumen
cross laminated self adhesive membrane and the 2nd layer shall be with a 3 mm thick
self adhesive membrane protection board with a tough geo-textile surfacing. The
membranes shall comply with the technical specifications as given in Cl. 7.2.2.1 (a).
2. The surface on which the waterproofing membrane is to be applied shall be

smooth and free of any sharp edges or protrusions. The surface should be primed
with an approved primer recommended by the membrane manufacturer.
3. Once the primer is completely cured, the membrane shall be laid on the surface.
The silicon release film is peeled off the sticky side and the membrane is to be
carefully laid on the surface. Care should be taken to minimize the entrapped air.
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The minimum overlap should be 100 mm at side and end and minimum 200 mm at
the corners.
4. The corners and pipe joints shall be sealed with a 1.5 mm thick two side
adhesive bitumen tape. The tape shall comprise of a non-reinforced SBS modified
bitumen layer sandwiched between two layers of plastic release film. The bitumen
tape should have a minimum ultimate elongation of 1500%. The tape shall be of
minimum 300 mm width. The silicon release film on the top side shall be removed at
the time of laying the waterproofing membrane. In the event adhesive side of the
tape gets contaminated with dust or other debris, the tape should be removed with a
heated scraper. The surface shall then be primed again and the tape re-applied. If
the contamination is very minor and localised, the tape can be repaired with heating it
up with a hot air gun.
5. Protection Board (3 mm thick)
The membrane shall be protected with a self-adhesive protection membrane

board with a tough, UV resistant, polyester surface. Staggered overlaps to be
ensured while application of protection membranes. The protection membrane shall
comply with the following properties.
Table 7. 15 – Protection Membrane Properties
Thickness 3 mm
Puncture resistance ASTM E 154 1500 N
Tear resistance ASTM D 5147 500 N
Min: top surfacing weight of 350 gm/m²

fabric
Elongation of compound ASTM D 638 1500%
Any punctures on the membrane shall be repaired with an additional patch which
would extend at least 5 cm from the edges of the damage. The waterproofing
membrane shall be protected immediately with the protection membrane to avoid any
damages to the system because of ongoing site activities.
The end termination of the composite system shall be as shown in the approved
drawings or as recommended by the membrane manufacturer and approved by the
Engineer.
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c) Brush Applied Bituminous Emulsion
1. The bitumen emulsion shall be cold applied thixotropic coating conforming to

ASTM D 1227 Type III Class 1. The coating shall have a solid content of Min 50%.
The coating shall be applied in two coats with a priming coat which will be made by
diluting the bitumen emulsion with max 20% clean potable water or as per
manufacturer’s recommendations. Two undiluted coats of the bitumen paint shall be
applied @ 1.1 lit /m2 in two coats. The total Dry Film Thickness of the coating shall
be a minimum 0.5 mm.
2. The second coat shall be applied at right angles of the first coat and only after
the coat has dried completely.
3. The above coating system shall be protected with 1000 gauge polyethylene
sheet or building paper as specified for specific location to use.
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Table 7. 16
Application Procedure for Impervious Bituminous Tanking Membrane System (Clause 7.2.2 (1) (a) & (b) on Concrete Surfaces &
Structures (External) up to the Ground Level (For Major Structures)
Item Description and/or Application / Surface Shop Type of Coat No. of Description & generic type of Thick- Remarks
Location of work location preparation / site coats material ness
Microns
1. Buried concrete Blinding layer Levelled – 1000 guage One PE sheet 1000 guage as 250 To be placed
external surface in under raft formation Polyethylene layer specified on the
contact with soil and foundation sheet formation
groundwater for major (a) under the
structures; blinding blinding
under the raft
foundation
(b) over the Sweep – Primer One Rubberised bitumen emulsion 50 By brush
blinding blast System T1 coat application
Membrane One Self-adhesive type SBS modified 1.5 mm By hand
System T2 layer Bitumen non-reinforced thick application
membrane as specified
Membrane One Self-adhesive Bituminous 2 mm By Hand in
System T3 layer membrane cross laminated with thick staggered
white PE at top as specified Joints
Membrane One Self-adhesive type Bituminous 6 mm -Ditto-
System T4 layer Protection board. thick
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Dubai Municipality
Microns
2. Ditto – Raft (a) Raft Sweep – Primer One Solvented Bituminous Primer. 50 By brush
Foundation sides and foundation blast System T1 coat application
tank walls and roof base slab
slab in contact with sides and tank
ground soil / water walls
Membrane One Self adhesive type SBS modified 1.5 mm By hand
System T2 layer bitumen membrane (non thick application
reinforced) as specified.
One Self adhesive type bituminous 2 mm Fix in
System T3 layer membrane cross laminated with thick staggered
white PE at top as specified. joints
System T5 layer protection board with UV & thick staggered
puncture resistant fabric layer on joints.
top.
3. Ditto – for Minor Concrete Levelled – 1000 guage One PE sheet 1000 guage as 250 To be placed
Structures like blinding formation Polyethylene layer specified on the
manholes, chambers, (a) under the sheet formation
strip footing and its blinding
blinding layers.
(b) over the Sweep – Primer One Solvented bitumen primer as 50 By brush
blinding blast System T1 coat specified application
Membrane One Self-adhesive Bituminous 2 mm By hand
System T3 layer membrane cross laminated with thick application
white P.E. at top as specified
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Dubai Municipality
Microns
Membrane One Self-adhesive type bituminous 3 mm Fix in

System T5 layer protection board with polyester thick staggered
fabric at top as specified joints
4. Ditto – for wall, roof Manhole wall, Sweep – Primer One Solvented Bituminous Primer as 50 By brush
slab, the buildings roof slab Blast System T1 coat specified application
strip footing, and on
chambers below
ground
Membrane One Self adhesive type bituminous 2 mm By hand
System T3 layer membrane with cross laminated thick application
at top with white PE as specified
System T5 layer protection board with polyester thick staggered
fabric at top as specified joints
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Dubai Municipality
Table 7. 17 [System – I, J, K, L, M & N] : TANKING MEMBRANE AND PROTECTIVE COATING TO CONCRETE Clause 7.2.5.1 [d
& e] SCHEDULE OF IN-SITU BITUMINOUS MEMBRANE/GRP/ COATING SYSTEM (FOR MINOR STRUCTURES)
STRUCTURE INTERNAL EXTERNAL

FLOOR WALL CEILING Base Slab/Strip footing Base slab sides, Wall
/foundation and Top of Cover Slab
1. Storm water Manholes Epoxy Resin mortar 300 micron thick 300 micron thick * System T1+
as specified in CL Epoxy coating system Epoxy coating P.E. sheet under the blinding * System T3 +
7.1.7 * System T5
*Rubberised Bitumen emulsion
System ‘K’ System ‘L’ System ‘L’ over the blinding + * System For each structure
T1+ * System T3
+ * System T5
2. Storm water chambers & Epoxy Resin mortar 300 micron thick 300 micron thick System M Rubberised emulsion
similar as specified in CL Epoxy coating system Epoxy coating Rubberised Bitumen emulsion + + P E Sheet
7.1.7 1000 gauge Polyethylene sheet
System ‘K’ System ‘L’ System ‘L’ System M

3. Building Strip footing, N/A N/A N/A *System T1 + -
compound wall foundation etc. *System T3 +
*System T5
4. Anchor blocks Protection N/A N/A N/A  P.E. sheet at formation
slab, concrete surround, & other  2 Coats Rubberised
similar burried concrete Bitumen emulsion over
concrete
 1 Layer P.E. sheet on top
System ‘M’
5. Above ground structures like System ‘D’ as System ‘D’ as N/A Same as item 1 above Ditto
Panel plinth (Exposed Surfaces) specified specified
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Dubai Municipality
d) Alternative Proposal for Membrane Protection
3 mm thick two component spray in place flexible 100% solid content thermoplastic
(Tpu) polyurethane /Polyurea Coating System.
Table 7.18 Physical Data of Coating System
Physical Properties ASTM Test Value
Density (kg/m3) D - 1622 1121.3 (kg/m3)
Permeability (more 0.000 (metric/m2)

than 1 mm)
Hardness (Shore D – 2240 98

‘A’)
Abrasion D – 4060 0.001/1000 Cycles

Resistance (Taber)
Tensile Strength D - 2370 126.67

(kg/cm2)
Elongation (%) D – 2370 82.24% @ yield
Adhesion D - 4541 77 (kg cm2)
Tear Resistance Absolute Load 123.56 (N)

(N)
Colour FED STD 595B Black or other
Table 7.19 Resin Liquid Chemical Properties @24°C
Properties ASTM Test Value

Method
Viscosity (cps) D - 1638
Component ‘A’ 600 + 100
Component ‘B’ 1100 + 100
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Dubai Municipality
Specific Gravity D - 1638

(gr/cc)
Component ‘A’ 1.15
Component ‘B’ 1.08
Mixing Ratio (A:B)

by volume
50:50
A Trial sample of the ‘Tpu’ coating is to be applied on any one of the concrete
structures external surfaces and the relevant sample is to be subjected to 100 days
acid immersion test in 10% concentrated sulphuric acid @ 50 C. This coating will be
acceptable only, if the chemical resistance of the “coating” fully comply with the
specification. The test shall be conducted in accordance ASTM C 581.
e) Application of Epoxy Coating
The material specifications and the area of uses of epoxy coatings shall be as per
clause 7.1.5. The epoxy coating shall be applied as per the followings:
1. Coatings shall be mixed and applied in strict accordance with the manufacture’s
recommendations.
2. Special attention shall be given to ensure that edges, corners, crevices and other
areas receive a film thickness at least equivalent to that of adjacent coated surfaces.
3. The penetrating solvent containing two component epoxy amine primer shall be
applied over the whole area to be coated by suitable nylon bristle brush or spray. The
primer shall soak into the concrete and shall not leave a resin rich layer on the
surface. Primers containing fillers or pigments shall not be used . A minimum of 24
hours shall lapse before filling the surface.
4. The surface of the primed concrete shall be scraped with an approved two
component solvent free epoxy filler supplied by the coating manufacturer. The filler
shall be squeezed into blowholes. The filler shall have the property of being resin rich
such that the finished surface shall look semi glossed when finished.
5. There shall be strict control of surface cleanliness between coats. Dust and sand
shall be used by vacuuming and any dust embedded in the coated surface shall be
removed with abrasive paper.
6. Two coats of a solvent free coating system as specified above shall be used .
Any thick runs or collections of coating shall be removed before they harden. Any
bowholes visible after each topcoat shall be filled and sealed.
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Dubai Municipality
7. Wet film thickness shall be continually checked by the coating operators to verify
that sufficient coating is being applied to achieve the required dry film thickness.
8. Dry film thickness shall be checked for every 100m2 of coated surface.
9. Coated surfaces shall be visually inspected to ensure proper and complete

coverage has been obtained.
10. At least one adhesion test shall be conducted for every 100m2 of coated surface.
The resulting test specimens shall show no evidence of poor adhesion to the
substrate , residual laitance or intercoat adhesion weakness.
f) Waterproofing on Building’s Roof where thermal insulation is required.
The roofing system shall incorporate the materials and methodology specified in
Section 8 - Building Works.
7.2.3 GRP Prefabricated benching unit for Sewer Inspection Chambers
GRP prefabricated benching units shall be manufactured to the same process as

specified in CL. 7.1.6 for in-situ lamination but the work shall be carried out in
manufacturer’s yard with a wall thickness of 5 mm.
7.2.4 Cutting and Sealing of Reinforced Liners
a) Where the Contractor is required for any reason to cut reinforced plastic liners,
he shall seal the exposed ends with an approved resin before incorporating the cut
reinforced plastic in the work. No cut reinforced plastic shall be used until the resin
has cured.
b) The resin shall be as recommended by the manufacturer of the reinforced plastic

item and shall be pigmented so that the areas where it has been applied are easily
identifiable.
c) It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labelled as to its content and shelf life.
d) For flexible pipe materials a rubber protection strip shall be inserted between the
pipe barrel and the steel band.
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Dubai Municipality
7.2.5 Protective Coatings to Concrete Works
7.2.5.1 Protective Coating on Concrete (Internal & External)
a) General Requirements
1. The coating system and the surface preparation shall be to the approved
standard and shall conform to the ‘schedule of surface preparation and protection
systems’ given below for concrete work.
2. The coating system proposed shall be applied by Client approved specialist

applicator.
Table 7-20 Surface Preparation on Concrete
System Description Surface Preparation
a) Sweep blasting The surface shall be sweep blasted with

non-metallic mineral abrasive to achieve
a minimum surface roughness of 100
micron on concrete or as recommended
by the paint manufacturer.
b) Surface Cleaning The concrete surface shall be cleaned to

remove dirt, oil, dust, laitance and all
other surface contaminations.
c) Epoxy binder / One coat 100 micron D.F.T two

sealer component polyamide epoxy based
transparent sealer coat shall be applied
by spray application to seal the porous
concrete substrate if any.
d) Filler One coat of alkali resistant acrylic based

filler 100 micron DFT shall be applied by
steel trowel or hand application to fill the
surface voids or as recommended by the
paint manufacturer.
b) Application of Field Coatings:
1. Coating shall be applied with a spraying equipment recommended by the

Manufacturer.
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Dubai Municipality
i. Areas inaccessible to spray coating or rolling shall be coated by brushing or

other suitable means.
2. Give special attention to ensure that edges, corners, crevices, welds, bolts, and
other areas, as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.
3. Protective coating materials shall be applied in strict accordance with the

manufacturer’s printed instructions.
4. Prime coat shall be applied to clean surfaces:
i. Within a 4-hour period of the cleaning.
ii. Prior to deterioration or oxidation of the surface.
iii. In accordance with the manufacturer’s recommendations.
5. Coatings shall be applied in dry and dust-free environment.
i. No coating shall be applied during following conditions:
– When the surrounding air temperature, measured in the shade, is below 17 C
– To wet or damp surfaces.
– In rain, fog or mist or when the relative humidity exceeds 85%.
– When it is expected that the relative humidity will exceed 85% or that the air
temperature will drop below 5 C within 18 hours after the application of the coating
or paint.
– Dew or moisture condensation shall be anticipated.
– The cement laitance is removed with non-metallic mineral abrasive blasting
– Minimum specified surface roughness is achieved.
– Specified primer /sealer coat is applied.
– Filling the surface voids/cracks/and imperfections with approved epoxy filler.
ii. If the above conditions are prevalent, coating shall be delayed until surfaces are
dry.
iii. The day’s coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time prior
to the formation of moisture.
6. Care shall be exercised to avoid lapping, coating on adjacent surfaces.

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i. Coatings shall be sharply cut to lines.
ii. Finished coated surfaces shall be free from defects or blemishes.
iii. Drop cloths shall be used to protect floors, fixtures, and equipment.
iv. Care shall be exercised to prevent paint from being spattered onto surfaces from
which such paint cannot be removed.
v. Surfaces from which paint cannot be removed shall be painted or repainted as

required to produce a finish satisfactory to the Engineer.
vi. Apply second coat at right angles to first coat, ensuring pinholes are covered.
7. Surfaces inaccessible after assembly shall be coated before erection.
8. Touchup of surfaces shall be performed after installation.
9. Surfaces to be coated shall be clean and dry at the time of application.
10. Time of Coating:
i. Manufacturer’s recommended recoat time shall be complied with.
ii. Sufficient time shall be allowed to elapse between successive coats to permit
satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.
iii. No additional coating of any structure, equipment, or either item designated to be

painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment, or
other item.
11. Thickness of Coating:
i. Dry film thickness specified shall be achieved for each coat.
12. Clean up
– Concrete surfaces shall be visually inspected to ensure proper and complete

coverage has been attained.
– Upon completion of the work, staging, scaffolding, and containers shall be

removed from the site or destroyed in an approved manner.
– Coating spots, oil, or stains upon adjacent surfaces shall be removed.
13. Protective coating properties tests are to be conducted on the final coated
surface and shall comply with the requirements specified in Table 7 –22.
c) Schedule of Concrete Protection System
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Dubai Municipality
1. For Major Structures Internal:
System - ‘A’ 7mm thick in-situ GRP lamination as specified in CL 7.1.6.
System- A - 1 7 mm thick in-situ GRP lamination with grit bonding on top of final
finish coat as specified in CL.7.1.14.
System - ‘B’ 1mm thick heavy duty glass flake vinylester resin based coating
250 micron each. Total D.F.T 4 x 250 microns + Approved Primer recommended by
the paint manufacturer.
System - ‘C’ 1mm thick Polysulphide modified Epoxy resin coating system
designed for superior adhesion, corrosion Protection, Chemical resistance &
waterproof coating 250 micron for each coat. Total D.F.T (4 x 250 micron) = 1 mm +
approved primer recommended by the paint manufacturer.
System - ‘D’ 0.5 mm thick solvent free 100% solid content polyamine based
Epoxy + Polyurethane resin coating.
Epoxy = 300 microns thick
Polyurethane = 200 microns thick
Total DFT = 500 microns + Approved Primer recommended by the paint

manufacturer.
System - ‘E’ Aggregate dressed (3 component) heavy duty, hard wearing,

solvent less Epoxy, anti slip deck coating minimum D.F.T = 3 mm. +75 micron high
build epoxy finish top coat with anti-fungi and antibacterial agents.
System - ‘F’ Fibre reinforced acid resistant, mineral based alkaline silicate
mortar minimum 6 mm thick with finish top coat for hard floor coating.
System - ‘G’ Double sided PVC lined membrane as specified in section

mechanical specification.
2. For Major Structures External Surfaces above Ground Exposed to Sunlight
System - ‘H’ Alkali Resistant Acrylic based anticarbonation coating + Sealer

coat + filler Coat
Epoxy binder / Sealer Coat – 100 microns thick.
Alkali Resistant Acrylic based filler 100 microns thick.
Alkali Resistant acrylic based anticarbonation coating – 100 x 3 coats = 300

microns thick.
d) For minor Structures (Internal Surfaces)
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Dubai Municipality
System - ‘I’ 7mm thick in-situ GRP lamination over grano benching for sewer
MH’s as specified in CL 7.1.6.
System - ‘J’ 7mm thick Prefabricated GRP liner as specified in CL 7.1.5 for
sewer manholes.
System - ‘K’ Two component Epoxy mortar 10mm thick over grano benching of
storm water MH’s as specified in CL 7.1.7
System - ‘L’ Solvent free 100% solid content Polyamine based pure Epoxy 300
micron thick + primer, for storm water MH’s and Inspection chambers (sewer) etc.
e) For Minor Structures (External surfaces)
System - ‘M’ Rubberised bitumen emulsion + P.E sheet on top as specified in

7.1.8.
System - ‘N’ 5 mm thick GRP pre fabricated benching or in-situ lamination over
benching of inspection chambers (sewer) as specified in Clause 7.2.3.
Table: 7. 21 Schedules of Concrete Protection Details
Sr. Particular Protection Protection details

System
EXTERNAL PROTECTION FOR ALL MAJOR STRUCTURES
1 Below Ground Level
a. Below Blinding P.E 1000 gauge PE Sheet (250 micron thick)
b. Above Blinding (raft) System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T4 thick each & 6 mm thick protection board as
specified.
c. Walls outer surface System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T5 thick each with 3 mm thick protection board
on top as specified.
2 Above Ground Level System ‘H’ Approved sealer coat and filler coat and
Alkali resistant acrylic based anticarbonation
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coating (300 micron) thick
INTERNAL PROTECTION AND ROOFING DETAILS –
1 Stilling Tank, Pump Station,

Discharge chamber, Outfall
Floor, Wall, Roof System ‘D’ Approved primer recommended by the paint
manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint
2 Chemical Storage Area Bund System ‘A’ GRP Liner (7mm thick)
3 Potable Water Tank
Concrete Base floor and support System ‘D’ Approved primer recommended by the paint
wall manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint
4 Aeration Tanks
Floors, Walls & Ceiling, inlet/ System ‘B’ Approved primer recommended by the paint
Outlet channels manufacturer + 1 mm thick heavy duty glass
flake vinyl ester resin based coating.
Top Walkways System ‘E’ 3 mm thick heavy duty (3 component) non-

slip epoxy abrasion resistant deck coating +
high build 75 micron finish coat on top with
anti-fungi and anti-bacterial agents.
Valve chamber ( Waste activated System ‘L’ 300 micron pure epoxy paint ( Polyamine
Sludge) based) ( Solvent free 100% solid content)
5 FST Distribution / RAS Bellmouth

Chamber
All chambers walls / floors System ‘C’ Approved primer recommended by the paint
manufacturer + Polysulphide modified epoxy
resin coating 1mm thick
6 Gas Holders
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Dubai Municipality
Gas holders System ‘G’ Double sided PVC membrane as specified
Table 7. 22 Test on Protective Coating of Concrete
Sr. Properties Test Method Minimum Requirements
1 Dry film thickness BS 3900 Specified thickness for each

coat
2 Discontinuity (holiday) National Association of 100% pin hole free

detection Corrosion Engineer’s
standard recommended
practice
3 Pull of adhesion strength ASTM D4541/ISO 4624 3.00 N/mm2 for epoxy coating
2.00 N/mm2 for anti

carbonation coating
Notes: (1) Freedom from pinhole shall be established by the use of a spark tester.
(2) Coating system should be resistant to:
(a) Sulphate and chloride ion penetration
(b) CO2 diffusion
(c) Bacterial and fungus growth
(d) Atmospheric temperature resistant
(e) Acids and alkalis of PH2 -14
(f) To accommodate shrinkage cracks appearing on concrete

substrate.
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Dubai Municipality
7.2.6 Coating System for Ferrous, Non Ferrous Metals and Plastics
7.2.6.1 GENERAL
a) DESCRIPTION
Provide all labour, materials, equipment, services and accessories necessary to

furnish and install the coating system work of this Section, complete and functional as
indicated in Contract Documents and as specified herein.
1. Coatings for all ferrous, Non-ferrous surfaces, interior and exterior.
2. Submerged ferrous metal surfaces.
3. Structural and miscellaneous steel including tanks, hoppers and similar
equipment.
4. Equipment furnished without factory finished surfaces.
5. Exposed galvanized metal except handrails, grating, piping and checkered plate.
b) SUBMITTALS.
Manufacturer’s Data
1. Manufacturers current printed product description, materials safety and technical

data sheets for coating systems.
2. Detailed mixing, thinning and application instructions, minimum and maximum

application temperature, curing and drying times between coatings.
3. Instructions for surface preparation requirements, number and types of
Coats required for each surface.
4. Colour charts for each coating system.
5. Certifications from manufacturer verifying factory applied prime coatings are

compatible with the specified finish coatings.
6. Detailed maintenance manual including the following information:
i. Product name and number.
ii. Name, address and telephone number of manufacturer and local distributor.
iii. Detailed procedures for routine maintenance and cleaning.
iv. Detailed procedures for light repairs such as scratches and staining.
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7. Abrasive:
i. Certified information of:
– Particle size distribution.
– Dust generation at proposed operating pressure and distance.
– pH value.
– Soluble chloride content.
– Analysis for free silica.
– Trace toxic contaminants.
ii. Sample Panels
– Apply a complete coating system to a panel of the same material as that on

which the coating will be applied and submit for approval for each colour specified.
– Approved sample panels will be used for quality control in applying coating
systems.
iii. C. Certificates of Compliance.
iv. E. Inspection Reports.
v. F. Test Reports.
c) DELIVERY, STORAGE AND HANDLING
1. Delivery
i. Deliver materials in original, unopened packages and containers bearing

manufacturer's name and label including the following information:
– Name or title of material.
– Manufacturer's stock number and date of manufacture.
– Manufacturer's name.
– Contents by volume for major pigment and vehicle constituents.
– Thinning instructions where recommended.
– Application instructions.
– Colour code and name.
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Dubai Municipality
2. Storage
ii. Store materials on site in a suitable location, protected from exposure to extreme
weather.
iii. Keep area clean and accessible.
iv. Restrict storage of coating materials and related equipment.
v. Keep temperature of storage area between 18 C and 32°C.
vi. Comply with Local Laws and Regulations.
vii. Cloth and Cotton wastes that might constitute of fire hazard shall be placed in
closed metal containers or destroyed at the end of each workday.
viii. Provide approved fire extinguishers in material storage area.
d) QUALITY ASSURANCE
1. Applicator Qualifications
i. Submit name and experience record of manufacturers recommended coating

applicator.
ii. Include list of utility or industrial installations painted, responsible officials,

architects, or engineers concerned with the project and the approximate contract
price.
2. Inspect surface and correct defects prior to application of each coat.
3. The protective coating systems specification, report on paint work progress and
the final report on corrosion protection should be provided by the applicator in the
formats (A), (B) and (C) given in this clause.
Form A – Form for a Protective Paint System Specification for New Work
(To be filled in for each constituent element of the structure by the applicator)
Project:
Name of Client:
Project: Protective paint system:
Location: ISO 12944-5 paint system No.
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Dubai Municipality
Constituent element: Environment:
Drawing No. / area: Required durability:
Position No.: Sheet No:
Shop Application
Surface Preparation Grade:
Type of Prefabrication Primer (if used):
Paint manufacturer: Area:………..m2
Protective Paint Nominal dry Overcoating interval Drying time

System film at ….C (h)
thickness µm
Minimum (h) Maximum (h)
1st Coat
2nd Coat
3rd Coat
4th Coat
Total:
Site Application
Surface Preparation Grade:
Touch up:
Complete:
Paint Manufacturer: Area: ………..m2
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Dubai Municipality
Protective Paint Nominal dry Overcoating interval Drying time

System film at ….C (h)
thickness µm
Minimum (h) Maximum (h)
1st Coat
2nd Coat
3rd Coat
4th Coat
Total:
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Dubai Municipality
Form B – Form for a Report on Paint Work Progress and Application Conditions
(To be filled in by the coating applicator during the progress of work)
Project: Drawing No: Inspected by: Comments:

Location: Corrosion Protection Plan No:
Constituent Element: Position No:

Area:
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Date Time Type of work (i.e. Metho General Temp Temp Rel. Dew Blast Paint Colou Remarks Signatur
surface d used weather Air Struct/Constitue air poin cleaning batch r (eg. ISO e/
preparation, condition C nt element C humidity t C abrasive no. standard, initials
application of s % (material surface
priming coats, no.) prepar,
intermediate grade,
coats, top coats) irregularities
_______________ __________________ ___________________________ ________________________

_______________
(Place) (Date) (1st Signature) (2nd Signature) (3rd Signature)
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Dubai Municipality
Form C – Form for Final Report on Corrosion Protection Work
(To be filled in by the applicator after the completion of the paint works)
Name of structure: Project No: Drawing No:
Protective paint system:
ISO 12944-5 paint system No. (if applicable)
1st Coat 2nd Coat 3rd Coat 4th Coat 5th Coat
Paint work contractor:
New work
Rust grade of steel surface (ISO 8501-1)
A .B .C .D
 Milling imperfections found

 Sharp edges and burrs removed
 Welding residues, including weld spatter,
not removed
Specified surface preparation grade (ISO 8501 –1 or ISO 8501-2):
Balst-cleaning  Sa2  Sa 2½  Sa 3
 PSa 2  PSa 2½  PSa 3
Flame cleaning  FI
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Dubai Municipality
Hand and power tool  St2  St3

 PSt2  PSt3
Cleaning
 Pma
Machine abrading
Specified surface profile (ISO 8503-1):
Comparator G · Fine · Medium · Coarse ·
Comparator S · Fine · Medium · Coarse ·
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e) ENVIRONMENTAL CONDITIONS
1. Unless otherwise recommended by coating manufacturer, the ambient

temperature shall be between 7°C and 35°C when applying coatings other than
water-thinned epoxy.
2. Water-thinned coatings shall be applied only when ambient temperature is

between 10 C and 32°C.
3. Epoxy coatings will be applied only within the minimum and maximum
temperatures recommended by the coating manufacturer.
4. Coatings, except water-thinned types shall be applied only to' surfaces that are
completely free of moisture as determined by sight or touch.
5. Do not apply to surfaces which have visible frost or ice.
7.2.6.2 PRODUCTS
a) MANUFACTURER
1. Products and manufacturers specified hereinafter are specified for the purpose
of establishing minimum quality standards.
2. Products equal in quality to, or better than those specified will be considered
acceptable.
3. Decision of acceptability will rest with the Engineer.
4. Paint shall be from or approved supplier’s list specified.
5. Approved Paint Suppliers List:
i. Leigh’s Paints Sharjah
ii. Hempals Paints Dubai
iii. Sika Gulf BSC Dubai
iv. Polybit Industries Sharjah
v. Sigma Paints Dubai
vi. APS Dubai
vii. Fosroc Dubai

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Dubai Municipality
viii. ICI Dulux Paints
b) GENERAL
1. No substitutions shall be considered that decrease:
i. Film thickness.
ii. Number of coats.
iii. Surface preparation.
iv. Performance criteria of the generic type of coating specified.
2. Furnish coatings and coating products under this Section from a single
manufacturer unless otherwise specified.
3. Compatibility
i. Compatible materials shall be used as primer and finish coats of systems.
ii. Compatible barrier coats may be used between factory-applied prime coats, or
finish coats on existing surfaces to be refinished and subsequent field coats with the
Engineer's approval.
4. Colours
i. Colors shall be as scheduled or selected by the Engineer.
ii. Prime and intermediate coats shall be tinted as approved by the Engineer to
facilitate inspection of coverage for each coat
c) HAZARDOUS MATERIALS RESTRICTIONS
Paints and painting practices shall comply with all applicable state and local
requirements limiting the emission of volatile organic compounds.
d) MATERIALS
1. Abrasive
i. Chose particle size, shape, and specific gravity to produce desired surface
profile for coating adhesion recommended by coating manufacturer. If not listed in
manufacturer's literature, provide for a 50 to 75 microns average profile.
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Dubai Municipality
ii. pH value : Not less than 4 nor greater than 10 when

mixed in neutral water
iii. Soluble Chloride : None.
iv. Free Silica : To meet government regulations
v. Trace Toxic Contaminants : To meet government regulations
2. Colours as selected by Engineer from manufacturer's standards.
7.2.6.3 EXECUTION
a) WORKMANSHIP
1. Paint and coatings shall be applied so as to produce an even film of specified

thickness.
2. Edges, corners, crevices and joints shall receive special attention to ensure that
they have been thoroughly cleaned and that they receive an adequate thickness of
paint.
3. Finished surfaces shall be free from runs, drips, ridges, waves, laps, brush
marks and variations in colour, texture and finish.
4. Coverage shall be complete so that the addition of another coat of paint would
not increase the coverage.
5. Adjacent surfaces shall be protected by the use of drop cloths or other approved
precautionary measures.
b) ITEMS NOT TO BE COATED
1. Hardware, hardware accessories, nameplate data tags, machined surfaces and

similar items shall not be coated.
i. In contact with coated surfaces shall be removed or masked prior to surface

preparation and painting operations.
2. Following completion of coating of each piece, removed items shall be

reinstalled.
3. Removal and installation shall be done by workmen skilled in the trades involved.
c) PREPARATION
1. Surfaces to receive paint and protective coatings shall be cleaned as specified to

application of coating materials.
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Dubai Municipality
2. Examine surfaces to be finished and correct surface defects before application of

any coating material.
3. Beginning the work of this section without reporting unsuitable conditions to the
Engineer constitutes acceptance of conditions.
4. Marred or abraded areas on shop-primed 'and factory-finished surfaces shall

receive touch-up restoration prior to any other coating applications.
d) SANDBLASTING
1. All sandblasting shall be done in strict accordance with the referenced

specifications of the Steel Structures Painting Council.
2. When items to be shop primed or shop primed and finish coated in the shop,
surface preparation shall be as specified in this Section.
3. The Engineer shall have the right to witness, inspect and reject any sandblasting
done in the shop.
4. When sandblasting is done in the field, care shall be taken to prevent damage to
structures and equipment.
i. Pumps, motors and other equipment shall be shielded, covered or protected to

prevent the entrance of sand.
ii. No sandblasting may begin before the Engineer inspects and approves the
protective measures.
5. Following surface preparations for metal surfaces to be painted or given coatings

shall form part of this Section:
i. White Metal Blast Cleaning (For very corrosive atmosphere).
– Removal of all visible rust, will scale, paint and foreign matter by blast
cleaning by wheel or nozzle (dry) using sand, grit or shot.
ii. Near-White Blast Cleaning (For high humidity, chemical atmosphere, or other
corrosive environment).
– Blast Cleaning nearly to White Metal Cleanliness, until at least 95 percent of

each element of surface area is free of all visible residues.
iii. Commercial Blast
– Blast cleaning until at least 67 percent of each element of surface area is free of
all visible residues.
iv. Brush- off Blast Cleaning

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Dubai Municipality
– Blast cleaning of all except tightly adhering residues of mill scale rust and
coatings, exposing numerous evenly distributed flecks of underlying metal.
v. Solvent Cleaning
– Removal of oil, grease, dirt, soil, salts and other contaminants by cleaning with
solvent, vapour alkali, emulsion or steam.
6. Surface preparations shall be done to the satisfaction of the Engineer.
i. No painting or protective coating shall be applied before the Engineer has

inspected and approved the preparation.
7. After sandblasting, dust and spent sand shall be removed from the surfaces by
brushing or vacuum cleaning.
e) APPLICATION OF PROTECTIVE COATINGS
1. Shop Coating
i. Fabricated metalwork and equipment which requires coating may be shop

primed with specified primer.
ii. Any such work delivered to the job site with any other shop coat shall have this
coating removed and the specified coating applied in the field. Manufactured
equipment with approved corrosion-resistant factory finishes and galvanized finishes
shall be exempt from this requirement of stripping.
2. Field Coating
i. Except where in conflict with the manufacturer's printed instructions or where

otherwise specified herein, use choice of brush, roller, spray or airless spray
application.
– Any spray painting must first have the approval of the Engineer.
– Areas inaccessible to spray coating or rolling shall be coated by brushing or

ii. Give special attention to ensure that edges, comers, crevices, welds, bolts and
other areas as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.
iii. All protective coating materials shall be applied in strict accordance with the
manufacturer's printed instructions.
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Dubai Municipality
iv. Prime coat shall be applied to clean surfaces within a 4-hour period of the
cleaning and prior to deterioration or oxidation of the surface and in accordance with
the manufacturer's recommendations.
v. Coatings shall be applied in dry and dust-free environment:
vi. No coating or paint shall be applied during following conditions:
– When the surrounding air temperature, measured in the shade is below 15 C.
– To wet or damp surfaces.
– In rain, fog or mist, or when the relative humidity exceeds 85%.
– When it is expected that the relative humidity will exceed 85% or that the air
temperature will drop below 5°C within 18 hours after the application of the coating or
paint.
– Dew or moisture condensation shall be anticipated.
vii. If above conditions are prevalent, painting shall be delayed until surfaces are dry.
viii. The day's coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time prior
to the formation of moisture.
ix. Care shall be exercised to avoid lapping paint on adjacent surfaces:
– Coatings shall be sharply cut to lines.
– Finished coated surfaces shall be 'free from defects or blemishes.
– Drop cloths shall be used to protect floors, fixtures, and equipment.
– Care shall be exercised to prevent paint from being spattered onto surfaces from
which such paint cannot be removed.
– Surfaces from which paint cannot be removed shall be painted or repainted as

required to produce a finish satisfactory to the Engineer.
– Whenever two coats of a dark coloured paint are specified, the first coat shall
contain sufficient powdered aluminium to act as an indicator of proper coverage, or
the second coating shall be of a contrasting colour.
x. Surfaces inaccessible after assembly shall be coated before erection:
– a. No structural friction connections, high-strength bolts and nuts shall be painted

before erection.
– b. Areas damaged during erection shall be hand or power-tool cleaned and

recoated with prime coat.
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Dubai Municipality
xi. Touch up of surfaces shall be performed after installation.
xii. All surfaces to be coated shall be clean and dry at the time of application.
3. Time of Coating
i. Manufacturer's recommended recoat time shall be complied with.
– Sufficient time shall be allowed to elapse between successive coats to permit

satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.
– No additional coating of any structure, equipment or other item designated to be

painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment or
other item.
ii. Piping shall not be finish coated until it has been pressure tested and approved.
4. Thickness of Coating
i. Dry film thickness specified shall be achieved and verified for each coat.
f) TESTING AND INSPECTION
1. Inspection Devices
i. Provide, until final acceptance of coating and' painting, inspection devices in

good working condition for detection of holidays and measurement of DFT of coatings
and paints. .
ii. Furnish U.S. Department of Commerce, National Bureau of Standards or

equivalent certified thickness calibration plates to test accuracy of DFT gauge and
certified instrumentation to test accuracy.
iii. Dry film thickness gauges shall be made available for the Engineer's use until
final acceptance of application.
iv. Holiday detection devices shall be operated in the presence of the Engineer.
v. Inspection devices shall be operated in accordance with the manufacturer's

instructions and when directed by the Engineer's representative.
2. Conduct DFT measurements and electrical inspection of the coated surfaces.
3. Recoat and repair as necessary for compliance with the specifications.
4. After repaired and recoated ferrous metals areas have cured, final inspection
tests shall be conducted by the Engineer.
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Dubai Municipality
i. Coating thickness specified in mils on ferrous substrates shall be measured with

a nondestructive magnetic or digital type dry-film thickness gauge
ii. Discontinuities, voids and pinholes in the coatings will be determined with
nondestructive type electrical holiday detector.
iii. Epoxy coatings and thin film coatings shall be checked for discontinuities and
voids with a Iow-voltage detector of the wet-sponge type,
iv. Use a non-sudsing type wetting agent, which shall be added to the water prior to
wetting the sponge.
v. A high-voltage, low-current, spark type detector shall be used for electrical

inspection of coal tar enamel only.
vi. Tape-type coatings shall be inspected for holidays using a device designed for
use in detecting such flaws.
vii. Pinholes shall be marked, repaired in accordance with the manufacturer's printed
recommendations and retested.
viii. No pinholes or other irregularities will be permitted.
ix. Coatings not in compliance with the specifications will not be acceptable and
shall be replaced and reinspected at Contractor's expense until the requirements of
the specifications are met.
5. All gauges and detectors shall be provided with calibration by the Contractor
facilities subject to the approval of the Engineer.
6. Paint Properties tests are to be conducted on final coated surface and shall
comply with the following test.
7. Test on protective coating to metal works shall be as given in Table 7 – 24
Table 7.24 TEST ON PROTECTIVE COATINGS OF METAL WORKS
Sr. Properties Test Method Minimum Test Requirements
1. Dry film thickness BS 3900 Specified thickness for each

coat
2. Pull of adhesion ASTM D 4541 / ISO 4624 6N/mm2

strength
3. Discontinuity National Association of 100% pin hole free

corrosion Engineering standard
(Holiday recommended practice
2016

Dubai Municipality
Sr. Properties Test Method Minimum Test Requirements
detection)
4. Abrasion ASTM D 4060 0.22gm weight loss in 1000

resistance cycles
5. Coating BS 3900 : PG8 RG5 Permeability–Nil

resistance to
cracking (bend Visible defects - Nil
test)
g) CLEANUP
1. Upon completion of the work staging, scaffolding and containers shall be

removed from the site or destroyed in an approved manner.
2. Paint spots, oil or stains upon adjacent surfaces shall be removed.
h) PAINT AND COATING SCHEDULE
1. General
i. The schedule here-in shall indicate the surface preparation and practice coating
system to be used.
ii. The list shall not be construed as a complete list of surfaces to be coated, but
rather as a guide as to the application of the various coating systems.
iii. All surfaces shall be painted except those specifically deleted herein.
iv. Where reference is made to ferrous metal in this schedule, it shall not include
stainless steel or galvanized metals except as specified in paragraph C - Paint
Schedule.
2. Painting Systems
i. On ferrous metal subject to corrosive moisture or atmosphere and condensation.

Typical examples include the screening facility and grit dewatering facility.
– Surface Preparation:
• All metal surfaces shall be sandblasted near White Blast Cleaning using proper
abrasive size to achieve 35 to 40 micron anchor pattern.
2016

Dubai Municipality
• Weld surface, edges and sharp corners shall be ground to a curve and all weld
splatter removed.
– Coating:
• Shall be applied by airless spray or by brush for small areas.
• Coating Thickness:
Minimum Dry Film Component

Thickness
Primer 50 microns or as specified in Table 7-25
Intermediate Coat 200 microns or as specified in Table 7-25
Finish Coat 50 microns or as specified in Table 7-25
– Time Between Coatings:
• A minimum of 12 hours time is required before additional coats are applied to the
prime coat.
• Two hours for the intermediate coat
• Two hours for the finish coat
ii. On ferrous metals subject to normal indoor or outdoor exposure, except as

specified for buildings and not subject to chemical attack.
• All surfaces shall be free of dirt, dust, grease or other foreign matter before
coating.
• Surfaces shall be cleaned and, Brush off Blast Cleaning.
• Weld surfaces and rough edges shall be ground and weld splatter removed.
– Coating:
• Application shall be in strict conformance with the manufacturer's

recommendations.
• All sharp edges, nuts, bolts or other items difficult to coat shall receive a brush-
applied coat of the specified coating prior to application each coat.
Minimum Dry Component

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Dubai Municipality
Film Thickness
50 micro as specified in
Primer
or Table 7 – 25
Intermediate Coat 200 microns as specified in

or Table 7 – 25
50 microns as specified in
Finish Coat
or Table 7 - 25
– Time Between Coatings
• As stated in B1 (d) above
iii. On ferrous metals submerged or intermittently submerged in water or corrosive

liquid. Typical examples include the primary settling tanks and aeration tanks.
• All metal surfaces shall be sandblasted with near White Blast Cleaning using
proper abrasive to achieve 50 to 75 microns anchor pattern.
• Weld surface, edges and sharp comers shall be ground to a curve and all weld
splatter removed and welds neutralized with thinner.
– Coating:
• Application shall be in strict conformance with the manufacturer's

recommendations.
• All sharp edges, nuts, bolts or other items difficult to coat shall receive a brush-
applied coat of the specified coating prior to application of each coat.
Minimum Dry Film Component
Thickness
Primer
or Table 7 – 25

Finish Coat
or Table 7 - 25
– Time between Coatings:
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Dubai Municipality
iv. For exterior galvanized steel including the operating platform, handrail, piping
etc.
• Galvanized surfaces shall be washed with solvent thinner as

recommended by the paint manufacturer.
• Use power tool cleaning to remove insoluble contaminants.
– Coating:
• Given in schedule of protection system for metal surface.
– Time Between Coatings:
3. Paint Schedule
i. General
– The coating system to be used is specified here-in the schedule of protection

system for metal surface.
– All surfaces shall be painted except those specified in paragraph 1.01.
– The Engineer shall select the colours.
ii. Process Piping Colour Code
– As specified in “Mechanical Identification".
iii. Equipment Colour Code
– All plant and equipment shall be painted to the colours detailed below or
equivalent RAL colours unless otherwise instructed by the Engineer.
BS 4800 Colour Description
Baseplates and } 00 A 05 Light Grey

mounting stools
handrails, }
walkways & steel }
supporting
2016

Dubai Municipality
structures
Screw pumps } 00 E 53 Black

} Light Green
Non Potable Water
Tanks
Coupling & Fly }

wheels
}
Drive Shafting
} 04 E 53 Red
Valve handwheels
}
Lifting equipment, }
including rails }
beams,Bogies,
gantry girders crab,
block and control
cabin
Pumps }
} 08 E 51 Mid Yellow
Gearboxes
Transformers } 18 E 51 Sky Blue

}
Control,
switchgear, }
distribution &
mimic panels
Motors } Mid Blue

} 18 E 53
Alternators
}
All other exposed

2016

Dubai Municipality
metalwork
Shafts and coupling } Self Colour

guards
}
Aluminium or GRP
hand railing
4. General Coating System
i. The following list shall indicate the coating system.
ii. Piping shall be defined as all pipe, valves, fittings, supports, operating systems
and guides.
iii. Mechanical equipment shall include all drives, motor control panels, and all other
electrical equipment requiring a protective coating.
iv. The colours of other surface shall be selected by the Engineer.
Item System Color
Pump Station Wet Wells andAs specified in

 Sewage and Sludge Treatmentschedule of protective
Equipment: coating on metal works
 All exposed mechanical equipment *
All submerged mechanical

 .. Black
equipment and piping
Pump Station Dry Wells and Motor

 Rooms:
All mechanical equipment and

 .. *
piping
 Offices/Store/Workshops: ..
 All exposed metal .. *
 Miscellaneous:
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Dubai Municipality
All miscellaneous interior exposed

 .. *
metal surfaces
 All miscellaneous exterior exposed .. *
metal surfaces
 All submerged metal surfaces .. Black
Colour per equipment or pipe color code

schedules.
v. All structural steel shall be hot-dip Galvanised in accordance with BS729 and to
be painted as per the schedule of protection system after applied paint
manufacturer’s particulars recommended wash primer.
SCHEDULE OF SURFACE PREPARATIONS ON FERROUS & NONFERROUS

METALS & PLASTICS
System Description Surface Preparation
(a) Degreasing Shop cleaning to remove group 1
contaminants in accordance with the

approved standard.
(b) Blast Cleaning The surface shall be shot or grit
blasted to remove all rust, millscale,

in accordance with the approved
standard first quality finish for steel,
second quality finish for cast iron.
Blasting materials shall be free of
deleterious substances.
(c) Fettling The surface shall be cleaned to
2016

Dubai Municipality
remove all scale, rust, etc., by hand

cleaning using a powered wire brush
or other approved method.
(d) Site cleaning Immediately before site painting all
dirt, oil or grease shall be removed

from the surface with white spirit or
other approved solvent.
(e) Wire wool or On site preparation to provide key
for Abrasive cloth primers and

undercoats.
(f) Polish and /or Shop treatment for aluminium.
Anodise
(g) Sweep Blast Site preparation for glavanized
areas.
(h) Spot Blast cleaning Welded spot shall be spot blast
cleaned to Sa 2½ to remove the

accumulated dirt & welding
resounds.
(i) Prickling (stainless steel) The passive layer on the welded
parts of stainless steel shall be

removed & restored by prickling the
metal in a tank and then treating it
with passivating solution.
(j) Electro Chemical Polishing Electrolyte bath to produce a
(Stainless steel) homogeneously

polished surface with a dirt repelling
effect.
SCHEDULE OF PROTECTIVE COATINGS ON FERROUS & NONFERROUS

METALS
System Description
P1 Zinc metallisation or zinc spray to the approved standard.
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Dubai Municipality
Or thicker metallic zinc coating
P2 Sealer primer to follow hot dip galvanising.
P3 Etch primer or wash Primer to follow zinc spray.
P4 Micaceous Iron Oxide Paint containing not less than 80% iron
Oxide and not more than 5% anti-settling agent.
P5 Alkyd Resin base undercoat
P6 Alkyd Resin base gloss finish paint
P7 Zinc Chromate primer with 85% zinc on dry film
P8 Epoxy or Polyester prefabrication primer
P9 Epoxy Zinc phosphate submersible primer
P10 High build Polyamine based Epoxy or Polyester airless spray
coating
P11 Approved nylon, PVC or other synthetic dip or spray applied
coating.
P12 Hand wrapping with hydrocarbon paste, mastic, Denso PVC tape
and Insulation
P13 Polyurethane tie coat for non ferrous substrate
P14 Polyurethane based coating for ferrous and non-ferrous metal
P15 Acrylic urethane based finish coat
P16 High alumina fibre cement mortar lining to specified thickness.
P17 Air drying modified polysiloxane resin based coating to withstand
250C. temperature
P18 Fusion bonded Epoxy
P19 High build Epoxy aluminium primer/build coat.
P20 Vinyl ester based primer
P21 Glass flake vinyl ester
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Dubai Municipality
P22 Zinc Phosphate Primer Epoxy for ferrous substrate
P23 Modified Epoxy
P24 Epoxy high build MIO (for Galvanized)
P25 Special Red oxide Primer for non-ferrous areas.
P26 Polyethylene Sleeve / Thermal Insulation
P27 Anti Slip Deck Coat (3mm thick)
P28 Sprayed aluminium
P29 High build Epoxy for Potable water resistant
Notes:(1) For manufactured items all cutting and drilling shall be completed before
application of any of the surface treatment specified.
(2) All paint systems shall achieve a minimum dry film thickness (dft) of 300 and a
maximum of 500 micron unless otherwise stated separately. The number of coatings
to achieve this thickness may vary according to method and time of application.
(3) Epoxy/polyester coatings must be applied by airless spray of electrostatic

charging of particles and stoving.
(4) Freedom from pin holes shall be established by a spark tester or such other
means recommended by the coating applicators/manufacturer. Such equipment shall
be provided and maintained by the contractor and be available at all times for the sole
use of the engineer.
(5) Hot dip Galvanizing shall be as specified.
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Dubai Municipality
Table 7.25 SCHEDULES OF PROTECTION SYSTEMS ON FERROUS & NON- FERROUS METALS
[A] INTERNAL SURFACES

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
1.  Ductile Iron (a) Fully  Pipes (a) & (b) P1, P16, 10 4mm* 10 10 (d) & (e) P1 P1 4300
submerged & P10, P10 0 0 0 0 0
in Sewage fittings
or in
contact
with
 Cast Iron Sewage Ditto Ditto P1,P9,P10,P 50 " 350
vapours 10 10 10 10
0 0 0 P1 P1
 Carbon 0 0
Steel Ditto Ditto 50 " 350
P1,P9,P10,P
10 10 10 10
0 0 0
P1 P1
0 0
 Mild Steel Ditto Ditto P1,P9,P10,P 10 50 10 10 " P1 P1 350
10 0 0 0 0 0
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Dubai Municipality
thickness
including
Primer
 Ductile Iron (b) Partially  Pipes P1,P16,P10, 10 4mm* 15 50 " P1 P1 4300

submerged & P15 0 0 0 5
in sewage Fitting
or in s
contact
with
sewage
vapours
 Cast Iron Ditto Ditto P1,P3, 10 50 15 50 " P1 P1 350

P10,P15 0 0 0 5
 Carbon Ditto Ditto
Steel P1,P3, 10 50 15 50 " P1 P1 350
P10,P15 0 0 0 5
 Mild Steel Ditto Ditto P1,P3, 10 50 15 50 " P1 P1 350
P10,P15 0 0 0 5
 Ductile Iron (c) Submerge  Pipes (a) & (b) P1,P16,P10, 10 4mm* 10 10 " 4300
d Potable & P10 0 0 0
/effluent Fitting
water
2016

Dubai Municipality
thickness
including
Primer
 Cast Iron Ditto Ditto P1,P9,P29,P 50 50 12 12 " 350
29 5 5
Steel P1,P9,P29,P 50 50 12 12 " 350
29 5 5
 Mild Steel Ditto Ditto P1,P9,P29,P 50 50 12 12 350
29 5 5
 Ductile Iron (d) Exposed to  Pipes (a) & (b) P22,P16,P10 50 4mm* 12 " P1 P1 4175
ambient & 5 0 0
conditions fitting
 Cast Iron Ditto Ditto P22,P29,P29 50 125 12 P2 P2 300

5 9 9
Steel P22,P29,P29 50 125 12 " P2 P2 300
5 9 9
 Mild Steel Ditto Ditto P22,P29,P29 50 125 12 " P2 P2 300
5 9 9
 Ductile Iron (e) Buried Pipes & (a) & (b) P22,P16,P10 10 4mm* 10 10 (d) & (e) P2 4300
under the Fittings ,P29 0 0 0 9
ground
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Dubai Municipality
thickness
including
Primer
 Cast Iron Ditto Ditto P9,P29,P29 50 125 12 Ditto P2 300
5 9
Steel P9,P29,P29 50 125 12 Ditto P2 300
5 9
 Mild Steel Ditto Ditto P9,P29,P29 50 125 12 Ditto P2 300
5 9
2. Stainless Steel  Exposed to  Hot No Coating

GR: ambient water Internal
316L/GR304 conditions pipes
 Buried
under the No Coating
ground Internal
3. Galvanised (a) Exposed to  Pipes
Metals ambient &
conditions fittings
 Ductile Iron Ditto P3,P22,P16, 10 50 4m 15 10 (g) P1 4310

P10, P15 m* 0 0 5
 Cast Iron Ditto P3,P22,P24, 10 50 15 10 " P1 310
P15 0 0 5
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Dubai Municipality
thickness
including
Primer
 Carbon Ditto "
Steel P3,P22,P24, 10 50 15 10 P1 310
P15 0 0 5
 Mild Steel Ditto P3,P22,P24, 10 50 15 10 " P1 310
P15 0 0 5
 Galvanised Ditto "
Iron P3,P22,P24, 10 50 15 10 P1 310
P15 0 0 5
(b) Buried
under
Ground
 Ductile Iron Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Cast Iron Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Carbon Ditto "
Steel P3,P22,P23, 10 75 12 10 P2 310
P23 5 0 3
 Mild Steel Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Galvanised Ditto
Iron P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
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Dubai Municipality
thickness
including
Primer
4. Thermo  Pipes No Coating
Plastics & & required
Thermo Set fittings Internal
Plastics in
uPVC/GRP/
GRE
* 4 mm thick cement mortar lining
Table 7.25 SCHEDULES OF PROTECTION SYSTEMS ON FERROUS, NON- FERROUS METALS & PLASTICS
[B] EXTERNAL SURFACES
Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
1. Ferrous Metals
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Dubai Municipality
 Ductile Iron (a) Fully  Mechanical (a) (b) & h P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
submerged Equipment 1 0 microns
in sewage  Pipe work
or in **
contact
with
sewage
vapours
 Carbon (a) (b) & h P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
Steel 1 0 microns
 Structural Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
Steel 1 0 microns
 Mild Steel Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
1 0 microns
 Cast Iron Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
1 0 microns
 Ditto (b) Exposed to *Mechanical (a) (b) & h P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
Ambient equipments , microns
Conditions P15
** Pipe works " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
, microns
P15
2016

Dubai Municipality
 Valves " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
, microns
P15
 Gratings " P22,P14,P1 75 250 25 (d) (e) (g) P14 P14 575
4 0 microns
 Handrails " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
,P15 microns
* Mechanical equipment shall include all drives, motor control Panel and all other electrical equipment requiring a Protective Coating.
** Pipe work shall include all Pipes, Valves, fittings, supports operating system and guides
 M.S.Pipe " P7,P3,P5,P 10 10 10 10 (e) (g) P5 P6 310
Protection 6 0 0 0 microns
Barrier
 Plat forms " P22,P14,P1 75 250 25 (d) (e) (g) P14 P14 575
4 0 microns
 MH & " P9,P10,P10 75 200 20 50 (d) (e) (g) P10 P15 525
PSTN , 0 microns
Covers P15
 Pipe work " P7,P17,P17 25 75 50 (d) (e) P17 150
to with microns
stand
temperature
up to 250C
2016

Dubai Municipality
 Ditto (c) Buried  Pipe works " P22,P23,P2 75 125 12 (d) (e) (g) P23 P23 P12 325
under the 3 5 microns
ground
2. Ditto Fully  Mechanical (a) (b) & h P9,P29,P29 12 125 12 (d) (e) (g) P29 P29 375
submerged in equipment 5 5 microns
effluent  Pipe works Ditto P9,P29,P29 125 (d) (e) (g) P29 P29
/Potable water 12 12 375
5 5 microns
3 Galvanised (a) Exposed to  Galvanised (g) P3,P24,P14 10 100 25 25 (d) (e) (g) P14 P14 610
Metals ambient steel , 0 0 microns
conditions gratings P14
 G.I (g) P3,P24,P24 10 100 25 25 (d) (e) (g) P14 P14 610
multispan , 0 0 microns
covers P14
 G.I Panel (g) P3,P24,P5, 10 100 10 10 P15 P15 310
support 24 0 0 microns
frames P15
 Galvanised (g) P3,P24,P24 10 100 10 50, (d) (e) (g) P15 P15 310
electric ,P15, 0 50 micron
light poles P15 (clear)
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Dubai Municipality
 G. I. Pipes (g) P3,P24,P24 10 100 10 50, (d) (e) (g) P12 P12 310
, 0 50 Insul microns
P15,P15 ation
(b) Buried G. I. pipes P3,P24,P23 10 100 10 10 (d) (e) (g) P23 P23 310
under , 0 0 microns
the ground P23
4. Non- Ferrous
metal.
Stainless steel (a) Fully  Pipe works (e) & g , P25,P21,P2 50 500 50 (e) (g) P21 P21 1050
GR 316L/304 submerged (h) (i)(j) 1 0 microns
in sewage
or in
contact
with
sewage
vapours
Ditto (b) Exposed to  Pipe works " P25,P15,P1 50 50 10 (e) (g) P15 P15 P12 200
ambient carrying hot 5 0 Ins microns
conditions water up to ulati
50C on
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Dubai Municipality
 Ditto above " P25,P28 50 100 (e) (g) P12 150
50C to Ins microns
120C ulati
on
 Covers & " P25,P14,P1 50 250 25 (e) (g) P14 P14 550
platforms 4 0 microns
 Handrails " No coating
external &
internal
(Natural
Finish)
Ditto (c) Fully  Mechanical " P25,P29,P2 50 125 12 (e) (g) P29 P29 300
submersed equipment 9 5 microns
in  Pipe works " 50 125 " " P29 P29
effluent/Pot P25,P29,P2 12 300
able water 9 5 microns
Ditto (d) Buried  Pipe works " P25,P23,P2 50 125 12 " " P23 P23 300
under the 3 5 microns
ground
5. Aluminium Exposed to  covers (g) & (f) P25,P15,P1 50 50 50 (d) (e) P15 P15 P12 150
ambient 5 Ins microns
conditions ulati
on
2016

Dubai Municipality
6. Thermo (a) Exposed to  pipe works (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Plastics ambient 5 microns
uPVC/P.P/ conditions
HDPE
(b) Buried
under the No Coating
ground Required
7 Thermo (a) Exposed to  Odour (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Setting ambient Control 5 microns
Plastics conditions GRP Duct
(GRP/GRE) Pipes &
fittings
GRP "  GRP Pipes (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
and fittings 5 microns
for water
distribution
2016

Dubai Municipality
GRP  GRP Non  Type ‘A’ (d) & (e) Cover
Slip cover on manufacture
pedestrian Odour rs
trafficable Control Unit recommend
covers ed
protective
coating
system
resistant to
corrosion ,
Non slip and
U.V
resistant
GRP  GRP Non  Type ‘B’ (d) & (e) Cover
Slip covers on manufacture
Pedestrian odour r’s
trafficable Control recommend
covers with Units ed
chequer protective
plate coating
wearing
surface
2016

Dubai Municipality
GRP  GRP  Tanks (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Chemical external & 5 microns
Storage related
tanks / fittings
GRP
potable
water
storage
tanks
GRE (b) Potable  Tanks pipes (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150micro
Water & Fittings 5 50 50 50 (d) (e) P15 P15 ns
Pipes external P25,P15,P1 150micro
exposed to surfaces 5 ns
ambient
conditions
for fire
fighting
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Dubai Municipality
Note: (1) Final Coat protective coating on exposed surfaces of all GRP, GRE items Multi Colour Shades for beautification purposes will be selected by Dubai
Municipality Architect / Engineer at site.
(2) All structural steel items are to be hot dip galvanised to a minimum thickness of 140 microns.
(3) Colour shades of the metal works should match with relevant structures concrete paint system or as decided by the Engineer/Architect.
(4) All buried ferrous and non ferrous metal painted pipes & fittings shall be protected further with any one of the Protection wrapping system specified
in CL.7.2.6.4 on top of Protective Coating specified.
(5) All S.S bolts, nuts & washers are to be removed from the fittings before to apply paints and rectified after painting.
(6) All S.S bolted fitting, burried under the ground shall be protected with approved insulation system specified.
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Dubai Municipality
7.2.6.4 Protective Wrapping Tapes and Sleeve on Buried Pipes and Fittings
Buried ferrous and stainless steel pipelines, joints, valves and other fittings shall be
protected either by wrapping with adhesive tape, synthetic resin or plastic tape or
plastic sleeves. When applying wrapping tape an overlap of at least half the width of
the tape for pipes up to 300 mm dia is required.
a) Adhesive Tape
Adhesive tape shall be either a synthetic fibre or glass cloth impregnated with a
mixture of petroleum jelly and neutral mineral filler. When used for above ground
pipes these tapes shall be protected by a bituminous tape.
b) Synthetic Resin or Plastic Tape
Synthetic Resin or Plastic Tape shall be PVC or black polyethylene strips 250 micron
thick with fabric core coated one side with a compact adhesive normally of synthetic
rubber base.
c) Two-Pack Taping
Two-pack taping system shall be woven glass tape or sheet form impregnated with a
two pack solventless composition of polyester or epoxy. The surface to be protected
should first be cleaned and primed to receive with two pack epoxy. It should then be
wrapped with glass cloth in tape form with polyester or epoxy. A thin coat of
impregnating tape and then reinforcing substrate are applied. Several layers are be
built up and the final layer shall be trowelled smooth. The coating should set to a
hard glass like protective coating which is impermeable to water
7.2.6.5 Plastic Sleeves
Plastic sleeve shall be a black colour high density polyethylene 250 micron thick
which shall be used as a protective sleeve on pipes. The sleeving is to be applied at
the time of laying the pipe and joints are taped with adhesive tape.
7.2.6.6 Hot Dip Galvanising
Hot dip galvanised coating on iron and steel articles shall be carried out in
accordance with the requirements of BS 729:1971. The minimum average coating
thickness shall be 140 microns (equivalent to 720-1000g/m2).The coating operation
shall consist of dipping the steel parts into a molten Zinc bath at a temperature of
450 C. After completion of the dipping further treatment comprising of degreasing,
pickling, rinsing, fluxing and drying shall be carried out separately.
7.2.6.7 Water Level Marking Paint
The paint shall be a thermoplastic non-toxic ‘WRAS APPROVED’ product suitable for
application by brush or airless spray, day light reflecting type acrylic paint with
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fluorescent pigments which give intense colour impression and high visibility.
Suitable colour shades shall be as approved by the Engineer.
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 8
BUILDING WORKS
DM/SRPD Section 8 Building Works Rev 00 June
2016

Dubai Municipality
DM/SRPD Section 8 Building Works Rev 00 June Page i of iv
2016

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SECTION 8
BUILDING WORKS
CONTENTS
8 BUILDING WORKS............................................................................................................ 1
8.1 GENERAL...................................................................................................................... 1
8.2 CONCRETE ................................................................................................................... 1
8.2.1 Tolerance .............................................................................................................. 1
8.2.2 Concrete Finish ..................................................................................................... 1
8.2.3 Construction Bays ................................................................................................. 1
8.2.4 Small Precast Items .............................................................................................. 2
8.2.5 Cast in Fixings ...................................................................................................... 2
8.2.6 Timber Cast in Fixings .......................................................................................... 2
8.3 BRICKWORK AND BLOCKWORK .............................................................................. 2

8.3.1 Damp Proof Course .............................................................................................. 2
8.3.2 Wall Ties ............................................................................................................... 2
8.3.3 Door and Window Frame Ties .............................................................................. 3
8.3.4 Mastic ................................................................................................................... 3
8.3.5 Brickwork and Blockwork ...................................................................................... 3
8.3.6 Cement Mortar ...................................................................................................... 3
8.3.7 Pointing ................................................................................................................. 3
8.3.8 Hollow Walls ......................................................................................................... 3
8.4 ROOFING ...................................................................................................................... 3

8.4.1 Roof Screed .......................................................................................................... 3
8.4.2 Roof Primer ........................................................................................................... 4
8.4.3 Waterproofing Membrane ..................................................................................... 4
8.4.4 Roof Insulation ...................................................................................................... 4
8.4.5 Roof Surface ......................................................................................................... 4
8.4.6 Roof Decking ........................................................................................................ 4
8.4.7 Fascia Cladding .................................................................................................... 4
8.5 JOINERY ....................................................................................................................... 4

8.5.1 Timber-General ..................................................................................................... 4
8.5.2 Timber Sizes ......................................................................................................... 5
8.5.3 Hardwood ............................................................................................................. 5
8.5.4 Plywood ................................................................................................................ 5
8.5.5 Timber Fixing Accessories .................................................................................... 5
DM/SRPD Section 8 Building Works Rev 00 June Page ii of iv
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8.5.6 Timber Preservative .............................................................................................. 6

8.5.7 Ironmongery .......................................................................................................... 6
8.5.8 Workmanship ........................................................................................................ 6
8.5.9 Fabrication ............................................................................................................ 6
8.5.10 Storage ................................................................................................................. 6
8.5.11 Door Frames ......................................................................................................... 7
8.5.12 Doors .................................................................................................................... 7
8.6 METALWORK ............................................................................................................... 7

8.6.1 Aluminium ............................................................................................................. 7
8.6.2 Aluminium Louvers ............................................................................................... 7
8.6.3 Aluminium Windows ............................................................................................. 8
8.6.4 Ironmongery .......................................................................................................... 8
8.7 PLUMBING .................................................................................................................... 8

8.7.1 General ................................................................................................................. 8
8.7.2 Sanitary Fixtures ................................................................................................... 8
8.7.3 Copper Tubes ..................................................................................................... 11
8.7.4 Copper Fittings, Waste Pipes, Ball Valves etc. ................................................... 11
8.7.5 uPVC Pressure Pipes and Fittings ..................................................................... 12
8.7.6 Workmanship ...................................................................................................... 12
8.7.7 Pipe work ............................................................................................................ 12
8.7.8 Copper Tube Fixing ............................................................................................ 12
8.7.9 Waste Pipes ........................................................................................................ 12
8.7.10 Sleeves ............................................................................................................... 12
8.7.11 Testing ................................................................................................................ 13
8.7.12 Storage Tanks .................................................................................................... 13
8.8 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES ......................... 14
8.8.1 Cement ............................................................................................................... 14
8.8.2 Lime .................................................................................................................... 14
8.8.3 Sand ................................................................................................................... 14
8.8.4 Gypsum Plasters ................................................................................................ 14
8.8.5 Plaster Trims ....................................................................................................... 14
8.8.6 Metal Lathing ...................................................................................................... 14
8.8.7 Plasticizers .......................................................................................................... 14
8.8.8 Bonding Agents .................................................................................................. 15
8.8.9 Storage ............................................................................................................... 15
8.8.10 Floor Tiles ........................................................................................................... 15
8.8.11 Wall Tiles (Internal) ............................................................................................. 15
8.8.12 Wall Tiles (External) ............................................................................................ 15
8.8.13 Tile Adhesive ...................................................................................................... 16
8.8.14 Tile Grout ............................................................................................................ 16
8.8.15 Expansion Joints ................................................................................................. 16
8.8.16 Backgrounds ....................................................................................................... 16
DM/SRPD Section 8 Building Works Rev 00 June Page iii of iv
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8.8.17 Dissimilar Materials ............................................................................................. 17

8.8.18 Hacking ............................................................................................................... 17
8.8.19 Dubbing Out ........................................................................................................ 17
8.8.20 Splatterdash or Stipple Coat ............................................................................... 17
8.8.21 Internal Finishes-General ................................................................................... 17
8.8.22 Internal Render ................................................................................................... 17
8.8.23 Stucco ................................................................................................................. 17
8.8.24 External Render .................................................................................................. 18
8.8.25 Insitu Floor Finishes ............................................................................................ 18
8.9 GLAZING ..................................................................................................................... 20

8.9.1 Glass................................................................................................................... 20
8.9.2 Glazing................................................................................................................ 21
8.9.3 Bedding Compound ............................................................................................ 21
8.9.4 Proprietary Curtain Glazing ................................................................................ 21
8.10 PAINTING AND DECORATING .................................................................................. 21

8.10.1 Painting-General ................................................................................................. 21
8.10.2 Exterior Stain ...................................................................................................... 21
8.10.3 Stopping to Plaster ............................................................................................. 22
8.10.4 Steel Priming ...................................................................................................... 22
8.10.5 Oil Based Paint ................................................................................................... 22
8.10.6 Internal Finish to Walls ....................................................................................... 22
8.10.7 Ironmongery ........................................................................................................ 22
8.10.8 Workmanship ...................................................................................................... 22
8.11 Water Supply and Drainage ...................................................................................... 24

8.11.1 Water Supply System ......................................................................................... 24
8.11.2 Water Drainage System ...................................................................................... 32
DM/SRPD Section 8 Building Works Rev 00 June Page iv of iv
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Dubai Municipality
8 BUILDING WORKS
8.1 GENERAL
a) This specification defines the general requirements for the building works.
b) No deviations or exceptions from this specification shall be permitted without the

written approval of the Engineer.
c) Compliance with this specification shall not relieve the Contractor of the
responsibility of furnishing specified material.
d) The Contractor shall co-ordinate, expedite and resolve any problems with the
manufacturer / supplier. The Contractor shall be responsible for ensuring that all
relevant information and documentation is passed on to the manufacturer /
supplier, to complete the work to the satisfaction of the Engineer.
e) The final responsibility for the satisfactory completion of the work shall lie with the
Contractor.
8.2 CONCRETE
8.2.1 Tolerance
Floor and roof slabs shall be level to a point within  5 mm of the level shown on the
drawings. Columns and beams shall have no irregularities exceeding 3 mm in a 3m
length. The position of the face of columns, beams and walls at any point shall be
within 5 mm of its position derived from the drawings.
8.2.2 Concrete Finish
All exposed concrete beams, columns and slab surface described as fair-faced shall
be Type f.f. as follows:
(i) Type f.f. shall be an as struck finish entirely free from honeycombing, stains,
pins, clippings, lining joint marks, nail and screw marks, raised grain marks,
air holes and surface defects and shall be uniform in colour tone and
surface texture with clean true faces and arises.
8.2.3 Construction Bays
The Contractor shall submit to the Engineer for his approval prior to concreting his
proposals for the sequence of placing concrete and the position of horizontal and
vertical construction joints.
DM/SRPD Section 8 Building Works Rev 00 June Page 1 of 43
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Dubai Municipality
8.2.4 Small Precast Items
a) Small precast items such as lintels, sills and padstones shall be built in as the
work proceeds and shall have a fair-faced Type f.f. finish where exposed to view
and hacked surfaces where plastered.
b) Lintels shall have a minimum bearing of 100 mm or larger if indicated on the

drawings and shall have inserts for fixing windows and/or doors cast in.
c) Sills shall be weathered and have a throat as described, if projecting, and shall
have inserts for fixing windows and/or doors cast in.
8.2.5 Cast in Fixings
Cast in fixings shall be securely fixed to formwork ready for casting and shall be true
to line in the positions shown on the drawings.
8.2.6 Timber Cast in Fixings
Timber cast in fixings shall be made from 38 mm x 38 mm dovetailed shaped

softwood battens pressure impregnated with preservative.
8.3 BRICKWORK AND BLOCKWORK
8.3.1 Damp Proof Course
a) Horizontal and vertical damp proof courses shall be hessian based lead cored
bituminous damp proof course weighing not less than 4.4 kg/m2 to accepted
standards and approved by the Engineer.
b) Horizontal damp proof courses shall be laid on an even level bed of fresh mortar
and shall be lapped for the full width of the sheet at corners and junctions.
Stepped damp proof courses shall be wide enough to be built in to both skins of
the wall and to cross the cavity in one piece.
c) Vertical damp proof courses shall be continuous and shall be the width of the
block closing the reveal.
d) Damp proof courses shall not be bridged with mortar.
8.3.2 Wall Ties
a) Wall ties shall be 18/8 stainless steel vertical twist type 200 mm long.
b) Wall ties shall be built in the mortar beds as the work proceeds and shall be
spaced at a maximum of 900 mm horizontally and 450 mm vertically and shall be
staggered. Each door and window opening shall have wall ties at each joint at
225 mm centres vertically.
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Dubai Municipality
8.3.3 Door and Window Frame Ties
As described for Joinery Fixing Accessories. Door and window frame ties shall be
fixed as described under Joinery Work.
8.3.4 Mastic
a) Mastic for pointing door and window frames shall be one part gun-grade
polysulphide mastic to accepted standards and approved by the Engineer.
b) Mastic seals to windows or door frames shall be neatly gun applied to clean, solid
and dry backgrounds in one operation. The mastic shall be a triangular seal
across the whole joint and any surplus shall be cleaned off when set.
8.3.5 Brickwork and Blockwork
Brickwork and blockwork shall be as specified in Section 5.
8.3.6 Cement Mortar
Cement Mortar shall be as specified in Section 5.
8.3.7 Pointing
All pointing shall be done as the work proceeds and shall be flush with face of
blockwork.
8.3.8 Hollow Walls
Hollow walls shall be constructed with an outer skin of blockwork and an inner skin of
blockwork leaving a cavity of the widths shown. The two walls shall be tied together
with wall ties as described and the cavity shall be kept and left clear of all droppings.
Openings shall be left at intervals in the blockwork at the bottom of the cavities and all
debris shall be cleared out and the openings bricked up on completion. Cavities shall
be closed at opening reveals with either brick or block to match the surrounding
material and a continuous vertical damp proof course shall be built in.
8.4 ROOFING
8.4.1 Roof Screed
Roof screed shall be laid to fall over the concrete roof slab and shall have a minimum
thickness of 35 mm and maximum thickness of 75 mm. The screed shall be
thoroughly mixed 1:4 cement/sharp sand mix with very little water added. The screed
shall be laid and compacted and shall be levelled off and finished with a steel trowel.
Precautions must be taken to prevent rapid or excessive drying out.
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Dubai Municipality
8.4.2 Roof Primer
Primer for concrete shall be suitable for use with the waterproofing membrane and
shall be applied in accordance with the manufacturer's instructions.
8.4.3 Waterproofing Membrane
a) Flexible waterproofing membrane for roofing shall be bitumen based to accepted

standards and approved by the Engineer.
b) Surfaces to receive the membrane shall be smooth, dry and free from dust. The
membrane shall be laid on a primed surface and in accordance with the
manufacturer's recommendations.
8.4.4 Roof Insulation
Roof insulation shall be 75 mm thick closed cell non-absorbent rigid polystyrene

insulation board. The insulation boards shall be placed immediately after the
membrane has been laid.
8.4.5 Roof Surface
Roof surface shall be 50 mm thick 450 mm x 450 mm precast concrete paving slabs
laid dry.
8.4.6 Roof Decking
The roof decking shall be aluminium profiled sandwich sheeting fixed to Metsec ‘Z’
section purlins all in accordance with the manufacturer’s instructions. The Contractor
shall provide working drawings and manufacturers literature for approval before
ordering the same.
8.4.7 Fascia Cladding
The fascia cladding shall be of single skin construction formed from profiled
aluminium sheeting with matching aluminium-profiled flashings. The Contractor shall
provide working drawings and manufacturer’s literature for approval before ordering
the same.
8.5 JOINERY
8.5.1 Timber-General
All joinery shall be manufactured from timber complying with BS EN 942. No joinery
component shall be made from any species of timber which is indicated in BS En 942
as being unsuitable for that purpose. Timber for joinery shall be air dried and the
moisture content be allowed to reduce until it reaches a level in equilibrium with local
conditions. It will be deemed to have reached equilibrium when the moisture content
is 12% + 2%. All timber shall be sound and free from any fungal or insect attack. No
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Dubai Municipality
timber is to be incorporated in the Works which has been used for formwork,
planking, strutting, scaffolding, or any other form of plant work
8.5.2 Timber Sizes
Timber shall be 3 mm less per wrought or finished face than the sawn size.
8.5.3 Hardwood
Hardwood for joinery shall be sound, well conditioned and seasoned Mahogany or
Meranti with an average density of 529 Kg/m3 and a moisture content of 12% + 2%.
Exposed surfaces of joinery shall comply with the following requirements.
Knots : Pin knots up to 6 mm diameter will be permitted.
Checks & Shakes: Checks up to 3 mm width and 300 mm long will be permitted.
Pitch Pockets : Not permitted unless cut out and filled.
Plugs and Inserts : Not permitted.
Joints and Lamination
Glue Lines : Not permitted.
Rate of Growth : Not fewer than 8 growth rings per 25 mm at any point on any
cross section.
Slope of Grain : Not greater than 1 in 8.
Species & Character : Same on all surfaces and matched as far as possible.
Pinholes : Permitted if filled.
A sample of each representative section for use in the work shall be previously
submitted for approval by the Engineer's Representative.
8.5.4 Plywood
Plywood shall be from a manufacturing source approved by the Engineer and shall
comply in all respects with the requirements of BS 6566.
8.5.5 Timber Fixing Accessories
a) Nails for fixing joinery shall be aluminium or sheradised mild steel.
b) Screws for fixing joinery shall be sheradised mild steel.
c) Bolts shall be stainless steel.
d) Adhesives for exterior use shall be synthetic resin types, weather and boil proof,
complying with the approved standard. Adhesives for interior use shall be
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Dubai Municipality
synthetic resin types, moisture resistant and moderately weather resistant,

complying with the approved standard.
e) Door frame and lining fixing cramps shall be of 25 mm wide x 14 swg thick x 250
mm girth stainless steel, one end turned up 50 mm and twice drilled and the end
fishtailed for building in.
f) Dowels for fixing door frames shall be 10 mm dia. x 100 mm long stainless steel.
8.5.6 Timber Preservative
Timber preservative shall be water repellent and protect the timber from all wood
destroying fungi and insects particularly termites. The preservative shall be applied in
accordance with the manufacturer's instructions including treatment to all ends,
notches and joints in treated timber out on site.
8.5.7 Ironmongery
Ironmongery shall be as shown on the drawings.
8.5.8 Workmanship
a) All exposed faces of joiners work shall have wrought faces.
b) All arises shall be rounded to a 1.5 mm minimum radius unless specified or drawn
to a greater radius.
c) Where the term 'framing or framed' is used it shall mean all halvings, dovetails,
tenons and hardwood pins and the best known means of putting this work
together.
8.5.9 Fabrication
a) All joinery is to be purpose made and constructed in workmanlike manner,

morticed and tenoned, dovetailed, tongued and grooved, glued, pinned, screwed,
etc., as best suited to the particular part. All mortice and tenon joints are to be
pinned with hardwood dowels or with brass pins in addition to wedging and
gluing. All joinery shall be put together with waterproof adhesive.
b) All carpenter's work shall be accurately set out and shall be framed together and
securely fixed in the best possible manner with properly made joints. All
necessary brads, nails and screws, etc., shall be provided to the approval of the
Engineer.
8.5.10 Storage
a) All joinery shall be protected from the weather during transit and shall be stored
under cover, clear of the ground in clean, dry ventilated conditions so as to
maintain the specified moisture content.
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Dubai Municipality
b) All framework shall be put together loosely and stored as described and shall not
be wedged and glued together until required for fixing.
8.5.11 Door Frames
External door frames shall be built in as work proceeds with fixing cramps as
described. The fixing cramps shall be screwed to the back of the frames at 450 mm
maximum centres with two serialised screws 25 mm long. The fishtail ends shall be
built in to the brickwork or blockwork mortar joints as the work proceeds.
8.5.12 Doors
a) External doors shall be hung on one and a half pairs of hinges unless otherwise
detailed, to give a maximum tolerance all round of 2 mm.
b) Panel doors shall be constructed in hardwood and shall comply with the
requirements of BS 459 and BS 4787.
c) Flush doors shall be solid cored, faced on both sides with 6 mm exterior marine
quality plywood with hardwood veneer to match panel doors and lipped with
hardwood. They shall be constructed in accordance with BS 4787.
d) Door sizes shall be as given in drawings and schedules.
e) Where shown on drawings doors shall have inset vision panels complete with
glazing to match adjacent windows.
f) Fire ratings for doors shall be minimum 2 hour in accordance with BS 476.
g) Door frames shall be screwed and plugged or cramped to brickwork or blockwork

to the satisfaction of the Engineer.
h) Where required on drawings proprietary plate glass double swing doors shall be
provided. Glazing shall match that for adjacent windows. Doors shall be installed
in accordance with manufacturer / supplier requirements.
i) No doors or frames shall be incorporated in the works without first obtaining the
Engineer approval of a sample.
8.6 METALWORK
8.6.1 Aluminium
Aluminium alloy sections for aluminium shall be type H59 TF box sections.
8.6.2 Aluminium Louvers
Aluminium louvers shall be made from NS 4 H3 aluminium and have a natural or

bronze anodised finish. Sizes to be as shown on the drawings.
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Dubai Municipality
8.6.3 Aluminium Windows
a) Aluminium windows shall be manufactured by an approved specialist window

manufacturer from extruded aluminium sections mechanically cleared and sealed.
Glazing to be fixed into opening with clip on aluminium beads and gasket sealed.
b) Finish to windows to be natural anodised 25 microns in thickness. Windows are to

be fixed into openings with stainless steel screws and sealed all round in mastic
bedding.
8.6.4 Ironmongery
a) Rates for supplying and fixing ironmongery shall include for all boring, cutting,
mortising, sinking, making good, replacing damaged screws, oiling, adjusting,
leaving in good working order and mastering all locks.
b) Screws shall be of suitable gauge and material for the purpose and shall match
the item to be fixed.
8.7 PLUMBING
8.7.1 General
a) The works covered under this contract include all the supply, installation testing
and delivery in good operating conditions of all the plumbing works as described
in these specifications and/or shown on the drawings.
b) The Contractor shall supply all the necessary components and accessories as
well as manpower, scaffolding, painting, etc., to provide a complete operational
system.
8.7.2 Sanitary Fixtures
a) Supply and install all sanitary fixtures as shown on the drawings and described in
the specifications.
b) Sanitary tapware and waste fittings for basins shall be in accordance with BS EN
274.
c) Vitreous china fixtures shall be of first quality with smooth glazed surfaces, free
from warp, cracks, discolorations or other imperfections.
d) Fixtures shall be set in a neat; finished and uniform manner making the
connection to all fixtures at right angles to the wall of concealed holding type,
unless otherwise directed by the Engineer. Fixtures are not to be set until so
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Dubai Municipality
e) Ample application of petroleum jelly shall be made to all surfaces of exposed

chromium plated piping, valves and fittings and stainless steel fixtures
immediately after installation.
f) Concealed brackets, hangers and plates shall have a shop coat of paint.
g) Plastic piping systems for soil and waste discharge (low and high temperature)
within the building superstructure shall be uPVC as per BS EN 1329-1.
8.7.2.2 Wash Hand Basins (W.H.B)
a) Supply and install W.H.Bs wherever shown on the drawings. Each W.H.B shall
be white coloured vitreous china complete with its pedestal.
b) The lavatory shall be furnished with the following:
(i) • Wall supports.
(ii) • Wash hand basin mixer and tap unit.
(iii) • Chrome plated bottle trap with wall flange.
(iv) • Vitreous china shelf 560 mm of the same colour as the fixture.
(v) • Vitreous china soap holder.
(vi) • Chrome plated angle valves for hot and cold water supply complete with
copper tube and handle.
8.7.2.3 Showers
Showers shall be supplied and installed wherever shown on the drawings. Each
shower shall be white coloured vitreous china with complete accessories.
(i) Floor support and fixings.
(ii) Combined mixer and tap unit.
(iii) Concealed piped fixed shower head and spray rose.
(iv) Vitreous china soap holder.
(v) Metal shower rail and fixtures and curtain rings.
(vi) Shower curtain.
(vii) Chrome plated outlet with bottle trap (removable type).
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Dubai Municipality
8.7.2.4 European water closets
Water closets of this type shall be supplied and installed wherever shown on the
drawings. Each closet shall be white coloured with complete accessories. It shall be
of floor mounted type with floor outlets trap.
(i) Coloured seat and cover
(ii) Outlet connector with rubber sealing ring and fixing pins.
(iii) 80 cm long chrome plated hose complete with angle valve, nozzle and
hook.
(iv) Chrome plated floor fixing screws and gaskets.
(v) Toilet paper holder.
(vi) All necessary fixing and accessories required for its installation, fixing and
connections to water supply and waste and its satisfactory operation.
8.7.2.5 Asian water closets
Water closets of this type shall be supplied and installed wherever shown on the
drawings. Each closet shall be white coloured with complete accessories. It shall be
of flush floor type with back outlet trap.
(i) 80 cm long chrome plated hose complete with angle valve, nozzle and
hook.
(ii) Toilet paper holder.
(iii) All necessary fixing and accessories required for installation, fixing and
connections to water supply and wastewater and its satisfactory operation.
8.7.2.6 Electric water heaters
a) Electric water heaters of capacities shown shall be supplied and installed

wherever shown on the drawing.
b) Electric water heaters shall be of the storage type, cylindrical shape white
enamelled, insulated and complete with the following:
(i) Electric heating element of capacity corresponding to the following

schedule:
Capacity Litres Capacity Watts
50 1000
(ii) • Chrome plated recessed type gate valves at the inlet and outlet.
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Dubai Municipality
(iii) • Non return valve at inlet.
(iv) • Thermometer. -Thermostat.
(v) • Electrical connection.
(vi) • Relief valve.
(vii) • Metallic supports and accessories required for its installation, connection,
support, fixing and its satisfactory operation.
8.7.2.7 Air hand dryers
Electric powered automatic air hand dryers shall be supplied and installed wherever
shown on the drawings. Each unit shall be white enamelled, insulated and with
electric supply and local isolation switch and shall be in accordance with IEE
regulations. Units shall be supplied complete with fixings.
8.7.2.8 Towel holders
Proprietary industrial duty paper towel dispensers shall be supplied and installed
wherever shown on the drawings. All units shall be of a single type and size, and
shall be supplied complete with opening keys (2 No./Unit) and necessary fixings.
8.7.3 Copper Tubes
a) Copper tubes shall be half hard copper tube of accepted standard approved by
the Engineer.
b) All Hot and Cold water installations shall be made using copper pipes. Copper
pipes shall be of the seamless hard drawn type.
c) Pipes of appropriate types shall be used for underground and over ground
installation.
d) Soldered joints for tubing shall be made with approved fittings. Surface to be
soldered shall be cleaned bright. The joints shall be given a thin coating of
approved soldering flux and the tubing end inserted into the fitting as far as
possible.
8.7.4 Copper Fittings, Waste Pipes, Ball Valves etc.
a) All fittings shall be of an accepted standard approved by the Engineer and as

described on the drawings.
b) Fittings shall be of the same material and weight as the pipes and shall be
suitable for solder jointing pressure type. Heating and finishing of the joint shall
be done in accordance with the recommendations of the manufacturer/supplier of
the fittings, using solid string or wire solder composed of 50 percent lead for
inside and 95 percent tin and 5 percent antimony for underground.
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8.7.5 uPVC Pressure Pipes and Fittings
a) uPVC pressure pipes and fittings for water supply shall be of an accepted
standard approved by the Engineer.
b) The pipe shall be homogenous throughout and free from visible cracks, holes,
foreign inclusions or other defects. The pipe shall be as uniform as commercially
practicable in colour, capacity, density and other physical properties.
c) All fittings and accessories shall be of same material and quality as the pipe and
jointing shall be of the spigot and socket cemented type where solvent cement is
applied to both parts. After pushing the pipe into the socket the joint shall be
allowed to set for at least 10 hours.
8.7.6 Workmanship
The plumbing installation shall be carried out to the satisfaction and in accordance
with the Acts and By-laws of the Dubai Electricity and Water Authority.
8.7.7 Pipe work
All pipework shall be neatly executed in long lengths to avoid unnecessary jointing.
Horizontal pipes shall be fixed with a slight fall to prevent airlocks and to enable the
system to be easily drained down.
8.7.8 Copper Tube Fixing
a) Copper tube shall be fixed clear of walls and ceilings with two piece copper
spacing clips or with proprietary plastic pipe clips. Clips shall be at 1.20m
horizontally and 1.50m vertically for 15mm diameter pipes and at 1.80m and
2.40m respectively for 22mm and 28mm diameter pipes. Capillary joints shall be
neatly made with all surplus solder removed.
b) Screw threads on compression joints shall be wrapped with PTFE tape prior to
tightening.
8.7.9 Waste Pipes
uPVC waste pipes for sinks and urinals shall be fixed and jointed in accordance with
the manufacturer's instructions. Fixing clips shall be at 0.50m horizontally and 1.20 m
vertically and joints shall be by 'O' rings, seals or solvent cement. Care shall be taken
to allow for expansion in accordance with manufacturer's instructions.
8.7.10 Sleeves
uPVC sleeves shall be provided through walls and ceilings for pipes and shall be
internally 3 mm minimum larger than the pipes.
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8.7.11 Testing
a) Soil and waste pipes shall be air tested for leaks to a pressure of 38 mm water
gauge, constant for three minutes.
b) Rainwater pipes shall be tested for leaks as above and gutters shall be tested by
filling with water to overflow level.
c) Testing shall be undertaken to hidden sections of pipework before they are built
in.
d) All leaks found shall be rectified and retested.
8.7.12 Storage Tanks
a) GRP cold-water storage tanks shall be provided.
b) Water storage tanks shall be supplied, erected and connected in the position
indicated on the approved drawing and in accordance with the details provided.
The tank shall be under a shade.
c) The tank shall be of the size and capacity indicated on the drawing.
d) The capacity shall be without free board unless specifically indicated otherwise.
The tank shall be made of insulated GRP panels to suit the dimensions and
capacity indicated
e) The tank shall have connections as required by the Water Supply Authority
regulations positioned as required to conform to the regulations and shall include
the following:
(i) Mains cold water inlet to tank complete with ball valve as indicated
elsewhere and full way gate pattern isolating valve.
(ii) Cold Water down feed connection complete with full way gate pattern
isolating valve for parent service.
(iii) Overflow connection.
(iv) Drain connection complete with bronze gate valve having wheel handle,
non-rising stem, screwed bonnet, solid wedge type manufactured in
accordance with BS 19 arranged to drain from the bottom of the tank.
f) All tank connections shall be full bore of the sizes indicated on the drawings.
g) The outlet from the drain valve shall be run to the position indicated on the
drawing.
h) All tank overflows shall be run to the position indicated on the drawing.
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i) The tank shall be provided with a lightweight dust lid complete with easily
removable 300 mm min. square flanged and bolted on access cover positioned
directly above the ball valve, and complete with mushroom cowled ventilator.
j) The tank shall be supported on RSJ's not less than 75 mm wide at 610 mm
centres in one direction only and in accordance with the manufacturer's
requirements.
k) On completion of installation the tank shall be filled and tested for a minimum
period of 2 hours. For a satisfactory test all joints shall remain watertight, no leaks
shall be detected, and no visible bulging of the tank walls shall occur. Should the
test not prove satisfactory, all defects shall be repaired and the tank re-tested at
no cost to the contract.
8.8 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES
8.8.1 Cement
Cement shall be Portland Cement as described in Section 3.
8.8.2 Lime
Lime shall be the hydrated type to the approved standard.
8.8.3 Sand
Sand for plasterwork with gypsum plasters shall be suitable for use with the brand of
gypsum plaster used. Sand for rendering, internally and externally, and floor screeds
shall comply with requirements as specified in Section 5 .
8.8.4 Gypsum Plasters
Gypsum plaster shall be of an accepted standard approved by the Engineer.
8.8.5 Plaster Trims
Metal angle beads and plaster stops for plasterwork and plasterboard shall be
manufactured from galvanised mild steel.
8.8.6 Metal Lathing
Metal lathing shall be manufactured from galvanised mild steel having a minimum
shortway aperture of 6 mm.
8.8.7 Plasticizers
Plasticizers shall be an approved vinyl resin type and used in the manner and
proportions recommended by the manufacturer.
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8.8.8 Bonding Agents
Bonding agents generally shall be an approved polyvinyl acetate (PVA) type and
used in the manner and proportions recommended by the manufacturer.
8.8.9 Storage
a) Plaster shall be stored in a building in dry condition on timber platforms and shall
be used within two months of manufacture.
b) Plasterboards shall be stored in a building in dry condition and shall be laid flat
and stacked on a sheet of polythene.
8.8.10 Floor Tiles
a) Vitrified and fully vitrified floor tiles shall be as detailed on the drawings.
b) Floor tiling shall be laid with a proprietary tile adhesive (approved by the
Engineer) either directly onto a clean, dry and level concrete sub floor, or on a
cement/sand screed laid over the sub floor. The sub-floor surface shall be
scabbled to remove all surface laitance prior to tiling or screeding. The screed
shall be mixed semi dry by hand or in a pan mixer and shall be a 1:4
cement/sharp sand mix with just enough water to enable it to hold together when
squeezed in the hand. The sub floor shall be kept damp for 24 hours and the
screed shall be laid and well compacted to a thickness of 56mm and brought to
the required levels using a draw float. The finished floor screed shall be kept
damp for a period of 7 days prior to commencement of tiling. The tile adhesive
shall be spread evenly by steel trowel to a thickness of 3mm onto which the
clean, dry tiles shall be laid to give a 3mm minimum joint width. The tiles shall be
grouted with a proprietary and approved tile grout within a minimum period of 24
hours after laying.
8.8.11 Wall Tiles (Internal)
Coloured wall tiles shall be 152 x 152 x 5.5mm thick glazed tiles approved by the
Engineer.
8.8.12 Wall Tiles (External)
a) External wall tiles shall be as detailed on the drawings.
b) The concrete surface to receive tiling shall be prepared as follows:
(i) Concrete surface to be 100% keyed by either bush hammering, hacking or

water scabbling of smooth surface.
(ii) Concrete surface shall be thoroughly moistened and a concrete slurry mix
of one part cement to two parts of medium sharp sand applied as
splatterdash thrown onto concrete surface.
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(iii) While the surface is wet apply 1:3.5 mix sand/cement render to a thickness
of 12mm in two coats to a plumb and level finish and with wood float finish.
c) The completed rendering is to be protected and allowed to dry slowly with

damping as necessary. After curing, the surface is to be allowed to dry completely
before the fixing of tiles.
d) Tiles shall be fixed with proprietary tile adhesive (approved by the Engineer). The
tiles are to be bedded strictly in accordance with the manufacturer's instructions
with 10mm joints between tiles.
e) At least 24 hours after fixing tiles are to be jointed using approved mortar.
f) Movement joints are to be formed between tiles in positions shown on the

drawings to the full depth of the tiles, bedding and render. Joints are to be 10mm
wide and are to be filled to within 8mm of surface with inert filler and finished with
2 part polysulphide pointing in colour to match tile jointing.
8.8.13 Tile Adhesive
Tile adhesive for floor and wall tiling shall be as recommended by the Tile
Manufacturer and used in accordance with the adhesive manufacturer's instructions.
8.8.14 Tile Grout
Tile grout for floor or wall tiles shall be as recommended by the manufacturers of the
ceramic tiles and used in accordance with the manufacturer's instructions.
8.8.15 Expansion Joints
a) Expansion joints in floor and wall tiling shall be 6.5 mm wide Polyethylene backing
strip with 6.5 mm wide approved silicone sealant, gun applied on the face in
accordance with the manufacturer's instructions.
b) Expansion joints in floor tiling shall be at 6 m maximum centres in both directions

and around the perimeter of rooms, over structural joints and around machine
bases and holes in the floor. The joints shall be the full depth of the floor tiles,
bedding and screed x 6.5 mm minimum width. The joints shall be primed with two
coats of approved primer and when dry, filled up to within 6 mm of the tile finish
with polyethylene compressible foam strip. An approved joint sealant shall then
be gun applied and tooled to a slightly concave smooth even finish.
8.8.16 Backgrounds
All backgrounds shall be clean, dry, and free from efflorescence, paint, oil and dust
and adequately prepared to provide a good key. All loose, flaking and unsound
material shall be completely removed and all mortar joints shall be raked out, if
required, to a minimum depth of 10 mm. Concrete surfaces shall be well wetted five
minutes prior to plastering or rendering.
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8.8.17 Dissimilar Materials
Joints between dissimilar materials such as blockwork and concrete shall be covered
with a 300 mm wide continuous strip of expanded metal lathing fixed to both sides
with masonry nails or plugs and screws at 200 mm centres.
8.8.18 Hacking
Concrete surfaces shall be well hacked to expose the aggregate thus providing a firm
coarse textured background.
8.8.19 Dubbing Out
Dubbing out of all areas to receive plaster or render shall be in the same mix as the
subsequent coat, not exceeding 10 mm thickness in one application, and shall be
allowed to harden.
8.8.20 Splatterdash or Stipple Coat
Splatterdash or stipple coats shall consist of 1:1.5 cement/sharp sand mixed with
50% water/50% PVA bonding agent to form thick slurry. The mixture shall be
vigorously brushed onto the background and stippled to give a close textured key.
The resulting finish shall be kept damp to prevent rapid drying out and allowed to
harden for seven days minimum before subsequent coats are applied.
8.8.21 Internal Finishes-General
All internal finishes shall not commence until the building is watertight, including
glazing, and reasonably dried out.
8.8.22 Internal Render
Internal render shall be applied to concrete blocks as follows:
The render shall be two coat work comprising a stipple coat as described previously
and a finishing coat giving a maximum thickness of 12 mm. The mix shall be in the
proportion 1:1:6 cement/lime/sand. The render shall be kept damp for a minimum of
three days. All window and door openings must be closed to prevent through
draughts causing rapid drying out.
8.8.23 Stucco
A PVA copolymer based putty for concrete and plaster shall be applied, in
accordance with the manufacturer's instructions, to the surface of the internal render
after curing has taken place. The stucco shall only be applied in sufficient thickness to
seal the surface of the render and remove minor surface irregularities to give a
smooth surface ready to receive the decorative finish.
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8.8.24 External Render
a) External render shall be applied to concrete, concrete blocks and clay bricks as
follows:
b) The render shall be three coat work comprising a stipple coat as described
previously, an undercoat and a finish coat giving a maximum thickness of 16 mm.
The mixes shall be in the proportions shown on the schedule of mixes. The
undercoat shall be level, true and of sufficient thickness to prevent the
background joints showing through and shall be kept damp for three days before
applying the final coat.
c) Where shown on the drawings the final coat shall be approximately 5 mm thick
coloured Tyrolean open honeycombed texture machine applied render.
d) A key for the final coat shall be provided by combing the undercoat prior to setting
with wavy lines 20 mm apart and 5 mm deep. The final coat shall be 6 mm
minimum thickness and worked to a level and smooth finish with a wooden float
with clean, true and level arises. The whole shall be protected from rapid drying
out in hot, dry and windy weather.
Table 8.1:Schedule of Mixes for External Render

Mix Type Concrete, Concrete Blocks or Aerated Concrete Blocks of
Engineering Bricks Soft Clay Bricks
Undercoat Finish Undercoat Finish
Cement:Lime:Sand 1:1.5:4 to 4.5 1:1:5 to 6 1:2:8 to 9 1:2:8 to 9
Cement:Ready 1:4 to 4.5 1:5 to 6 1:8 to 9 1:8 to 9

Mixed Lime / Sand
Cement:Sand with 1:3 to 4 1:5 to 6 1:7 to 8 1:7 to 8

Plasticizers
8.8.25 Insitu Floor Finishes
8.8.25.1 Terrazzo finish
a) Cast in situ terrazzo flooring shall conform to BS 8204.
b) The size of terrazzo panels shall be as directed by the Engineer The sub-floor
shall be clean from dust, oil or grease and any other foreign matter and shall
provide a good mechanical key.
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c) The screened bed shall be of a minimum thickness of 25 mm and the mix shall be
1 part cement to 1 part of fine aggregate and 2 parts of coarse aggregate by
volume. The amount of water added shall be the minimum necessary to give
sufficient plasticity for laying and compacting. The "green" concrete shall be
covered with sacks, polyethylene sheet, or tarpaulins, carefully lapped and
supported on a temporary framework.
d) Dividing strips shall be of ebonite 4 mm thick and shall be embedded to the full
depth of the screened bed and reach to the exact level of the finished floor.
e) The main body of the flooring shall not be less than 16 mm thick. The mix shall be
1 part of cement, pigmented in the approved colour shade, to 2½ parts of crushed
marble. The marble chipping shall be free from fines, dust, dirt or other impurities
and shall be approved by the Engineer. The amount of water added shall be
sufficient to produce a plastic but not fluid mix.
f) The terrazzo finish shall stop 10 mm from the walls and covered skirtings shall be
added. They shall be of the same mix and rise to 100 mm above floor level.
8.8.25.2 Granolithic Flooring
a) Granolithic surfacing shall consist of 2½ parts of granite aggregate to one part

cement. The granite aggregate shall consist of clean chipping of 6 mm single
size in accordance with BS EN 12620, except that 100% shall pass the 10 mm
sieve and shall have sufficient fine sand to produce a mixture of satisfactory
workability. Aggregates shall be free from deleterious material in accordance with
the relevant clauses in the specification for concrete.
b) Normally the ratio of granite aggregate to sand is 2½:1. An approved hardener

shall be incorporated in the topping mix. The water/cement ratio shall be kept to a
minimum to provide a workable mix capable to being fully compacted.
8.8.25.3 Acid Resistant Floors
a) Where required by the drawings, rooms and enclosures liable to acid chemical
spillages shall be provided with acid resisting flooring.
b) Acid Resisting Asphalt, laid on a base coat shall be laid by a specialist sub-
contractor who must be approved by the Engineer, in accordance with BS 8204.
c) The asphalt shall be capable of withstanding dilute inorganic acids having a

specific gravity not exceeding 1.4 and temperature not exceeding 45ºC.
d) The finished thickness of the asphalt shall be 20 mm and shall be laid in two
coats over an impregnated flax felt to BS EN 13707 Type 4A (1) and weighing not
less than 15 kg per 23 metre roll.
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e) The asphalt floor shall be finished with a true and even surface ready to receive
tile paving.
f) Acid resisting vitrified tiles and fittings to BS 6431/BS EN ISO 10545 shall be
99.7% acid proof to BS EN 14483.
g) Coved corner skirting shall be provided around the perimeter of the room. Tiles
shall be bedded, straight joint, set true and level, on cement/sand screed mix
(1:3), thickness 36 mm, joints to be 5 mm wide.
h) The tiles to be thoroughly pointed up with a suitable and approved epoxy resin
type cement. The recess at the top edge of the skirting shall be pointed similarly
and finished neatly with a slight weathering flush to the top of the skirting tile.
i) Expansion joints 12 mm wide to full depth of tile and screed shall be formed
between the coved skirting and adjoining floor tiles and pointed up with a suitable
and approved flexible epoxy resin type cement.
8.8.25.4 Cleaning and Protection of Floors
All floor finishes shall be left in a clean and perfect condition, and all dirt, grease,
extrusions of bedding or other materials are to be carefully removed without
damaging the floor finish. The Contractor must protect all floors and skirtings from
damage after laying, using the most suitable and approved means for the type of floor
concerned. Any damage resulting from the floors not being properly protected shall
be made good to the satisfaction of the Engineer.
8.8.25.5 Finishes Generally
The quality of all final finishes shall be subject to the approval of the Engineer and
any remedial measures which he considers necessary, including the breaking out and
replacement of sub-standard areas, shall be carried out by the Contractor .
8.9 GLAZING
8.9.1 Glass
a) Glass for glazing shall be the best of its respective kind and free from blemishes
and imperfections. Glass shall be as shown on the drawings.
b) All glass shall comply with the requirements of BS 952-1 and shall be free from
specks, bubbles, smoke vanes, scratches and any other defects. All glass shall
be delivered in proper containers with manufacturer / supplier name, guarantee,
type of glass and thickness or weight of glass attached to the outside of the
containers.
c) All external glazing shall be laminated glass fabricated as factory sealed double
glazed units, and tinted to an approved shade and colour.
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d) All glass surfaces shall be kept dry during transit and storage. Glass becoming
moist from condensation or other causes shall be thoroughly dried and aired.
8.9.2 Glazing
a) Only single and complete sheets of glass shall be used in each opening to be
glazed. No butt joints will be permitted.
b) All glass shall be cut accurately to the rebates and all glazier's work shall be
carried out in the best approved manner and in accordance with the requirements
of BS 6262.
c) All glass shall have clean cut edges. Wired glass shall be cut so that the wires
are parallel to the edges.
d) The Contractor shall replace all cracked, scratched, damaged or defective glass
with new, and leave all glass sound and perfectly clear on completion.
8.9.3 Bedding Compound
a) The bedding compound for external glazing shall be an approved non setting
butyl rubber based proprietary compound and sufficiently elastic to allow for
thermal or other movement of the glass and timber, compatible with the approved
decorative wood stain.
b) The bedding compound shall show no sign of separation after bedding.
8.9.4 Proprietary Curtain Glazing
Where required by the drawings a proprietary curtain glazing system shall be used.
This shall be installed by suitably qualified personnel in strict accordance with system
manufacture / supplier recommendations.
8.10 PAINTING AND DECORATING
8.10.1 Painting-General
a) All primers, oil bound undercoats and finishes, emulsions and polyurethane
interior varnishes shall be used in strict accordance with the manufacturer's
recommendations and shall be obtained from an approved manufacturer.
b) Only fresh paint delivered to site in original sealed containers shall be used. Each
container shall be labelled with the manufacturer's name, contents, colour,
quantity, batch number and date and instruction on method of application.
8.10.2 Exterior Stain
Pigmented stain shall be PX 65 as manufactured by Sadolin's Ltd., and used in

accordance with their recommendations, or other equal and approved, two coats
before fixing and one coat after fixing.
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8.10.3 Stopping to Plaster
Plaster shall be clean and dry and free from loose material. Holes and cracks shall be
cut back and solidly filled, allowed to dry and rubbed down smooth.
8.10.4 Steel Priming
Mild steel shall be blast cleaned and primed with two coats of primer within four hours
of cleaning.
Galvanised mild steel shall be degreased with white spirit and primed with two coats
of primer.
8.10.5 Oil Based Paint
Interior primed softwood and all primed mild steel shall be painted with two
undercoats and one gloss or semi-matt finish coat of oil-based paint to give a smooth,
even and solid finish, all as instructed. Each coat shall dry overnight before applying
further coats.
8.10.6 Internal Finish to Walls
The paint finish to internal walls shall be PVA copolymer matt emulsion paint or as
detailed on the drawings.
8.10.7 Ironmongery
All fixed ironmongery except hinges shall be removed before painting and refixed on
completion.
8.10.8 Workmanship
a) All painting shall be carefully executed with clean brushes and in the best manner
and applied strictly in accordance with the manufacturer's instructions.
b) All paints, stains and varnishes shall be well stirred before use and thinned only in
accordance with the manufacturer's recommendations.
c) Painting of exterior work shall not be carried out in wet, dusty or foggy weather
and interior work shall not proceed in dusty conditions.
d) All woodwork shall be prepared to a fine clean finish by scraping or sanding all
made dust free immediately before painting and coating.
8.10.8.2 Painting of Metalwork
a) Steelwork delivered to the Site unprimed shall be cleaned of impurities, shot

blasted, scraped or wire brushed to remove rust to the approval of the Engineer,
and painted with one coat of priming paint applied by brush.
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b) Steelwork delivered to the Site primed shall be cleaned of impurities and damage
to the priming paint repaired to the approval of the Engineer.
c) Galvanized metal work to be painted shall be cleaned of impurities. Where rusting

has occurred the rust shall be removed by wire brushing and made good with an
approved rust inhibitor. The surface shall be coated with a mordant solution,
washed with clean water and painted with two coats of priming paint applied by
brush and one finishing coat of paint applied by brush.
d) Metalwork which is exposed shall be prepared and primed as above and shall be
painted with two undercoats and one finishing coat applied by brush.
8.10.8.3 Painting of Concrete, Blockwork and Plaster
a) Concrete, blockwork and plaster surfaces to be painted or decorated shall have

all cracks cut out and made good to the satisfaction of the Engineer. The surface
shall be completely dry and shall be brushed free of impurities immediately prior
to the commencement of painting work.
b) Efflorescence shall be completely removed by rubbing down with dry coarse

cloths followed by wiping down with damp cloths and allowed to dry. All surfaces
shall be rubbed down with damp cloths and allowed to dry. All surfaces shall be
rubbed down with fine glass paper and brushed free of dust before applying any
forms of decoration.
c) Concrete blockwork and plastered surfaces which are to receive paint shall be
given one thin coat of oil putty and allowed to dry for at least two days. The
surfaces shall then be rubbed down with fine sand paper and given second thin
coat of oil putty and when completely set shall be rubbed down again with fine
glass paper before applying the primary coat of paint.
d) Emulsion of chlorinated rubber paint shall be applied by brush or roller and shall
consist of a mist coat and three coats of interior quality paint internally and a mist
coat and three coats of exterior quality paint externally.
e) Oil paint shall be applied by brush or roller and shall consist of a priming coat, two
undercoats and one finishing coat of paint.
f) Plastic resin paint shall be applied strictly in accordance with manufacturer/

supplier’s instructions.
8.10.8.4 Painting of Woodwork
Holes, cracks, knots and other defects in the surfaces of woodwork to be finished with
paint or varnish, shall be treated so as to ensure a smooth appearance of the coating.
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8.11 WATER SUPPLY AND DRAINAGE
8.11.1 Water Supply System
The water supply system consists of three sub-systems as follows:
i. Potable Water Supply System
ii. Sanitary Water Supply System
iii. Hot Water Supply System
Except for minor modifications, all fittings shall be standard manufactured products
commercially available for a minimum of two years after the scheduled completion
date of construction works.
All fittings shall be suitable for service and operating conditions as identified within
this specification.
All pipes and fittings shall be suitable for the fluid temperature between 10 °C and 35
°C.
The minimum design life of various components shall be as below:
- Civil, Structural & Piping – 50 years
- Mechanical – 25 years
- Electrical, Instrumentation & Controls – 10 years
All fittings shall be capable of satisfactory operation at the working pressure of the
pipeline into which it is installed, plus any surge.
All parts and components shall be designed and built for operation at normal flows
without seizure, cavitation, excessive vibration or strain and requiring only that degree
of maintenance generally accepted as normal for the specific type of equipment.
All parts and components shall be designed and built for interchangeability so that
replacement parts may be installed without additional fitting or machining.
8.11.1.2 Technical Requirements
1. General
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Detailed design of water supply system shall be provided at the proposed facilities as
specified on the drawings and in Particular Specifications. The Contractor shall
submit the shop drawings of the water supply system to Engineer approval before
commencing the work at site.
2. Installation of Pipes and Ducts
All pipe work shall be installed by skilled and experienced personnel.
The Water Supply Systems shall be installed accurately in straight lines with
proprietary fittings used at any change in direction or level. All socketted pipes shall
be laid with the sockets facing upstream. All pipes shall be fully supported at the
intervals and using mounting in strict accordance with the recommendations of the
pipe material manufacturer.
Immediately prior to laying, all pipes and fittings shall be examined carefully to ensure
that they are sound. No damaged or defective items shall be used. Any part length
used shall be cut squarely and cleanly at the end.
All pipes shall be clean before installation and jointing. All Water Supply Systems
shall include bends, tapers, junctions and other special pipes of a particular pattern
as required.
When pipes pass through walls, floors or ceilings they shall be sleeved and sealed.
All concealed pipes within walls, ceilings or floors shall be run within protective
conduit.
Pipes which are laid, or built into walls and manholes, but not immediately connected
up, shall be fitted with suitable temporary stoppers or seals, and the position of such
pipes shall be clearly defined by means of stakes or training wires properly marked or
labelled.
Before the commencement and for the smooth progress of the pipework installation,
the Concrator shall coordinate and finalize the routes, ground/invert levels, positions
of the manholes etc. with Engineer.
All the changes in the design shall be subject to the approval of Engineer.
3. Pipe Bedding and Surrounding Material
Pipe bedding and surrounding material shall be well rounded not angular.
When the as dug material is suitable, the bottom of the trench shall be trimmed and
loosened to form the bed otherwise the trench shall be excavated to a depth below
the invert level to allow for the thickness of bedding material. No sharp material shall
be in contact with the supply pipe.
When as dug material is not suitable, imported granular material as per BS EN 12620
shall be used.
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All surround and backfill materials up to 300 mm above the pipe shall be loose laid
and hand compacted only.
If the as dug material contains stones larger than 40 mm the bedding material must
be extended 150 mm above the circumference of the pipe. Alternatively, the backfill
can be graded to eliminate stones exceeding 40 mm and this selected backfill used
for the first 300 mm above the circumference of the pipe. The remainder of the trench
may be backfilled with suitable excavated material.
4. Inspection Chambers, Valve Chambers and Pits
All water supply related concrete and steel structures shall be carried out in
accordance with the relevant specifications.
All chambers and pits shall be constructed of reinforced concrete or of solid concrete
blocks to the internal dimensions laid out in BS 5834. Chambers and Pits shall be
designed for the vehicular or other loading to which they will be subjected.
Foundations to chambers and pits shall be of concrete complying with the relevant
clauses of the Concrete Specification and shall finish flush with the chambers and pit
sides unless specifically otherwise required.
Concrete block walls shall be bedded and jointed in cement and sand 1:4 mortar and
the joints on the internal faces raked out to form a key for rendering. Walls shall be
constructed in stretcher bond.
The internal surfaces of concrete block walls shall be rendered with cement and sand
1:2 mortar 10mm thick and the rendering shall be finished with a smooth and even
surface.
The ends of all pipes shall be neatly built into the blockwork and finished flush with
mortar. Where subsequent pipework is to be installed adequate free end is to be left
for later coupling.
Where the depth of invert of chambers exceeds one metre below the finished ground
level, stainless steel grade 316 steps as specified in BS EN 13101 shall be built in at
vertical intervals of 300mm, with alternate steps in line vertically and at 225mm centre
to centre horizontally.
Entry to deep chambers (> 2500 mm) shall be by means of one or more caged
vertical GRP ladders.
Chamber covers and frames shall be coated cast-iron complying with BS EN 124
approved or equal and shall be designed for the loading category to which they will
be subjected. The CONTRACTOR shall bed and haunch frames in cement and sand
1:3 mortar and seal covers with thick grease. Two sets of keys shall be delivered to
the Engineer for each pattern of cover supplied.
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8.11.1.3 Potable Water System
The Potable Water Supply System shall be provided at proposed facilities as

specified on the drawings and in Particular Specifications.
The Potable Water Supply System also delivers water for service within buildings.
8.11.1.4 Sanitary Water Supply
a) The Sanitary Water Supply System is required to supply cold water to non-
potable consumers within the plant building and other buildings.
b) To ensure that no back contamination of the potable supply occurs, all sanitary
water is to be supplied from high level break tanks and cisterns fed from the
potable water system.
8.11.1.5 Hot Water Supply
a) The Hot Water Supply System is required to provide Hot Water to non potable
consumers within buildings.
b) Hot water is to be supplied from local water heater tanks located at convenient
proximity to the consumers. Fed from the high level break tanks and cisterns
each system shall be in consequence a low pressure system although for design,
installation and test purposes shall conform to the same requirements as those
for the potable water supply system.
8.11.1.6 Materials
a) General
All materials to be supplied and installed in accordance with this specification shall be
subject to Engineer’s approval. The materials of all pipes, fittings, valves and
equipment supplied for the project shall be new and of first class quality, free from
scale, lamination, inherent corrosion and any other defects. Pipes, fittings, valves and
equipment shall be manufactured, inspected and tested in accordance with the
relevant British Standards and Codes of Practice, and shall be suitable for service
under the stated pressures and temperatures. All component materials for
incorporating into the water supply system shall be procured with BSI certification.
All materials to be incorporated in the work shall be handled and stored strictly in
accordance with the recommendations of the manufacturer.
b) Cold Potable Water Supply Pipework
1. Pipes and Fittings
Cold water pipes less than 3" diameter shall be of one of the following options
throughout:
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- u-PVC pipes and fittings shall comply with BS EN 1452.
- Polyethylene pipes shall comply with BS EN 12201. Fittings to be of either

compatible thermoplastics to BS 7291 or Brassware to BS EN 12167/BS EN 1254.
- Copper pipes to BS EN 1057 with fittings to BS EN 12165/BS EN 1254.
Cold Water pipes of 3" diameter or greater shall be of one of the following options
throughout.
- GRP Pipes and Fittings to BS EN 1796.
- uPVC pipes and fittings to BS EN 1452.
- DI pipes and fittings to ISO 2531 BS EN 545.
The CONTRACTOR shall perform the detail design for each supply system using one
of the above material options. The CONTRACTOR's complete detail design including
calculations, detail drawings and samples shall be submitted for ENGINEER’s
approval.
c) Sanitary Water Supply Pipework
Pipes and Fittings for Sanitary Water Supply System shall be provided in accordance
with the materials options as specified in respect of Cold Potable Water Supply
System above.
d) Hot Water Supply Pipework
1. General
All Hot Water Supply System pipes shall be in copper and shall be provided with
readymade plastic cover.
Pipes and Fittings shall be provided in accordance with the following:
- Above ground copper pipes shall conform to BS EN 1057 related table and shall
have joints and fittings of copper alloy to BS EN 12165 or BS 1254.
- Below ground copper pipes shall conform to BS EN 1057 and shall have joints
and fittings of gun metal to BS EN 1982.
3. Thermal Insulation
All exposed Hot Water Supply System pipes and fittings shall have thermal insulation.
Hot Water Supply Pipes and Fittings buried within walls ceilings or floors shall be
surrounded with fine grade vermiculite mixture.
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e) Thermal Insulation & Weather Protection
1. Thermal Insulation
Minimum thickness of thermal insulation shall be as follows:
- Pipes up to 1½" diameter - 15 mm
- Pipes 1½" to 2½" diameter - 32 mm
- Pipes 3" diameter and above - 50 mm.
2. Weather Protection
All pipes and fittings exposed to the effects of weather shall be thermally insulated as
above and provided with an approved white abrasion resistant weather proof coating
system.
f) Stop Valves, Stopcocks and Fittings
Stop valves less than 3" diameter shall be of the medium pattern type with female
ends and manufactured and tested in accordance with the requirements of BS 1010.
- The stop valve shall withstand a test pressure of 16 bar without leakage.
- The valve shall close in a clockwise direction.
Stop valves of 3" diameter or greater shall be approved standard stainless steel ball
valves complete with flanges as per project specifications.
1. Ferrules (with combined stopcock)
The ferrule combined with stopcocks shall be of hot pressed brass to BS EN 12165
with heavy gauge, swivel balancing, screw down type. ½" square head for closing
and opening with female ends. The spindle shall be of high tensile manganese
bronze to BS EN 12167. Threads shall be B.S.P in accordance with BS EN 10226-1.
2. Compression fittings
Where pipe joints and equipment couplings are made using compression fittings,
these shall be threaded B.S.P in accordance with BS EN 10226-1. Inserts shall be of
copper and male and female fittings shall be chamfered to suit assemblage and to
avoid crossing of threads.
Suitable change pieces and adaptors shall be used where required for coupling of
individual items of equipment not available with B.S.P threads.
g) Flexible Hose Assemblies
All flexible hose assemblies shall comply with BS 6501 and shall be of a type suitable
of withstanding the same pressure as the piping to which they are attached.
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Assemblies shall be proprietary items and shall have compatible couplings with both
the pipe system and the individual consumer to which they are attached.
h) Water Filter Units
In-line water filter units shall be provided immediately upstream of each potable water
supply system consumer. Each filter unit shall be proprietary item capable of
withstanding the same pressure as the piping to which it is connected, shall be wall
mounted of canister type with removable porous unglazed ceramic filter element and
shall be protected by a stopcock at its inlet side. Filter units shall be supplied
complete with all fittings and fixings. Complete units shall be capable of delivering
water to meet the quality provisions of BS 6920.
i) Cold Water Cisterns & Break Tanks
Cold Water Cisterns shall be provided in accordance with BS 7181 for up to 500 litre
size. Cisterns provided for holding of potable water shall be of a suitable grade and
materials to meet the provisions of water quality required under BS 6920. Cisterns
provided for holding of sanitary water only shall be of either GRP construction in
compliance with BS EN 13280 or of polyolefin construction in compliance with BS
4213.
Where storage requirements as per design exceed 500 litres, storage shall be in
approved covered segmented galvanised steel Break Tanks. Tanks shall be suitably
jointed, coated, lined and insulated using materials to meet the provisions of water
quality required under BS 6920.
j) Water Heater Cylinders
Water Heater Cylinders shall be in strict compliance with the requirements BS 853.
Cylinders shall be of double walled pre insulated type and of 50 litres minimum
capacity for each consumer location.
8.11.1.7 INSPECTION TESTING & COMMISSIONING
a) Civil Works
The following items shall be subject to field inspection in respect of setting out,
excavation, concrete works including reinforcement, protective membranes and
linings, inserts fixings and supports, backfilling and finishes, covers and frames and
access provisions:
- All manholes, inspection and valve chambers and pits
- All pipe trenches, road crossings, sleeves and ducts.
b) Pipe Works
As a minimum the following acceptance tests shall be performed at site:

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- Visual inspection of all materials and fabrications installed
- Dimensional check
- Hydrostatic pressure test and leak test
- Impact resistance check.
c) Testing
(i) The Contractor shall test all water supply systems pipelines, joints and
fittings prior to surrounding, backfilling, building in to walls & floors or other
concealment.
(ii) All tests shall be performed in convenient sections for each system in the
presence and to the satisfaction of the Engineer by experienced personnel.
(iii) All costs in providing personnel, apparatus, equipment and temporary works
for testing shall be borne by the Contractor.
(iv) Prior to the commencement of testing the system shall be thoroughly

cleaned by flushing with potable quality water to ensure no foreign matter
remains within the pipe.
(v) During the filling operation care must be taken to ensure that there is no
entrapped air in the system. The test pressure shall be applied gradually by
means of a suitable pump connected to the pipe in a manner satisfactory to
the Engineer. The pressure test shall be in accordance with BS EN 850.
(vi) All gauges used shall be new and shall be accompanied by the valid
respective calibration and test certificates. Gauges used for testing
pressure pipelines shall either be circular type, not less than 200 mm
diameter, calibrated in metres head water, or shall have a digital indicator
capable of reading increments of 0.1 m head.
(vii) The pipes shall then be filled and allowed to stand for a period of 24 hours
before testing to achieve conditions as stable as possible for testing.
(viii) The pressure in the pipeline shall then be raised steadily until the specified
test pressure is reached in the lowest part of the section and the pressure in
the pipeline shall be checked after a period of 60 minutes and test pressure
shall be restored by pumping and the loss measured by drawing off water
from the pipeline till the pressure is reached again. During the test all
exposed pipes, joints, fittings, valves etc. shall be carefully examined, and
any joint or item showing signs of leakage shall be rejected. All sections or
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items rejected shall be removed and replaced by the Contractor at his own
expense, and the test shall be repeated to the satisfaction of the Engineer.
d) Commissioning
(i) Prior to final handover each supply system shall be drained of test water,
flushed, refilled and disinfected in accordance with the requirements of
AWWA C 651 or as directed by and to the satisfaction of the Engineer.
Pipes shall be flushed with sufficiently high velocities to remove any
sediment or debris. The flushing velocity shall be not less than 1 m/s. The
time required for flushing shall be at least the time necessary to discharge
three times the contents of the section being flushed.
(ii) Flushing water shall be discharged via temporary discharge hoses to either
the surface water drainage system, if commissioned, or to mobile tanker for
disposal.
(iii) All costs associated with providing experienced personnel, apparatus,

equipment, consumables and temporary works for flushing and disinfecting
shall be borne by the Contractor.
8.11.2 Water Drainage System
Except for minor modifications, all fittings shall be standard manufactured products
commercially available for a minimum of two years after the scheduled completion
date of construction works.
All fittings shall be suitable for service and operating conditions as identified within
this specification.
All pipes and fittings shall be suitable for the fluid temperature between 10 °C and 35
°C.
The minimum design life of various components shall be as below:
- Civil, Structural & Piping – 50 years
- Mechanical – 25 years
- Electrical, Instrumentation & Controls – 10 years
All fittings shall be capable of satisfactory operation at the working pressure of the
pipeline into which it is installed, plus any surge.
All parts and components shall be designed and built for operation at normal flows
without seizure, cavitation, excessive vibration or strain and requiring only that degree
of maintenance generally accepted as normal for the specific type of equipment.
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All parts and components shall be designed and built for interchangeability so that
replacement parts may be installed without additional fitting or machining.
8.11.2.2 Technical Requirements
a) General
Detailed design of water drainage system shall be provided at the proposed facilities
as specified on the drawings and in Particular Specifications. The Contractor shall
submit the shop drawings of the water drainage system to Engineer approval before
commencing the work at site.
b) Installation of Pipes and Ducts
All pipe work shall be installed by skilled and experienced personnel.
The drains shall be accurately laid in straight lines and to self-cleansing gradients.
Pipes shall be laid singly and the level of each pipe shall be tested in an approved
manner using sight rails erected at manholes and at intermediate positions as
necessary. Pipes shall be laid with the sockets facing upstream.
Immediately prior to laying, all pipes and fittings shall be examined carefully to ensure
that they are sound. No damaged or defective pipes shall be used. Any part length
used shall be cut squarely and cleanly at the end. All pipes shall be clean before
laying and jointing.
All service systems shall include bends, tapers, junctions and other special pipes of a
particular pattern as required.
When pipes pass through walls a flexible joint is to be fitted, situated as close as
possible to the outside face and permitting a minimum deflection between adjacent
pipes of 3°. The length of the next pipe ( rocker pipe) away from the structure shall
be as follow: for 150mm to 600mm nominal diameter pipes the length should be
0.6m, for nominal diameter over 600mm to 750mm pipes the length should be 1m
and for over 750mm nominal diameter pipes the length should be 1.25m.
Pipes which are laid, or built into walls and manholes, but not immediately connected
up, shall be fitted with suitable temporary stoppers or seals, and the position of such
pipes shall be clearly defined by means of stakes or training wires properly marked or
labelled.
Wherever the depth of cover to the pipe laid under a road or driveway is less than
1.20 m, a concrete cover slab spanning the trench width shall be provided.
Before the commencement and for the smooth progress of the pipeline work, the
Contractor shall coordinate and finalise the routes, ground/invert levels, positions of
the manholes etc. with the Engineer.
All changes in the design shall be subject to the approval of the Engineer.
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c) Pipe Bedding and Surrounding Material
Pipe bedding and surrounding material shall be well rounded not angular.
When the as dug material is suitable, the bottom of the trench shall be trimmed and
loosened to form the bed otherwise the trench shall be excavated to a depth below
the invert level to allow for the thickness of bedding material.
When as dug material is not suitable, imported granular material as per BS EN 12620
shall be used.
If the as dug material contains stones larger than 40 mm the bedding material must
be extended 100 mm above the circumference of the pipe. Alternatively, the backfill
can be graded to eliminate stones exceeding 40 mm and this selected backfill used
for the first 300 mm above the circumference of the pipe.
d) Manholes, Sump Pits and Inspection Chambers
These shall be constructed as per the specifications given in clause 4.9.2 ‘

Construction of Manholes , chambers and Special structure’ of Section 4 .
e) Gully Gratings and Frames
Gullies shall consist of a concrete pit with cover.
Gully gratings and frames shall comply with the requirements of BS EN 124 (Grade
A) or equal with straight bars. The Contractor shall bed and haunch frames in
cement and sand 1:3 mortar.
The finish of steel components shall be given 2 coats of black coal tar epoxy paint
with a minimum thickness of 250 microns.
f) Continuous Trench Soakaways
Continuous trench soakaways shall be constructed as per design. The filter

membrane provided for the soakaway surround shall be geotextile of appropriate
gauge. The Contractor shall take every care to avoid damage to the membrane. In
the event of damage to the membrane during construction, the Contractor shall make
good the damage with a minimum lap of 500 mm all to be carried out at the
Contractor ‘s expense.
g) Local Soakaways
Local soakaways shall be provided at locations determined by the Engineer and to

details as approved by him and shall be similar to the soakaway to be provided at the
septic tank.
h) Joints
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All joints shall have adequate strength which shall be demonstrated by the
Contractor.
Pipe joints shall be fully flexible and capable of bearing the same pressure that can
be borne by the pipes. Prior to importing any pipes, fittings or jointing rings to the site,
the Contractor shall submit a works test certificate from the manufacturer, as to their
conformity with the Specification, for the approval of the Engineer.
The Contractor shall ensure that there is adequate suitable equipment on site to
enable the works to be carried out to the specified standard, as approved by the
Engineer.
i) Valve Pits
All below ground valve pits and chambers shall have their invert laid to fall towards
collection sumps to allow pump out of accumulated rain water etc.
8.11.2.3 Surface Water Drainage
a) General
Surface water drainage is required to collect and direct rain water from apron and
paving areas and roof run-offs and will also be required to dispose of external
washdown.
b) System Characteristics
The surface to be drained shall be laid to fall at a minimum slope of 1:250 generally.
The collected rainwater, wash water is to be drained by means of surface falls only
towards local soakaways at appropriate locations.
Roof run-offs to be collected by means of gullies, hoppers & downpipes discharging

to grade level local soakaways at appropriate locations.
All roads, aprons and paving shall be delineated by kerbs and laid to fall towards
soakaways. Parking area to be similarly drained towards soakaways.
c) Areas Contributing Surface Water Drainage
The following areas contribute to the Surface Water Drainage:
- Roof of Pump Station & other Ancillary Buildings
- Electrical Substation and Control Building
- Paving Around the Building
- Roads & Aprons within the Plot
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- Parking and Approach Road
- Other areas as applicable
Unpaved areas are to be terraced and gravel (size 20 mm – average) finished to

allow insitu soakaway of rain water or washwater.
d) Surface Water Drain Manhole
Manholes shall be provided as shown on the drawings or as required by the detail

design of the Contractor.
e) Road Gully
Road gullies are to be provided with silt trap, heavy duty manhole, ductile iron grating
non rocking cover with frame and retaining bar as per the drawings. Road gullies
shall be provided as indicated on the Surface Water System layouts or as required by
the detail design of the Contractor.
f) Road Curb Gully
Road curb gullies are to be provided with silt trap, standard ductile iron cover and
frame with retaining bar as per the layouts and ocontractor’s drawings. Road curb
gullies are to be provided as indicated in the Surface Water System layouts or as
required by the detail design of the Contractor.
g) Roof Drain Pipe
Roof drain pipes shall be provided as indicated in the individual building details and
the storm water drain system layout or as required by the details of the Contractor.
The roof drain pipes shall be provided with an inlet hopper, support brackets, stack
and a splay end terminating 150mm above local paving level and directing water
away from the building towards local soakaways as per the drawings.
8.11.2.4 Foul Water Drainage
a) General
The Foul Water Drainage System is required to collect the foul wastewater from the
buildings. The toilets, sinks, showers and kitchens are to be connected and routed to
a septic tank and local soakaway or connected to the main drainage of the pumping
station. The scope of this work shall include all septic tank/soakaway pits and foul
drainage system pipework.
b) System Characteristics
The Foul Waste from Toilets, Washrooms and Kitchens shall be collected in the foul
drainage manholes & subsequently routed to the septic tank & soakaway pits. The
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system is to be suitably trapped & externally vented. The Foul Water System is to be
laid to fall at a minimum slope of 1:100 generally.
c) Areas Connected to Foul Water System
The following sources shall be considered for the Foul Water System:
- Toilets
- Kitchens
- Washroom sinks and showers
Note: Chemical storage & other industrial sinks shall be routed separately through
contaminated water drainage system.
d) Piping Requirements
(i) Pipes and Fittings
All pipes & fittings to be used on the project shall comply with the requirements of the
latest relevant British/other standards approved by Engineer.
The pipes and fitting for pipe diameter sizes up to 300 mm shall be of uPVC
conforming to BS 4660 and BS 5955. The joint sealing rings shall conform to BS EN
681-1. Products to be procured with BSI certification. The dimension & pressure
rating of the pipes shall be in accordance with ISO 161/1.
The pipes and fittings for pipe sizes equal to or greater than 300 mm shall be GRP
pipes. Requirements as per BS EN 14364 and BS EN 1796 are to be followed for the
pipes & pipe fittings. The pressure rating of the pipes shall be a minimum of 10 bar.
(ii) Jointing Systems
The surface preparation to consist of the minimum following steps:
- Surface to be jointed are to be cleared of glass fibre and to be ensured to be free

of grease, humidity or dust.
- Surface to be ground, external layer of resin to be taken off and first glass fibre
uncovered.
- Surface to be rubbed with an emery cloth and cleaned with a volatile solvent so
as to remove all traces of grease, dust & humidity.
- (No gluing shall be undertaken during sand storm or rainfall).
The minimum requirements for adhesive are as follows:
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- Adhesives shall be compatible with the resin and shall not be of a type affected
by hydrocarbon or inorganic contaminants that may be present.
- Type of adhesive shall be submitted by the Contractor for Engineer approval.
- Adhesives shall have two components, cold polymerization type. The two
components will be maintained within allowable temperature and mixed to form a
homogenous mixture just before application to the prepared joint.
- The joints shall have adequate strength and this shall be demonstrated by the
Contractor.
Pipe joints shall be fully flexible and capable of bearing the same pressure that can
be borne by the pipes. Prior to importing any pipes, fittings or joining rings to the site,
the Contractor shall submit a works test certificate from the manufacturer, as to their
conformity with the specification, for the approval of the Engineer.
The Contractor shall ensure that there is adequate suitable equipment on site to
enable the works to be carried out to the specified standard, as approved by the
Engineer.
For the uPVC piping, the following minimum steps are to be taken while making a
joint:
- Proper alignment of the two pipes to be ensured.
- The surfaces to be joined are to be thoroughly prepared using sandpaper.
- Surfaces to be cleaned with solvent.
- Even layer of cement is to be applied.
- Joint to be made.
It should be ensured that the joint is held together for the required drying time based
on ambient conditions. A minimum of 24 hrs. is required before pressure testing.
The joint shall be fully flexible and capable of bearing the same pressure as the
pipes. The joint strength shall be demonstrated by the Contractor .
e) Foul Water Drain Manholes
Manholes shall be provided as shown on approved Foul Water System Layouts or as

required by the detailed design of the Contractor. The details of the manholes are to
be as per drawings.
f) Soakaways
(i) Soakaways shall be constructed using precast/cast in-situ concrete

manhole rings to designated dimensions and depths.
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(ii) The concrete in the rings may be made using moderate sulphate resistant
portland cement in accordance with ASTM C 150 designation type II.
However Type of cement is to be verified as per relevant soil condition.
(iii) The bottom ring shall be founded on an in situ concrete base, to the
(iv) The soakaway shall be surrounded by granular material which shall in fill
the whole void between the soakaway and the undisturbed ground around
the excavation. The granular material shall be laid and tamped by hand in
300mm layers and shall be clean, crushed rock to the approval of the
Engineer and shall be 20-40mm nominal size with little or no fines.
(v) Manhole covers and frames shall be coated cast-iron complying with BS EN
124 or approved equal and shall be designed for the loading category to
which they will be subjected. The Contractor shall bed and haunch frames
in cement sand 1: 3 mortar and seal covers with thick grease. Two sets of
keys shall be delivered to the Engineer for each pattern of cover supplied.
(vi) Filter fabric material lining to soakaway excavation shall be Geotextile of

approved gauge & make. Placing and lapping sheets to be in accordance
with manufacturer/supplier's recommendations.
(vii) All pipes and fittings shall be assembled strictly in accordance with the
written instructions of the manufacturer/supplier and to the satisfaction of
the Engineer.
g) Continuous Trench Soakaways
Continuous trench soakaways shall be constructed at the location and to the details
as shown on the drawings. The Contractor shall take every care to avoid damage to
filter membrane. In the event of damage to the membrane during construction, the
Contractor shall make good the damage with a minimum lap of 500 mm all to be
carried out at the Contractor's expense.
h) Floor Drains
(i) All floor drains shall be supplied and installed at the locations and to the
details shown on the drawings and as specified herein.
(ii) Each floor drain shall be of heavy duty uPVC with "S" or "P" trap complete
with chrome plated heavy duty, 200 x 200mm, bronze strainer. The strainer
shall be screwed to the body of the drain. All floor drains shall have chrome
plated removable covers to their strainers or heavy duty aluminium cover.
i) Clean Outs
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(i) All clean outs shall be supplied and installed at the locations and to the
details shown on the Drawings and wherever specified herein.
(ii) Each clean-out shall be of the same material and dimensions as the pipe to
be cleaned, and shall be placed in walls, slabs or floors as required for ease
of operation.
(iii) Where cleanouts terminate in floors, a bronze cleanout tile 200 x 200mm,
with screwed and sealed cover shall be provided. Tile and cover shall be
chrome plated.
j) Vent Caps
Vent caps shall be supplied and installed on all waste, soil and vent stacks at the
locations and to the details shown on the drawings and in accordance with this
specification.
Each vent cap shall be of uPVC and shall be solvent cemented onto the waste, vent
and soil stack.
k) Septic Tank
(i) This shall be a rectangular chamber of concrete built underground and to

dimension and depth as shown on the approved drawings.
(ii) The base, walls and roof shall be of reinforced concrete construction.
Concrete shall be to grade C40.
(iii) The floor of the tank shall slope 1 in 30 towards one side or centre to
facilitate cleaning of sludge and the manhole shall be located directly over
this.
(iv) Initially the septic tank shall be filled with water to its outlet level before
sewage is allowed to enter the tank.
(v) A small quantity of decaying organic matter should preferably be put into the
septic tank to start the initial reaction.
8.11.2.5 Contaminated Water Drainage
a) General
The Contaminated Water drainage system is required to collect specific discharges of

predominantly contaminated water together with floor spillages within the buildings
and other contaminant spillages. Flow rates, salinity, other contaminant levels and
temperatures of the contaminated drainage shall be determined.
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Sources of possible spillage are to be routed via tundishes and hard piped systems
above-ground as detailed by the Contractor‘s piping/mechanical department,
discharging to suitable lined reinforced concrete gullies and trenches from where the
contaminated material shall be routed to the main drain sump outwit the building from
where it shall be pumped to outfall remote from the plant.
b) Areas Connected to Contaminated Sump Pits
The following areas are to be served by the contaminated water drainage system:
- Pump Station
- Workshop
- Battery Room
- Others as applicable
c) Piping Requirements
For details of all pipes and fittings refer to the Piping Requirements Section above.
d) Floor Gullies, Drain Trenches and Cut-Off Drain Channels
Refer to Section 8.11.2.4 h generally.
Linings, covers and frames shall be suitably chemical resistant.
e) Clean Outs
Refer to Section 8.11.2.4 i generally.
Linings, covers and frames shall be suitably chemical resistant.
f) Tundishes
Tundishes and their hard piping systems shall be provided at locations and to details
as determined by the Contractor's detailed design and shall be subject to the
g) Industrial Sinks
Industrial sinks shall be provided at the locations and to the details shown on the
drawings and shall drain to the contaminated water drainage system.
8.11.2.6 INSPECTION TESTING & COMMISSIONING
a) Inspection Requirements
(i) Civil Works
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The following items shall be subject to field inspection in respect of setting out,
excavation, concrete works including reinforcement, protective membranes and
linings, benching and inserts rack filling and finishes, covers and frames, handrailing
and access provisions:
Manholes, Inspection Chambers, Septic Tank, Soakaway Pits, Drain Sump, Floor
Gullies, Drain Trenches, Cut off Drain Channels.
(ii) GRE/ GRP Pipes and Pipe Fittings
As a minimum the following acceptance tests shall be performed at site:
- Visual inspection
- Dimension check
- Curing
- Glass content
- Hydrostatic pressure test
- Impact resistance test
uPVC Pipes & Pipe Fittings
The minimum number and type of acceptance tests at site is to be as per BS 5955:
Part 6.
b) Testing
(i) The Contractor shall test all drainage pipelines, joints and fittings before
carrying out haunching of pipe surrounds or backfilling trenches. The tests
shall be carried out between two manholes in the presence and to the
1. Water shall be introduced into the pipes to be tested,so that air is

expelled, and the pipes filled with water so that the highest point in the
line shall be subject to a pressure of 1.5 metre water head. The line
shall be considered acceptable if no leakage is visible from pipes,
connections or fittings and if the above water head in a testing pipe of
75 mm diameter is not reduced by more than 15mm per minute for each
30 metre length of pipe. The Contractor shall, after filling the pipes,
allow some time before conducting the test in order to allow the pipes
their first natural saturation with water for the elastic characteristics and
the relatively high thermal expansion of the uPVC piping. If any damage
is noticed in the pipeline the Contractor shall repair such damage to the
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2. If in the opinion of the Engineer any damage has occurred to the

pipelines during the processes of pouring concrete or backfilling, he
shall have the right to order retesting of the doubtful part. If a second
testing proves that the pipe is not serviceable, then the Contractor shall
locate the damage, make it good and carry out retesting until meeting
Engineer approval.
3. The Engineer may instruct the Contractor to carry out tests to the
manholes to establish their water tightness, prior to backfilling around
manholes, and any damage revealed by such tests shall be made good.
4. The Contractor shall provide all necessary testing equipment and shall
carry out such other tests as may be required by the Engineer. Ground
water shall not be used for the purpose of testing.
c) Commissioning
(i) All traps and flooded systems shall be charged and periodically refilled until
final handover. During commissioning flows shall be confirmed for all major
runs.
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DEPARTMENT
SECTION 9
METALS AND PLASTICS
DM/SRPD Section 9 Metals and Plastics Rev 00 June
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SECTION 9
METALS AND PLASTICS
CONTENTS
9 METALS AND PLASTICS ................................................................................................. 1
9.1 GENERAL...................................................................................................................... 1
9.1.1 Description ............................................................................................................ 1
9.1.2 Qualification .......................................................................................................... 1
9.1.3 Submittals ............................................................................................................. 1
9.1.4 Delivery, Storage and Handling ............................................................................ 2
9.1.5 Products ................................................................................................................ 2
9.1.6 Materials ............................................................................................................... 3
9.2 METAL AND PLASTIC PRODUCTS ............................................................................ 5

9.2.1 Ladders ................................................................................................................. 5
9.2.2 Ship Ladders......................................................................................................... 7
9.2.3 Staircase Assemblies ........................................................................................... 8
9.2.4 Handrailing............................................................................................................ 9
9.2.5 Gratings .............................................................................................................. 10
9.2.6 Chequered Plate Flooring ................................................................................... 11
9.2.7 Construction Castings ......................................................................................... 12
9.2.8 Steel Lintels ........................................................................................................ 13
9.2.9 Recess Infill Duct Covers .................................................................................... 13
9.2.10 Shade Canopies ................................................................................................. 13
9.2.11 Miscellaneous Trim ............................................................................................. 14
9.2.12 Edge Angles and Seating Angles ....................................................................... 14
9.2.13 Installation ........................................................................................................... 14
9.2.14 Fabrication .......................................................................................................... 15
9.2.15 Painting ............................................................................................................... 16
9.3 STRUCTURAL STEEL ................................................................................................ 18

9.3.1 Description .......................................................................................................... 18
9.3.2 Qualifications ...................................................................................................... 18
9.3.3 Submittals ........................................................................................................... 18
9.3.4 Testing ................................................................................................................ 20
9.3.5 Substitutions ....................................................................................................... 23
9.3.6 Delivery, Storage & Handling .............................................................................. 23
9.3.7 Steel Parameters ................................................................................................ 24
9.3.8 Bolts & Nuts ........................................................................................................ 24
9.3.9 Structural Tubing ................................................................................................ 24
9.3.10 Welding Electrodes ............................................................................................. 24
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9.3.11 Paint.................................................................................................................... 24

9.3.12 Quality Control .................................................................................................... 25
9.3.13 Bench marks ....................................................................................................... 26
9.3.14 Erection............................................................................................................... 27
9.3.15 Erection Tolerance .............................................................................................. 27
9.3.16 Connections ........................................................................................................ 28
9.3.17 Setting Bases and Bearing Plates ...................................................................... 29
9.3.18 Weld Testing Schedule ....................................................................................... 29
9.3.19 Survey ................................................................................................................. 30
9.4 STAINLESS STEEL .................................................................................................... 30

9.4.1 General ............................................................................................................... 30
9.4.2 Alternative Grades of Stainless Steel ................................................................. 31
9.4.3 Stainless Steel Products ..................................................................................... 35
9.5 ALUMINUM.................................................................................................................. 40

9.5.1 General ............................................................................................................... 40
9.5.2 Material ............................................................................................................... 40
9.5.3 Aluminium Products ............................................................................................ 41
9.6 GRP MOULDED GRATING AND GRP PULTRUDED SUPPORTS ........................... 44
9.6.1 General ............................................................................................................... 44
9.6.2 Construction ........................................................................................................ 46
9.6.3 Quality Control .................................................................................................... 47
9.6.4 Design Criteria: ................................................................................................... 48
9.6.5 Submittals ........................................................................................................... 49
9.6.6 Pultruded Supports ............................................................................................. 49
9.6.7 Structural Design Basis ...................................................................................... 50
9.7 GRP PULTRUDED LADDER ...................................................................................... 53

9.7.1 General ............................................................................................................... 53
9.7.2 Manufacturing Process ....................................................................................... 53
9.7.3 Construction ........................................................................................................ 54
9.7.4 Design / Standard ............................................................................................... 54
9.7.5 Submittals ........................................................................................................... 55
9.8 GRP PULTRUDED HANDRAILS ................................................................................ 55

9.8.1 General ............................................................................................................... 55
9.8.2 Manufacturing Process ....................................................................................... 56
9.8.3 Construction ........................................................................................................ 56
9.8.4 UV Protection ...................................................................................................... 57
9.8.5 Design / Standard ............................................................................................... 57
9.8.6 Submittals ........................................................................................................... 57
9.8.7 Mock -Up ............................................................................................................ 58
9.8.8 Delivery, Storage & Handling .............................................................................. 58
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9.8.9 Project Conditions ............................................................................................... 58

9.8.10 Fabrication .......................................................................................................... 58
9.8.11 Installation ........................................................................................................... 58
9.9 Glass Reinforced, Hot Pressed, SMC (Sheet Moulding Compound)

Potable Water Tank .................................................................................................... 59
9.9.2 General ............................................................................................................... 59
9.9.3 Construction ........................................................................................................ 60
9.9.4 Quality Control .................................................................................................... 64
9.9.5 Inlet, Outlet & Over Flow Pipes ........................................................................... 65
9.9.6 Drain Pipe ........................................................................................................... 65
9.9.7 Approval of Local / International Health Authorities ............................................ 65
9.9.8 Guarantee Certificates ........................................................................................ 66
9.9.9 GRP Baffles ........................................................................................................ 66
9.10 GLASS REINFORCED PLASTIC TANKS FOR CHEMICAL STORAGE ................... 67
9.10.1 General ............................................................................................................... 67
9.10.2 Products .............................................................................................................. 70
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9 METALS AND PLASTICS
9.1 GENERAL
9.1.1 Description
The work included in this Section comprises furnishing all labour, equipment,
appliances and materials and performing all operations in connection with metal
fabrication work.
Metal fabrication work is defined as including any items shown on the Drawings
and/or specified herein, fabricated from aluminium, steel, stainless steel and iron
shapes, plates, bars, pipes tubes, casting and roll-formed shapes which are not a part
of an overall system specified in any other Section of this Specification.
9.1.2 Qualification
a) Employ only experienced tradesmen for both fabrication and installation, who are
capable of producing work of the highest standards of quality in the industry.
9.1.3 Submittals
a) Manufacturer’s Literature
(i) Manufacturer’s specifications, load tables, dimensions diagrams, anchor

details and installation instructions for products to be used in the
manufacture of metal fabrications, including paint products.
b) Shop Drawings
(i) Shop drawings for the fabrication and erection of all assemblies of metal
fabrication work which are not completely shown by manufacturer’s data
sheets.
(ii) Include plans and elevations at not less than 1:10 scale, and include details
of sections and connections at not less than 1:4 scale.
(iii) Show anchorage and accessory items.
(iv) Give location, type, size and extent of welding and bolted connections and
clearly distinguish between shop and field connections.
(v) Prior to submittal co-ordinate shop drawings with related trades to ensure
proper mating of assemblies.
(vi) Detailed drawings shall show material type, thickness, grade/class,

dimensions, and construction scheme.
(vii) The submittal shall include catalogue pages, erection description,

manufacturer data/instructions and templates.
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c) Test Reports
(i) Furnish certified physical and chemical mill test reports for materials used
for major structural members.
d) Samples
(i) Handrail and railing assembly to show joints, bends, toeplate, posts and
anchorage.
(ii) Stair treads and safety nosings, 200 mm long.
(iii) Grating, support angles and plates, 200 x 200 mm.
(iv) Fasteners and anchoring devices.
(v) G.I & S.S cover samples.
9.1.4 Delivery, Storage and Handling
a) Store on blocking so that no metal touches the ground and water cannot collect
on them.
b) Protect from bending under own weight or superimposed loads.
9.1.5 Products
a) Products and manufacturers specified herein-after are specified for the purpose of
establishing minimum quality standards.
b) Structural steel fabrication and erection shall be performed by an organization

experienced in work of equivalent magnitude.
c) Contractor shall verify all measurements and shall take all field measurements
necessary before fabrication.
d) Contractor shall be responsible for correctness of detailing, fabrication, and for

the correct fitting of structural members.
e) Substitution of sections of modification of connection details, or both, will not be

accepted by the Engineer.
f) Connections fully designed and detailed on the Contract Drawings shall be

furnished as shown.
g) Members and connections, for any part of the structure, not shown on the
Contract Drawings shall be the Contractor’s responsibility.
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(i) Such connections shall be considered standard and designed and detailed
in accordance with AISC M016.
h) Welding shall be in accordance with AWS D1.1.
i) All anchor bolts shall be stainless steel in accordance with paragraph 9.1.6.C
(i) All other bolts, nuts washers and screws shall be 316L stainless steel
except where they are used with aluminium members.
j) The following materials shall be isolated from each other by bituminous paint,
PVC tape or neoprene gaskets as directed by the Engineer at no additional cost
to the Employer.
(i) Galvanized steel and stainless steel
(ii) Galvanized steel and aluminium
(iii) Aluminium and Concrete
9.1.6 Materials
a) Steel
Steel work shall be to the appropriate standard and where specified or details shall be
hot dipped galvanised at the place of manufacturer.
(i) Structural Steel : BS 4, Grade 43A or ASTM A36,
Grade 36,minimum thickness 4 mm
(ii) Steel pipe : ASTM A53, Types E or S,Grade B
(iii) Structural Tubing : ASTM A500, Grade B
(iv) Steel Forgings : ASTM A668
(v) Electrodes for welding steel : AWS A5.1, E70 series
b) Iron
(i) Ductile iron : ASTM A536/BSEN 545
(ii) Gray Cast iron : ASTM A48
(iii) Malleable iron : ASTM A47, A197
c) Stainless Steel
Stainless steel shall conform to ASTM A167 and ASTM A276 and the alloy types
shall be as follows:
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(i) Plates and basins : Grade 316L or 317L
(ii) Anchor bolts, bolts, nuts, washers and screws: Grade 316L
1. Yield Strength : min. 270 N/mm2
2. Tensile Strength : min. 480 N/mm2
(iii) Electrodes for welding stainless steel.
1. Use electrodes and techniques per AWS 5.0 series specifications and
as recommended in the International Nickel Co. publication ‘Welded
Austenitic Chromium – Nickel Stainless Steel Techniques and
Properties’.
d) Aluminium
(i) Rolled shapes and extrusion :ASTM B308 or B221
(ii) Castings :ASTM B26
(iii) Aluminium angles, beams, pipes, plates and channels :Alloy 6061 –
T6
(iv) Aluminum weir plates and baffles :Alloy 6061 – T6
(v) Aluminium bolts :ASTM F468,alloy2024 T4
(vi) Aluminium nuts :ASTM F467,alloy2024 T4
(vii) Electrodes for welding aluminium :AWS D1.2, filler alloy 4043 or 5356
(viii) Alloys specified
1. Aluminium alloys shall be selected as having properties appropriate to

the duty of unit, the method of fabrication and environmental conditions.
2. In general alloys of the following ISO designations shall be used:
a. For castings For Wrought items
b. A1 Sil Mg or AlSil2 Al Mg 4.5 min or Al Sil Mg Mn
3. Alternative alloys may be proposed by the contractor if the manufacturer

considers its properties more appropriate to the applications of the
environmental or physical conditions.
e) Galvanizing
(i) Iron and Steel
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1. Galvanising shall be done in accordance with ASTM A123 or BS EN

ISO 3834 with an average coating weight of 720-1000gm/m2.
(ii) Touch-up material for galvanized coatings
1. Galvanising coatings marred or damaged during erection or fabrication

shall be repaired in accordance with the coating manufacturer’s
instructions.
f) Post Drilled Adhesive/Resin Anchors
(i) Meet or exceed ICBO requirements.
(ii) Shall be Grade 316L stainless steel HVA anchors by Hilti or approved
equal.
(iii) Mechanical type anchors will not be permitted.
g) Headed Studs
(i) Conform to ASTM A108
(ii) Yield Strength : min. 345 N/mm2
(iii) Tensile Strength : min. 414 N/mm2
h) Deformed Bar Anchors
(i) Conform to ASTM A496
(ii) Tensile Strength : min. 550 N/mm2
(iii) Yield Strength : min. 482 N/mm2
i) Washers
(i) Same materials and alloy as found in accompanying bolts and nuts.
(ii) Provide two washers per each nut and bolt.
(iii) Provide neoprene pad between dissimilar metals.
j) Painting
(i) As specified in Section 8.
9.2 METAL AND PLASTIC PRODUCTS
9.2.1 Ladders
a) Material
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(i) Stainless Steel Grade 316L or
(ii) Aluminium, Grade 6082 (HE – 30) to BS EN 755-3 as indicated.
b) Stringers
(i) Minimum 65 x 10 mm flat or 38 mm OD tube with a thickness of 3.25mm.
c) Rungs
(i) Solid, min 20 mm diameter
(ii) Shall be at 250 mm centres
(iii) Minimum 380 mm wide between stringers
(iv) Minimum 200 mm from adjacent wall.
(v) Non slip tread pattern.
(vi) Capable of withstanding a point load of 5000 N applied at the centre close
to one end.
d) Brackets
(i) Fixing brackets shall be at max 2000 mm centres.
(ii) Capable of withstanding shear pull-out load of 5000 N.
e) Safety cages shall be provided when the distance between landings exceeds
2200mm.
(i) Cage construction shall be as follows:
1. Flat Hoops : min. 50 x 8 mm with a min internal diameter of 760

mm
2. Vertical Flats : min 40 x 4 mm
3. Hoops shall be at max 750 mm centres, supported by a minimum of 3

vertical straps at equal centres inside the hoops.
4. First hoop shall be 2400 mm above lowest platform.
5. Each hoop shall be able to withstand both a tangential point load of 740
N and a vertical point load of 1200 N applied at any point on the hoop.
6. All connections shall be constructed from same material as ladder.
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f) A rest platform shall be provided if the height of the ladder is more than 6Metres
and shall be equipped with one or more platform.
(i) Size : min 840 x 840 mm
(ii) Handrail : min 1000 mm high
(iii) Landing shall be provided at every 6m.
g) Construction
(i) Top of ladder shall extend 1000mm above the upper access level where
required.
(ii) Fully welded type.
(iii) All welds to be full penetration welds.
h) Ladder accessories
(i) Telescoping tubular section that automatically locks into place when fully
extended.
(ii) Accessories shall be constructed from same material as ladder.
(iii) Corrosion-resistant spring.
(iv) Factory assembled with all hardware necessary for mounting to ladder
where indicated on the Drawings.
9.2.2 Ship Ladders
a) Material
(ii) Aluminium as indicated
b) Design
(i) Construct to fit openings shown on the Drawings.
(ii) Provide minimum rake angle practical between 65° and 75°.
(iii) Provide same load carrying capabilities as specified for staircase

assemblies.
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(iv) Provide 42 mm diameter handrailing on both sides of ladder. Make

continuous with handrailing at upper platform or landing.
(v) Use maximum stair width practical between 450 mm and 550 mm.
(vi) Fix the ladder base to the concrete floor as required.
(vii) Fabricate and design components in accordance with NAAMM Metal Stairs
manual and BS 5395.
c) Treads/Stringers/Hardware
(i) As specified for staircase assemblies.
9.2.3 Staircase Assemblies
a) Material
(i) Stainless steel Grade 316L or
(ii) Aluminium as indicated.
b) Design
(i) Construct to the overall sizes detailed on the Drawings.
(ii) Provide minimum rake angle practical between 30° and 50°.
(iii) Capable of carrying 4.5 kN concentrated, moving load or 5 kN/m2 uniform

live load, whichever is higher.
(iv) Stringers shall be of adequate size to support treads/landing gratings.
c) Stringers
(i) Size for design live loads as well as treads, handrail and other fixed loads.
(ii) Use RS channel sections unless other sections are approved by the
Engineer.
(iii) Minimum width between stringers shall be 1000 mm.
d) Treads
(i) Use open type
(ii) Non Slip tread
(iii) Bull nose edge for strength
(iv) Provide end plated or shelf angles as necessary. Drill for bolting between
stringers.
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e) Landings
(i) Provide landing not exceeding 16 rises (15 treads).
(ii) Width > 750mm.
(iii) Capable of supporting a minimum loading of 5 kN/m.
(iv) Landing panels shall match the stair treads.
f) Handrailing
(i) All open sides of staircases and landing shall be protected by handrail.
(ii) Height from the nose of the tread to top of rail shall be between 840 mm to
1000 mm on the stairs and min 1000 mm from the floor to top rail on
landings.
(iii) Size and load carrying capabilities shall be as specified for handrails.
g) Hardware
(i) Use Grade 316L stainless steel hardware throughout.
(ii) Protect all hardware against corrosion.
h) Fabricate and design stair components in accordance with NAAMM Metal Stairs
Manual.
9.2.4 Handrailing
a) Comply with ANSI A 12.1 and ANSI A58.1/ BS EN ISO 14122.
b) Material
(ii) Aluminium, Grade 6082 (HE 30) to BS EN 755-3 as indicated.
c) Posts
(i) Outside diameter : 60 mm tube
(ii) Wall thickness : 4mm
(iii) Ball : 90mm
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d) Rails
(i) Outside diameter : 48mm
(ii) Wall thickness : 4mm
(iii) Capable of withstanding a 1.0kN load applied at any point or 740 N/m along
the rail whichever is higher at the level of top rail.
(iv) Curves shall be bent to a radius of not less then 100mm.
(v) Horizontal rail shall be 1000 mm high with an intermediate rail at 500 mm
high.
e) Provide hand rails on walls at stairs and similar locations as required by ANSI A
12.1.
f) Where shown or required removable sections and toe plates shall be provided.
g) Connections to concrete masonry/concrete surfaces shall be secured with

accurately positioned anchor bolts.
(i) Protect all hardware against corrosion.
h) Safety Chains
(i) 12.5 mm link
(ii) Grade 316L Stainless steel
9.2.5 Gratings
a) Material
(i) Aluminium
(ii) Galvanized Steel
(iii) Stainless Steel
b) Design
(i) Size to fit openings shown on Drawings.
(ii) Use alloy 6063-T6.
(iii) Minimum depth 38mm.
(iv) Minimum rectangular bar size 5 mm thick.
(v) Minimum 1 bar flange width 6 mm.
(vi) Live load:

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1. not less than 10 kN/m2.
2. maximum 6 mm deflection at a live load of 5 kN/m2.
(vii) Cross bars welded, swaged, or pressure locked to bearing bars.
(viii) Serrated edge on top of bars.
(ix) Standard mill finish.
(x) Provide openings at joint between individual grating sections.
1. reinforce openings to provide required load carrying and band with 100
mm high toe plate.
(xi) Use 316 stainless steel hardware (clips and bolts)
c) Unless otherwise specified or shown on the Drawings, the grating material,

fabrication, installation, and banding shall be in compliance with the National
Association of Architectural Metal Manufacturers’ ‘Metal Bar Grating Manual’ as
applicable.
(i) Banding is required at all openings and the perimeter of all grating.
d) Bar gratings shall be neatly and accurately cut to the configuration necessary to
clear structural members and pipes and to permit removal of the grating.
e) Gratings shall have bolted anchorage with a minimum 4 bolts per panel using
stainless steel fastners.
(i) The bolts shall be supplied with neoprene washers.
(ii) Aluminium grating in contact with steel members of concrete shall be

isolated with an approved material.
9.2.6 Chequered Plate Flooring
a) Conform to ASTM B632.
b) Material
(i) Aluminium, type 6061 – T6.
(ii) Galvanized steel conform to BSEN 10025-1 / BS EN 10025-2
c) Design
(i) Capable of withstanding a load of 5 kN/m2 with maximum deflection of 1/300

of span under a superimposed live load of 2.5 kN/m2.
(ii) Diamond pattern
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d) Plate Sections
(i) Maximum 1000 mm wide
(ii) Minimum 6 mm thick
e) Provide joints at centre of all openings unless shown otherwise.
(i) Reinforce joints and openings with additional angles to provide required
load carrying capacity.
f) Unless shown otherwise, frame for openings for aluminium checkered plate.
(i) Aluminium angles of minimum size 40 mm x 40 mm x 6 mm having 8 mm

dia x 150 mm long anchor bolts spaced at maximum of 600 mm along each
side with not less than two anchor bolts per side.
(ii) Drill and tap frame to receive 8 mm dia aluminium cap screws at not more
than 600mm centres with not less than two screws per side.
9.2.7 Construction Castings
a) General
(i) Conform to Employers standard patterns an designs
(ii) Pre-fabricated ductile or cast iron construction conforming to ASTM
(iii) A 48 or A536.
(iv) Design for AASHTO HS – 20 wheel loading for indicated span.
(v) Machine horizontal mating surfaces.
b) Storm Water Gutter
(i) Heavy duty, ductile iron, single piece construction complete with Bearer
bars.
(ii) Conform to BSEN 124, Class D400 loading.
(iii) Gutter clear opening 240 mm or as shown on the Drawings.
c) Channel Grating
(i) Heavy duty, ductile iron, single piece construction complete with Bearer
bars.
(ii) Conform to BSEN 124, Class D400 loading
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(iii) Cover clear opening 300mm or as shown on the Drawings. Or Polymer

concrete monoblock gratings conforming to DIN EN 1433 Class D400
loading.
d) Solid Top, Channel Covers
(i) Heavy duty, ductile iron construction
(ii) Conform to BSEN 124, Class D400 loading
(iii) Cover clear opening 300mm or as shown on the Drawings.
9.2.8 Steel Lintels
a) Conform to BS EN 845 : Part 2
b) Steel lintels shall be provided for openings as noted on the drawings, for openings
left in masonry work for ducts, and for similar items where openings are not steel
framed.
c) Lintels, unless otherwise shown, shall be fabricated from galvanised steel

conforming to BS EN 10346:2009.
d) Size as scheduled or the width of the opening plus at least 200 mm where not
scheduled, bearing on supports at each end.
9.2.9 Recess Infill Duct Covers
a) Covers shall be of Grade 316L stainless steel with Grade 35 concrete infilling
where specified.
b) Shall be capable of supporting a 5000 kg wheel load.
c) Covers shall, preferably, be single span but multi-span with Grade 316L stainless
steel intermediate beams are acceptable on larger openings.
d) Covers and frames shall have edging strips and keyhole extensions of barass for
floor finishes when provided in floors inside buildings.
9.2.10 Shade Canopies
a) Fabricate canopies from Structural Steel cantilevered frames, Hollow Steel Box
Section Rails and Purlins where shown on Drawings.
b) Fix steel framework to concrete substrate with requisite fixing devices.
c) Provide all trim as required.
d) Shop prime the complete assembly prior to erection.
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9.2.11 Miscellaneous Trim
a) Provide shapes and sizes as required for the profiles shown.
b) Except as otherwise noted, fabricate units from structural steel shapes, plates and
steel bars, with continuously welded joints and smooth exposed edges.
c) Use concealed field splices wherever possible.
d) Provide cutouts, fittings and anchorages as required for co-ordination of assembly

and installation with other work.
9.2.12 Edge Angles and Seating Angles
a) Provide edge angles or seating angles of size as shown on the Drawings with
welded on strap anchors 600 mm on centres.
b) Install angles in as long lengths as possible.
c) Mitre and weld corners and provide splice plates for alignment between sections.
9.2.13 Installation
a) Set metal fabrication work accurately in location, alignment and elevation, plumb,
level, true and free of rack, measured from established lines and levels.
b) Anchor securely as shown or as required for the intended use, using concealed
anchors wherever possible.
(i) Fastenings to wooden plugs will not be permitted.
(ii) Drill holes for bolts to the exact diameter of the bolt, using a rotary drill for
concrete and a percussion drill for masonry.
c) Where pipe sleeves are used to support miscellaneous ironwork, anchor sleeves
securely to supporting concrete or structure to provide rigid support.
d) Pipe sleeves shall be of galvanized steel of size shown and adequate to meet the
requirements.
(i) Fit exposed connections accurately together to form tight hairline joints.
(ii) Weld connections which are not to be left as exposed joints, but cannot be
shop welded because of shipping size limitations.
(iii) Grind joints smooth and touch up shop paint coat.
(iv) Do not weld, cut or abrade the surfaces of exterior units which have been
hot-dip galvanized after fabrication, and are intended for bolted or screwed
field connections.
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e) Deliver items which are to be built into the work of other sections in time so as not
to delay the progress of work.
f) Leave work exposed to view clean, smooth and neatly finished.
9.2.14 Fabrication
a) For the manufacture of metal fabrications which will be exposed to view, use only
materials which are smooth and free of surface blemishes including pitting, seam
marks, roller marks, rolled trade names and roughness.
(i) Remove such blemishes by grinding, or by welding and grinding, prior to

cleaning, treating and application of finishes including zinc coatings.
b) Use materials of the size and thickness shown, of the required size and thickness
to produce adequate strength and durability in the finished product for the
intended use.
(i) Work to the dimensions shown or approved on shop drawings, using proven
details and fabrication and support.
(ii) Use the type of materials specified for the various components of work.
c) From exposed work due to line and level with accurate angles and surfaces and
straight sharp edges.
(i) Ease exposed edges to a radius of approximately 1 mm unless otherwise

shown.
(ii) Form bent metal corners to the smallest radius possible without causing
grain separation or otherwise impairing the work.
d) Verify dimensions by accurate field measurement before fabrication wherever

work adjoins other work that precedes it in construction.
(i) Allow for trimming and fitting of metal fabrication work wherever the taking
of field measurements before fabrication might delay the work.
(ii) On shop drawings, note which dimensions have been verified by field
measurement.
e) Weld corners and seams continuously and in accordance with the

recommendations of AWS.
(i) Grind exposed welds smooth and flush, to match and blend with adjoining
surfaces.
f) Form exposed connections with hairline joints which are flush and smooth, using
concealed fastners wherever possible.
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(i) Use exposed fastners of the type shown, or if not shown, use Philips flat-
head (countersunk) screws or bolts.
(ii) All screws or bolts will be Grade 316L stainless steel.
g) Pre-drill bolt and/or screw holes as shown and as required for attachment of metal
fabrication work and for the attachment of adjacent materials.
h) Furnish inserts and anchoring devices which must be set in concrete or built into
masonry for the installation of metal fabrication work.
(i) Co-ordinate delivery of such devices with other work so as to avoid any
delay. See Concrete and Masonry Sections of these Specifications for
installation of such inserts and anchoring devices.
i) Provide for anchorage of the type shown, co-ordinated with the supporting
structure and the construction program.
(i) Fabricate and space anchoring devices as required to provide adequate

support.
j) Cut, reinforce, drill and tap metal fabrication work as may be required to receive
finish hardware and similar items of work.
k) Use hot-rolled steel bar for work fabricated from bar stock, except where shown
or specified to be fabricated from cold-finished or cold rolled stock.
l) Pre-assemble work at shop to the greatest extent possible, so as to minimize field

splicing of fabricated units at the project site.
(i) Disassemble units only to the extent necessary to comply with shipping
limitations.
(ii) Mark units clearly for reassembly and proper installation.
m) Where shown as galvanized, complete the shop fabrication prior to application of

the coating.
(i) Remove mill scale and rust, clean and pickle the units as required for
coating.
(ii) Apply hot-dip zinc coating of 0.72-1.000 kg/m2 in accordance with ASTM A
123.
9.2.15 Painting
a) General
(i) Primers selected shall be compatible with finish paints.
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(ii) Refer ‘Coating System for Ferrous Metals’ for finish paint material and
applications.
(iii) Clean, treat and paint metal fabrications work in the shop prior to delivery to
the project site, except for work which has been hot-dip galvanized after
fabrication.
(iv) Include all surfaces, inside and out, whether exposed or concealed in the
construction.
b) Aluminium
(i) Mill finished unless scheduled or otherwise specified or, if approved,

finished in manufacturer’s standard.
1. Coat surfaces in contact with dissimilar materials as specified here in.
c) Fully Concealed Items
(i) Clean steel and wrought iron work by ‘Solvent Cleaning’ method specified
followed by ‘Hand Tool Cleaning’ to remove loose mill scale and rust by
methods specified.
(ii) Apply paint as per ‘Coating system for Ferrous Metals’.
d) Exposed Interior Items
(i) Clean and paint work which is not accessible to foot traffic, floor cleaning
operations or hand contact, as specified, except that mill scale and rust
which would result in visible roughness must be removed and the surfaces
must be made smooth before painting.
(ii) Apply the following cleaning, treatment and painting to interior work which is
exposed (or partially exposed), and is subject to foot traffic, floor cleaning
operations or hand contact by the building occupants.
1. Clean by ‘Solvent Cleaning’ method followed by ‘Hand Tool Cleaning’ or

‘Power Tool Cleaning’ method to remove loose mill scale and rust.
a. ‘Pickle’ by methods specified to remove all remaining mill scale and

rust.
b. Grind rough surface as necessary to provide smooth metal surfaces.
c. Tool cleaning and pickling may be omitted from fabricated cold-

rolled or cold-finished stock and from castings, provided the surfaces
are not heavily rusted.
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2. Apply pre-treatment to inhibit corrosion and improve paint adhesion, by

methods specified for ‘Cold Phosphate’ treatment.
3. Apply prime coat or metal primer paint as soon as possible after pre-
treatment.
a. Provide a smooth coat, with uniform dry film thickness of 50 microns.
9.3 STRUCTURAL STEEL
9.3.1 Description
The work covered by this section comprises all plant, labour equipment, appliances
and materials and performing all operations in connection with Structural Steelwork.
9.3.2 Qualifications
a) Structural steel fabrication and erection shall be performed by an organization

experienced in structural steel of work of equivalent magnitude with minimum 5
years documented experience.
(i) Contractor shall verify all measurements and shall take all field
measurements necessary before fabrications.
(ii) Contractors shall be responsible for correctness of detailing, fabrication and

for the correct fitting of structural members.
(iii) Substitution of sections or modifications of connections details, or both will

not be accepted by the Engineer.
(iv) Connections fully designed and detailed on the Contract Drawings shall be
furnished as shown.
(v) Members and connections, for any part of the structure, not shown on the
Contract Drawings shall be the Contractor’s responsibility.
1. Such connections shall be considered standard and designed and

detailed in accordance with BS 5950: Part 1 and BS EN 1993-1-1 & BS
EN 1993-1-3.
2. Welding shall be in accordance with AWS D1.1.
3. High-strength bolting shall be in accordance with the AICS S329.
(vi) Welders qualified to ASME IX and utilizing a previously qualified Welding

Procedure would not require further qualification to weld structural steel.
9.3.3 Submittals
a) Shop Drawings
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(i) Shop drawings including structural calculations prepared by a qualified

structural engineer for all structural steel components and their connections,
all in accordance with the requirements of the Contract Documents showing
the following:
1. Shop fabrication drawings which show type of material.
a. Size and weight of members.
b. Other information necessary for the fabrications of each members.
c. Information for shop assembly of members of the structure.
2. Drawings shall include the type, size, locations and extent of all welds
and bolts.
3. Drawings shall clearly distinguish between shop and field, bolts and
welds.
4. Field assembly and erection drawings which show all field assembly
prior to erection and after erection.
5. Drawings shall indicate all details, schedule, procedures and diagrams

showing field assembly and sequence of erection.
6. Information shall indicate locations of shoring and how shoring is

stabilized and controlled.
7. Drawings shall indicate elevations of shored points and splice locations.
8. Procedures shall indicate step by step erection sequences including

intermediate surveys and allowances for temperature.
9. Diagram shall indicate erection equipment, size and weight and

additional elements which may be required to support or stabilize
elements during erection.
(ii) Written procedures for fabrication of the steel work.
1. Procedures shall describe the complete welding process including

machine, current, voltage, preheat, filler metal, welding system (manual,
semi – automatic or automatic), positions of welding, number of passes
for each weld size, preparation of surfaces prior to welding etc.
2. These procedures shall indicate the Contractor’s quality control

measures, monitoring and repair procedures.
(iii) Contractor shall be responsible for the arrangement of all joints and their
load carrying capacities.
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1. Connection may or may not be shown on the Contract Drawings.
2. All details along with the calculations to Engineer’ prior to fabrication.
b) Manufacturer’s Literature
(i) Manufacturer’s specifications and installation instructions for the following

products, including laboratory test reports and such other data to show
compliance with these Specifications (including specified standards):
1. Structural steel, (each type) including certified copies of mill reports

covering:
a. Chemical and physical properties,
b. Country and rolling mill of origin,
c. Statement indicating that the steel is new billet steel.
d. Testing has been performed in accordance with ASTM standards.
2. High strength bolts (each type) including nuts and washers.
3. Welding electrodes (each type).
4. Shop coat primer paint, field touch-up paint, and color samples of all
paint to be used.
5. Epoxy paint.
6. Bearing materials and assembles.
c) Testing Reports
1. The following reports shall be submitted in triplicate directly to the

Engineer by the Testing Laboratory, with copy to the Contractor.
a. Shop Welders Certifications.
b. Field Welders Certifications.
c. Magnetic particle tests.
d. Ultra-Sonic tests.
e. High strength bolted connection tests.
9.3.4 Testing
a) Contractor shall engage, at his own expense, an independent certified Testing

Laboratory approved by the Engineer.
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(i) To inspect high strength bolted connections and welds.
(ii) To perform all test reports to Engineer as herein specified.
b) Contractors shall submit evidence regarding qualification of the proposed Testing

Laboratory.
c) The Contractor shall provide the Testing Laboratory with the following:
(i) A complete set of shop fabrication and erection drawings.
(ii) Cutting lists order sheets, material bills, shipping bills and mill test reports.
(iii) Provide certified copies of mill test reports of:
1. Bolts, nuts, and washers.
2. Names and locations of mills and shops.
3. Analyses of chemical and physical properties.
(iv) Information as to time and place of all rolling and shipment of materials to
shops.
(v) Representative sample pieces requested for testing.
(vi) Full and ample means and assistance for testing all material.
(vii) Proper facilities, including scaffolding, temporary work platforms, hoisting

facilities, etc., for inspection of the work in the mills, shop and field.
d) Bolted connections shall be inspected by the Testing Laboratory in accordance

with AISC Specifications for “Structural Joints Using ASTM A325-83, ASTM
A325M-83 and ASTM A490-83A or ASTM A490-82.
e) Welding should be inspected and tested by a Testing Laboratory approved by the

Engineer during fabrication and erection of structural steel as follows:
(i) Certify all welders in accordance with AWS and make inspections and tests
as required.
1. Record types and locations of all defects found in the work, and
measures required and performed to correct such defects.
(ii) In addition to visual inspection of all welds, magnetic particle and ultra –
sonic inspection shall be made of all welds indicated on the Drawings.
1. Magnetic particle inspection shall be made on the root pass and finished
welds.
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(iii) The method of magnetic particle inspection shall be in accordance with

ASTM E109. Any type of crack or zone of incomplete fusion or penetration
will not be acceptable.
(iv) Ultra-sonic inspection shall be performed in accordance with AWS D1.1.
f) Each bolting crew and welder shall be assigned an identifying symbol or mark.
(i) All shops and field connections shall be so identified so that the inspector
can refer back to the crew or person making the connection.
g) Testing laboratories shall be responsible for conducting and interpreting the tests,
shall state in each report:
(i) Whether or not the test specimens conform to all requirements of the
Contract Documents.
(ii) Any deviations therefrom.
h) Access to places where the material for this Contract is being fabricated or
produced shall be provided to Engineer and the Testing Laboratory for the
purpose of inspections and testing.
i) Engineer and the Testing Laboratory may inspect structural steel at the plant
before shipment.
(i) The Engineer reserves the right to reject any material, at any time before
final acceptance, which does not conform to all requirements of the
Drawings and Specifications.
j) The Testing Laboratory shall perform specified tests and submit reports directly to
the Engineer.
(i) Corrective measures, including additional and more complete testing, which
may results from these tests shall be the contractor’s responsibility.
(ii) All cost of testing shall be the expense of the Contractor.
k) Contractor shall coordinate and allow for necessary time for the testing laboratory
to complete all testing and inspections prior to shop painting.
l) The Testing Laboratory shall prepare test specimen from steel samples cut from
delivered material and shall conduct tension tests in accordance with ASTM.
(i) Contractor shall mill order 1.0 meter extra length for the members noted on
the Drawings to provide the steel for testing.
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9.3.5 Substitutions
a) Contractor shall fabricate and erect the structural steelwork as shown on the
Drawings and Specifications.
b) Details all fabrication and construction shall be submitted to Engineer for

approval.
c) All changes and modifications require that the Contractor shall guarantee in
writing, with guarantee signed by a principal officer of the company, that the
equipment offered will provide comparable or superior features as the equipment
specified including the following:
(i) Performance;
(ii) Quality;
(iii) Material of construction.
d) Cost of any changes incidental to the installation of the alternate equipment such
as electrical wiring, relocation of piping, engineering supervision, ductwork,
building configuration and design, shall be at the expense of the Contractor with
no additional expense to the Employer.
e) If after installation to the alternate installation does not perform in accordance with
the specifications or other deficiencies are noted, the Employer will require the
modification or replacement of such equipment to meet the specifications at no
additional expense to the Employer.
9.3.6 Delivery, Storage & Handling
a) Do not handle structural steel until paint has thoroughly dried.
b) Care shall be exercised to avoid abrasions and other damage.
c) Stack material above ground out of mud and dirt and provide for proper drainage.
d) Protect from damage or soiling by adjacent construction operations.
e) Provide suitable separators to avoid individual items from coming into contact.
f) Do not deliver material to the project site until the proposed method and
sequence of erection has been reviewed by the Engineer.
g) Method and sequence shall be planned so as to avoid delay or damage to the

work of other trades.
h) Storage of fabricated steel at the job site shall be the responsibility of the
Contractor.
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i) Material stored at the job site shall not exceed design load on existing newly-
constructed structures so that members will not be distorted or otherwise
damaged and shall be protected against corrosion or deterioration.
9.3.7 Steel Parameters
a) All structural steel shall conform to BS 4: Part 1 and BS EN 10210-2/BSEN

10067/BSEN 10056-1, Grade 43A or ASTM A 36, Grade 36
b) Minimum yield stress : 245 N/mm2 unless noted otherwise.
c) Minimum thickness shall be 4 mm unless noted otherwise.
9.3.8 Bolts & Nuts
a) All bolts, nuts and washers shall be Grade 316 L stainless steel.
b) Provide two washers per each nut and bolt.
9.3.9 Structural Tubing
a) All structural tubing shall conform to ASTM A 500, Grade B, Seamless, yield
strength 317 N/mm2.
9.3.10 Welding Electrodes
a) All welding structures shall be E70XX and shall comply with the provisions of
AWS Specifications A5.1, A5.5, A5.17, A5.18, A5.20.
b) All weld not specified shall be continuous fillet welds using not less than the
minimum size based on thickness of the thicker part jointed.
Thickness Minimum weld size
12 mm 4 mm
Over 12 mm to 20 mm 6 mm
9.3.11 Paint
a) As specified in “Coating System for Ferrous Metal”.

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b) Use spray application for painting
(i) Minimum thickness shall be maintained on all corners, edges and ends of
pieces.
(ii) Surface to be painted shall dry and above 20C.
(iii) Temperature of the air shall be 50C.
(iv) Do not paint outdoors in rainy and dusty weather.
(v) Paint surface within 4 hours sandblasting.
(vi) Allow paint at least 24 hours drying time in good weather before recoating.
a) Testing and inspection of structural steel will be performed by an independent

structural steel testing agency engaged by the Contractor, at his own expense
and approved by the Engineer.
(i) Provide the testing agency with the following:
1. A complete set of accepted documents under paragraph 1.03 in –

“Submittals”.
2. Cutting lists, order sheets, material bills and shipping bills.
3. Information as to time and place of all rollings and shipment of materials

to shops.
4. Certification of chemical composition with each shipment of bolts and

fasteners to the project site.
5. Representative sample pieces as requested by the testing agency.
6. Full and ample means and assistance for testing all material.
7. Proper facilities, including scaffolding, temporary work platforms, etc.,

for inspection of the work in the mills, shop and field.
b) The Inspector will perform his duties in such way that fabrication and erection are
not unnecessarily delayed or impeded, and as follows:
(i) The inspector will make all tests and inspections as required by “Structural
Welding Code.”
(ii) The edges material to be welded will be ultrasonically examined for

evidence of laminations, inclusion or other discontinuous.
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1. The extent to which such defect will be permitted and the extent of
repair permitted shall be determined by the Inspector and made in
accordance with ASTM A6, Paragraph 9.
2. Repairs made by welding shall be done in compliance with the

requirements of AWS D1.1 and the accepted welding procedures.
(iii) The root layer of all multiple pass welds and the backside of groove welds
are made from both sides, after back gouging or chipping, will be examined
by magnetic particle inspection (or dye penetration if magnetic particle
inspection is not feasible).
(iv) The technique of radiographic inspection will be in accordance with the

requirements of AWS D1.1.
1. A double film technique will be used.
2. One copy of each film will be sent to the Engineer, the other will be
retained by the inspector.
(v) Where the inspections reveals defects, the extent of inspection will be
increased as much as necessary to ensure that:
1. Full extent of the defects in a joint has been found.
2. Same defects are not present in welds made on similar parts or under
similar circumstances.
(vi) Work that is not acceptable will be designated by “Repair” or “reject”, as

applicable.
(vii) Shop welds will be inspected in the shop before the work is painted or
approved for shipment.
(viii) the inspector will maintain a daily record of the work he has inspected and
its disposition.
1. Reports of tests will be made on form prescribed in AWS D1.1.
2. One copy of each of the reports will be submitted to the Engineer on a

weekly basis.
(ix) The inspector will make all tests and inspections of high strength bolt
connections as required by AISC S314.
9.3.13 Bench marks
a) Contractor shall employ the services of a qualified surveyor who shall:
(i) Establish permanent bench marks.
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1. Field check all elevations of concrete on which structural steel is to be

placed.
2. Locations of anchor bolts.
(ii) Reports discrepancies to the engineer.
(iii) Obtain the engineer’s approval before the work proceeds
9.3.14 Erection
a) Contractor shall be responsible for the accurate setting and levelling of all bearing
plated or setting plates.
(i) Bearing plates shall be levelled on steel wedges or shims or as otherwise

detailed.
(ii) Bearing and setting plates shall be grouted as specified. All shims to have
50mm grout coat.
b) Furnish templates for accurate setting of all anchor bolts.
(i) Furnish shim plates or developed fills required to obtain proper fit and
alignment.
c) Oxygen cutting of structural steel for “fitting-up” purpose shall not be done except
with the prior approval of the Engineer.
(i) The use of an oxygen cutting torch for correcting fabrications errors will not
be permitted.
9.3.15 Erection Tolerance
a) The Contractor shall be responsible for the correct fitting of all structural members
and for the elevation and alignment of the finished structure.
(i) Any adjustments necessary in the steel work because of discrepancies in

elevations and alignment shall be responsibility of the Contractor.
b) Unless otherwise noted, the structure shall be levelled and plumbed to accuracy
of 1 to 1000, but not to exceed 12 mm.
(i) The actual centerlines of truss chords shall not vary from theoretical
centerlines by more than 12 mm at any point.
(ii) The difference between offset to the actual centerlines of truss chords at
adjacent panel points shall not exceed 3mm.
(iii) All levelling and plumbing shall be done based on the mean operating
temperature of the structure.
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(iv) Allowance shall be made for the difference in temperature at time of

erection and the mean temperature at which the structure will be when
completed and in service.
c) All measurements relating to the above shall be on the theoretical centerlines of

the members.
9.3.16 Connections
a) Welding or bolting shall not be performed until all stiffening components of the
structure have been properly aligned.
b) Drift pins shall not be used to enlarge holes in primary members.
(i) Holes that must be enlarged to admit bolts shall be reamed.
(ii) Burning and drifting will not be permitted.
c) When high strength bolts or high strength bearing bolts are used, the AISC
specifications shall apply including values as noted therein, and installation with
torque wrenches.
(i) In using manual torque wrenches, the required torque can be read from the
wrench dial.
(ii) Care should be taken that the wrench is properly calibrated.
(iii) Nuts shall be in motion when torque is measured.
(iv) In using power wrenches, the recommendations of the wrench manufacturer

shall be followed.
(v) Use hardened washer under bolt head or nut whichever is turned in
tightening, unless the specified standards require hardened washer both
head and nut.
d) All bolts shall be kept in dry storage until needed for installation.
(i) A325 bolts 28mm and 32mm diameter and A490 bolts 25 mm diameter and
over shall have Johnson’s Stick Wax No. 140 applied to their threads before
being assembled in the work.
(ii) 2. If bolts have been left out and have become rusty before use, they shall
be rejected and shall not be used until they have been cleaned and waxed
with Johnson’s Stick Wax No. 140.
e) Welded and bolted connections shall be comply with BS 5950: Part 1, BS EN

1993-1-1 / BS EN 1993-1-3 and AICS S 329 and tested in accordance with the
requirements of paragraph 1.04 Testing.
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9.3.17 Setting Bases and Bearing Plates
a) Clean concrete and masonry bearing surfaces of bond-reducing materials and

roughen to improve bond to surface.
(i) Clean the bottom surface of base and bearing plates.
b) Set loose and attached baseplates and bearing plates for structural members on
wedges or other adjusting devices.
c) Tighten the anchor bolts after the supported members have been positioned and
plumbed.
(i) Do not remove wedges or shims, but if protruding, cut off flush with edge of
the base or bearing plate prior to packing with grout.
d) Pack grout solidly between bearing using surfaces and bases or plates to ensure
that no voids remain.
(i) Finish exposed surfaces, protect installed materials, and allow to cure in
strict compliance with the manufacturer’s instructions, or as otherwise
required.
9.3.18 Weld Testing Schedule
Weld Location Length of Weld Type of Weld Test ASTM Test

to be Tested
Specification
Other stress 300 mm in 3 m Fillet M.P.* E709

Carrying Welds
300mm (min. Groove U.T. E164
test)
Flange Splice 100% Groove U.T. E94 – Shop

(Full
Penetration) E164 – Field
(Weld only)
Web Splice Top 100% Groove U.T. E94 – Shop
Bottom-33% E164 – Field
Middle-34%
Bearing 300 mm in 1.2 m Fillet M.P* E709

Stiffener to web
300mm(min.test)
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Misc. 300 mm in3 m Fillet M.P.* E709

Secondary (min. test)
Members
Tension Zones
Compression Visual only

Zones
*Only for fields welds E165, liquid penetrant test may be substituted
9.3.19 Survey
a) Make an accurate survey of actual locations of steel members immediately upon

the completion of erection of steel but before removal of shoring.
b) Promptly submit same to the Engineer.
c) Should locations very beyond the allowable tolerances, necessary corrective

measures and procedures shall be performed with approval of the Engineer.
d) Survey the final erected structural steel after release of shoring but prior to final
removal of shoring elements and prior to the start of any other work.
e) Report any discrepancies from Contract requirements to the Engineer.
9.4 STAINLESS STEEL
9.4.1 General
Stainless steel shall have the following composition with mechanical properties to the
appropriate approved standard.
Table 9.4 Stainless Steel Composition
Element Percentage Chemical Composition
Fabrication Technique
Welded Cold
% minimum %maximum % minimum % maximum
Carbon - 0.03 - 0.07
Silicon 0.20 1.00 0.20 1.00
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Manganese 0.50 2.00 0.50 2.00
Nickel 11.00 14.00 10.00 13.00
Chromium 16.50 18.50 16.50 18.50
Molybdenum 2.25 3.00 2.25 3.00
Sulphur - 0.03 - 0.03
Phosphorous - 0.045 - 0.045
9.4.2 Alternative Grades of Stainless Steel
Alternative, higher grade, stainless steel may be proposed by the Contractor if the
manufacturer considers its properties more appropriate to the environmental or
physical conditions. Higher grade stainless steels shall conform with the parameters
given in tables 9.2, 9.3 and 9.4 for austenitic, ferritic and martenstic stainless steels
groups respectively.
Table 9.4 Austenitic Stainless Steels
BS AISI Forms Main Major Tensile Service

1449 * Characteristics Constituents Strength Temperature
% N/mm2 °C
301 301 Plate High cold work C CR Ni 0.15 max 540 800
S12 Precision hardening Rate, 16-18 6-8 (Softened to
Strip moderate 1240 (full
formability hand)
302 302 Precision Weldable with C Cr Ni 0.08max 510 800

S17 strip good formability 17-19 8- (Softened)
and general 11
corrosion
resistance
304 304 Plate Good C Cr Ni 0.06 max 510 800

S15 weldability, 17.5 –19 (Softened)
form-ability and 9-11
general
corrosion
resistance
304 304 Precision Excellent C Cr Ni 0.06 max 510 800

drawability, 17.5 –19
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Dubai Municipality

% N/mm2 °C
S16 strip good weldability 9-11 Softened)

and general
corrosion
resistance
304 304L Plate Weldable and C Cr Ni 0.03 max 490 800

S12 Precision resistance to 17.5 – 19 (Softened)
Strip sensitisation, 9-12
good corrosion
and oxidation
resistance
305 305 Precision Good C Cr Ni 0.1max 460 800

S19 Strip formability and 17-19 11- (Softened)
general 13
corrosion
resistance
309 309 Plate Excellent C Cr Ni 0.15 max 540 1050

S24 oxidation 22 –25 (Softened)
resistance, 13-16
Weldable
310 310 Plate Excellent C Cr Ni 0.15 max 540 1100

S24 oxidation 23-26 19- (Softened)
resistance, low 22
magnetic
permeability,
Weldable
315 - Precision Highly corrosion C Cr Ni Mo 0.07 max 540 800

S16 Strip resistant 16.5 – (Softened)
Weldable 18.5 10-
13 1.25 –
1.75
316 316 Plate Highly corrosion C Cr Ni Mo 0.07 max 540 800

S16 Precision resistant, and 16.5 – (Softened)
strip Weldable 18.5 9-11
1.25 –
1.75
316 316L Plate Highly corrosion C Cr Ni Mo 0.03 max 480 800

S12 Precision resistant, 16-5 – (Softened)
Strip Weldable and 18.5 11-
resistant to 14 2.25 –
sensitisation 3.0
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% N/mm2 °C
317 317 Plate Extremely high C Cr Ni Mo 0.06 max 540 800

S16 corrosion 17.5 – (Softened)
resistant, 19.5 12-
Weldable 15 3-4
317 317L Plate Extremely high C Cr Ni Mo 0.03 max 490 800

S12 corrosion 17.5-19.5 (Softened)
resistant, 14-17 3-4
Weldable,
resistant to
sensitisation
320 - Plate, Highly corrosion C Cr Ni Mo 0.08 max 540 800

S17 Precision resistant, 16.5 – (Softened)
Strip Weldable and 18.5 11-
resistant to 14 4 x C-
sensitisation 0.6 2.25 –
3.0
321 321 Plate, Weldable and C Cr Ni Ti 0.08 max 510 800

S12 Precision resistant to 17-19 9- (Softened)
Strip sensitisation. 12 5 x C-
Good corrosion 0.70
and oxidation
resistance
347 347 Plate, Weldable and C Cr Ni 0.08 max 510 800

S17 Precision resistant to 17-19 9- (Softened)
Strip sensitisation. 12
Highly resistant
to hot
concentrated
nitric acid
*The equivalent EN grades shall be applicable.
Table 9.4 Ferritic Stainless Steels

% N/mm2 °C
403 403 Plate, Weldable, Heat C Cr Ni 0.08 max 420 750

S17 Precision resistance and 12-14 (Softened)
Strip moderate 0.5max
corrosion
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resistance
405 405 Plate, Weldable, Heat C Cr Ni A1 0.08 max 420 750

S17 Precision resistance and 12-14 Softened)
Strip moderate 0.5max -
corrosion 0.3
resistance
409 409 Precision Weldable, Heat C Cr Ni Ti 0.09 max 420 750

S17 Strip resistance and 10.5 – (Softened)
moderate 12.5 0.7
corrosion max 5 x C
resistance min- 0.7
Max
430 430 Plate, Fairly good C CR Ni 0.1 max 430 800

S15 Precision general 16-18 0.5 (Softened)
Strip corrosion max
resistance.
Formable
434 434 Precision Good C Cr Ni Mo 0.1 Max 420 800

S19 Strip resistance to 16-18 0.5 (Softened)
atmospheric Max 0.9 –
corrosion. 1.3
Formable
Table 9.4 Martenstic Stainless Steels

1449* Characteristics Constituents Strength Temperature
% N/mm2 °C
410 410 Precision Hardenable. C Cr Ni 0.09 – H and T 750

S21 Strip Heat resistant 0.15 11.5 550/700
and Moderate – 12.3 1.0
corrosion max
resistance
420 420 Precision Hardenable. C Cr Ni 0.28 – H 540 mm -

S45 Strip Heat resistant 0.36 12.0
and Moderate – 14.0 1.0
corrosion max
resistance
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9.4.3 Stainless Steel Products
9.4.3.1 General
Stainless steel products must be of grade 316, any welded items to be manufactured
from grade 316 low carbon material, including welding wire. Any materials produced
in mill finish to have marks removed after fabrication by wire brushing or using a
solution of acid paste (pickled and passivated) or electropolishing.
9.4.3.2 Handrails
Handrails for walkways, platforms and stairs etc. will generally come under the
category of General Duty with a loading requirement of 0.36kN/m or Heavy duty with
a loading requirement of 0.74kN/m as defined in BS 6180/BSEN ISO 14122-2010.
The location to use each products and its sizes shall be as shown in the drawing.
a) Handrail for General Duty (0.36kN/m)
Handrails and standards shall be of stainless steel grade 316 L complying with the
requirements of BS 5395:Part 3: 1985, having top and intermediate rails. Handrails
shall be constructed from 60 mm o/d tube (minimum 4mm wall thickness) complete
with all bends and internal joints. Handrail joints to be of the internal ferrule type
secured with M8 stainless steel grub screws. Joints to be concealed within balls of
standards. Handrails shall be supported by ball type tubular handrail standards,
spaced at not greater than 1800mm centres standards shall be constructed from 42.4
mm/OD tubular shanks and fitted with 75 mm diameter balls drilled through of the
above described handrails and fitted with M8 grub screws to secure handrail.
Standards to have welded on round base plates (minimum 135mm x 12mm thick)
drilled for 3 nos holes at 100 pcd to be fitted with M12 resin anchor bolts having
stainless steel studs. Handrails to platforms, walkways and landings to be 1100mm
high and between 900mm and 1000mm above the pitch line on the stairs.
Finish: Handrails to be brush polished, pickled clean or electropolished with satin

finish.
b) Handrail for Heavy Duty (0.74kN/m)
Handrails and standards shall be of stainless steel grade 316L complying with the
requirements of BS 5395: Part 3 : 1985, having top and intermediate rails. Handrails
shall be constructed from 75 mm o/d tube (minimum 4mm wall thickness) complete
with all bends and internal joints. Handrail joints to be of the internal ferrule type
secured with M8 stainless steel grub screws. Joints to be concealed within balls of
standards. Handrails shall be supported by ball type tubular handrail standards,
spaced at not greater than 1500mm centres. Standards shall be constructed from 50
mm o/d tubular shanks and be fitted with 90mm diameter balls drilled through or the
above described handrails and fitted with M8 grub screws to secure handrail.
Standards to have welded on round base plates (minimum 150 mm & 12mm thick)
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Dubai Municipality
drilled for 3 nos. holes at 100 pcd to be fitted with M12 resin anchor bolts having
stainless steel studs. Handrails to platforms, walkways and landings to be 1100mm
high and between 900mm and 1000mm above the pitch line on the stairs.
9.4.3.3 Toe Plates
Toe plates shall be provided to all platforms and walkways and shall be a minimum of
100mm high x 6 mm thick secured to handrail standards with a clamp plate and 2
nos. M8 ‘U’ bolts. All joints in toe plates shall be made secure with 100mm square x
6mm thick joint plates and 4 no. M8 pan head stainless steel bolts. All joints in toe
plates shall be made secure with 100mm square x 6 mm thick joints plates and 4 nos.
M8 pan head stainless steel bolts. All corners shall be complete with clear
connections, again of bolted construction. Toe plates are not required to the slope of
stairs.
Finish: Toe plates and fittings to be brush polished, pickled clean or electropolished.
9.4.3.4 Ladders (Fixed Vertical or near Vertical)
All ladder sizes shall be as shown in the drawing. All access ladders shall be
fabricated from stainless steel grade 316L, complying with the requirements of BSEN
ISO 14122-2001 (BS 5395:Pt 3 : 1985 ), having flat stringers and solid round rungs.
Ladders shall be constructed from minimum 65mm x 10mm flat stringers, spaced
380mm apart (400mm overall width), fitted with 20mm diameter solid rungs at 250mm
centres of all welded construction. Fixing stays shall be provided at centres not
greater than 2.3m. Inclined ladders should be set at 75 or steeper. Landing where
required shall not be less than 840 mm square with handrails and toe plates to
protect open sides. Ladders rising more than 2.2 m should be fitted with a safety
cage. Handholds shall be provided to all ladders. Ladders rising above the floor level
to which they give access shall be fitted with hand holds where access is to one side
for a walk through access. The latter shall be fitted with safety chains or drop bars.
Where ladders terminate below the floor level to which they give access (manhole
type) they shall be fitted with handhold. Safety cages shall be constructed from 50mm
x 8mm flat hoops, complete with 3 vertical straps. Hoops shall be provided at centres
not greater then 750mm and shall be of bolted construction, M10 countersunk type.
Ladders tops shall be extended above floor level acting as handhold where required.
Pumping stations, tanks and deep manholes shall have ladder with top type
retractable handhold. For open top ladders single height or full height hinged gates
shall also be provided if required.
9.4.3.5 Step Ladders
Step ladders shall be of stainless steel grade 316 and shall comply with the design
requirement of BSEN ISO 14122-2001 (BS5395: Pt3: 1985), constructed from
130mm x 10mm flat stringers 550mm apart, cleated top and bottom for fixing and
fitted with open type treads, complete with end plates welded on and twice drilled at
each end for fixing to the stringers with M10 bolts. A single line handrail shall be
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Dubai Municipality
provided on each side of the step ladder, constructed from 60mm o/d x 4mm tube
supported by single ball tubular standards. Handrails shall be opened out at the top to
a minimum of 610mm and shall be turned to form continuity with the platform
handrail. At the lower end the handrails should be returned to the stringers.
Step ladders shall have untreated mill finish (weld as laid), pickled clean or
electropolished.
9.4.3.6 Safety Chains on Platforms
Safety chains shall be of 12.5mm diameter long link swivel eye, with ‘S’ hook and ‘D’
shackle each end as shown in the drawing made from grade 316 stainless steel,
bright finish.
9.4.3.7 Open Type Flooring
Open type flooring shall be of stainless steel grade 316L complying with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985 and BS4592: Pt 1 2006),
Suitable for a super imposed loading of 5kN/m.sq. The flooring shall be rectangular
pattern type constructed from main span bars designed to suit the loading and made
up of suitable size panels for ease of handling and complete with welded on nosing
bars. The mass of any individual panel shall not exceed 40kg. Where floor panels are
supported on structural members, adjustable type fixing clips or shot fired fixings shall
be provided with a minimum of 2 clips per panel, securing each corner with 2
additional clips for end panel covers. Where floor panels are contained within angle
curbing, fixing clips are not required. Where angle curbing is provided, this shall
complete with bent flat lugs welded on for grouting into the surrounding concrete at
maximum 900mm centres and at a maximum of 150mm from each end or corner.
Flooring shall be of such depth to ensure that deflection does not exceed span/200 or
10mm whichever is lesser when fully loaded. Support beams of grade 316 stainless
steel shall be provided, including all cleats and fixing bolts to facilitate easy removal
where necessary. Fixing clips shall be stainless steel grade 316 material. Where cut
outs are required in flooring around pipe work or other obstructions, a continuous
nosing bar shall be fully welded to all load bearing bars around the cut out. The
clearance around the obstruction shall not exceed 30mm.
Flooring shall be untreated mill finish (welds as laid), pickled clean or electropolished.
9.4.3.8 Solid Floor Plates
Solid floor plates shall be Durbar pattern stainless steel grade 316L and shall comply
with the requirements of BSEN ISO 14122-2001 (BS 5395: Pt 3: 1985). Floor plates
shall have a minimum 6mm base thickness, be provided with lifting holes and
secured with M10 stainless steel countersunk head screws. Where floor plates have
concrete surrounds they shall be provided with stainless steel flat curbing. The 6mm
flat base providing a 25mm wide seating. Bent flat lugs shall be welded on to the
underside at 900mm maximum centres and at 150mm from corners or ends for
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grouting into the surrounding concrete. Where necessary intermediate stainless steel
supports shall be provided and shall include all necessary cleats and fixing bolts to
enable removal when required. Where cut outs are required around pipe work or
other obstruction, these shall be neatly cut with all rough and sharp edges ground
smooth. Clearance between the floor plates and obstructions shall not exceed 30mm.
Floor plates shall be designed for a uniformally distributed loading of 5kN/m.sq. and
deflection shall not exceed span /200 or 10mm whichever is the lesser, when fully
loaded.
Flooring shall be untreated mill finish (weld as laid), pickled clean or electropolished.
9.4.3.9 Staircase
Staircases shall be of stainless grade 316L, S 31complying with the requirement of

BSEN ISO 14122-2001 (BS 5395: Pt 3: 1985). Staircases shall have a rake not
exceeding 38 degrees and shall have a width of between 800mm and 1 metre.
Handrails shall be provided on both sides and shall be continuous with walkway and
platform handrails. Stairs shall be fitted with open type stainless steel treads shall be
fitted with sight bars and have end plates welded on and twice drilled for M12
stainless steel fixing bolts for attaching to the stair stringers. The going of each tread
shall be 250mm and the maximum rise shall be 190mm. The stair stringers shall be of
minimum 180 x 10mm flat section stainless steel and shall be cleated top and bottom
for fixing. Stringers at the bottom of the staircase shall not extend more than 50mm
beyond the lowest tread. Stairs shall have no more than 16 risers or less than 3.
Where staircases are to be fitted with solid treads these shall be constructed from
floor plates with a flanged nosing and end plates for bolting to the stair stringers.
Where stairs have a rise exceeding 3040mm, intermediate landings shall be
introduced. A staircase shall be designed for a uniformly distributed loading of
5kN/m.sq.
Finishes: Stair case – Natural untreated mill finish (weld as laid), pickled clean or
electropolished. Handrails – Brush polished, pickled clean or electropolished.
9.4.3.10 Step Irons
Step irons shall be of stainless steel as described below.
Stainless steel irons shall be fabricated from 25 mm diameter solid bar twice bent to
form a ‘U’ shaped width 375 mm with two legs 350 mm long, the ends of the bar shall
be ragged and built 175 mm into the concrete wall. The tread of the rung shall be
stamped or otherwise roughened.
9.4.3.11 Stainless Steel Clamping Systems
Stainless steel band for fixing uPVC saddles to AC pipes or similar rigid pipes shall
comply with the requirements and be resistant to environment corrosion and
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electrolytic action. Standard band 19 mm wide shall be utilised with the edges of the
band rounded for ease of handling.
Clamping shall be by ‘standard’ buckles. Buckles shall be manufactured from the

same material as the standard band and have the same corrosion resistance.
9.4.3.12 Saftey Chains and Fittings for Manholes
Safety chains to guard railing shall be supplied by the guard railing manufacturer to
the dimensions shown on the Drawings.
Safety chains shall be fitted in manholes across the entries to all outlet pipes
exceeding 600mm diameter and shall be manufactured in stainless steel Grade 316
S16 capable of withstanding continuous exposure to the severe corrosive conditions
occurring in sewers or drains carrying septic sewage and groundwater.
The suitability of the chain and fittings for use in aggressive environment shall be
verified by immersing an approved length of chain together with fittings in a 20%
concentration of sulphuric acid at 35 C for 90 days. At the end of this period, neither
the chain not the fittings shall display any visible loss of material. The chain shall then
be subjected to a static tensile load of 1.5KN for 15 minutes. It shall not show any
deformation or visible strain.
The anchorages for the safety chains shall be of stainless steel Grade 316 S16.
9.4.3.13 Nuts, Screws, Washers and Bolts
Nuts, screws, washers and bolts shall be of such material to resist environmental
corrosion and electrolytic action with mating metals.
Unless an alternative is specifically approved, stainless steel items shall be supplied

for all dismantleable items.
Zinc coated items 10mm diameter and larger shall have the nuts cut oversize and
shall be spun galvanised (or equivalent). Smaller zinc coated items shall be
electroplated.
Black hexagonal bolts, screws and nuts shall be to a grade with a tensile strength of
400 N/mm2.
Bright (high tensile) items to a grade with a tensile strength of 800 N/mm2 may be
used instead of black items.
The items shall have coarse metric threads.
Bolting for pipes and fittings shall comply with the approved standard. Spheroidal
graphite iron bolts for use with ductile iron pipes and fittings shall have a tensile
strength of 500 N/mm2.
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9.4.3.14 Stainless Steel Weir Plates
The weir plates shall be stainless steel grade 316L with 10mm thick plates as shown
in the Drawings.
9.4.3.15 Stainless Steel Baffle Plate
The Baffle Plate shall be with Steel grade 316L and comply with the design
requirements as shown in the approved drawing.
9.4.3.16 Certification
The product manufacturer has to provide a compliance certification that the stainless
steel items supplied fully comply with the relevant standard requirements with
supporting test reports of materials, chemical composition, load/deflection,
concentrated & uniformly distributed load tests carried out on each unit.
9.4.3.17 List of Approved Product Supplier
a) European Platform Systems – UK International
b) Standard Fabrications – Dubai
c) Al shabia Engineering Ltd - Sharjah
9.5 ALUMINUM
9.5.1 General
The following specification relates to aluminium equipment based on current British

and European Standards.
9.5.2 Material
All aluminium alloy must be marine grade 6082 to BS EN 755-3, fully heat treated
T.6. condition, except that T.4 condition shall be used for the upper and lower tubular
horizontal handrails. (Note: handrail tube T.4 condition is more ductile and allows
bends to be formed). Material certificates shall be required to demonstrate conformity.
9.5.2.1 Precautions Against Electrolytic Action
Precautions should be taken in damp or moist conditions to avoid electrolytic action

between dissimilar metals, particularly with aluminium. The good corrosion resistance
of aluminium and its alloys is attributable to the protective oxide film which forms on
the metal surface spontaneously on exposure to air. The protective film is relatively
inert and forms naturally. After fairly rapid initial formation of the oxide film, very little
further action occurs. Such behaviour is consistent for practically all external freely
exposed conditions and for all internal or shielded conditions, except where extremes
of acidity or alkalinity can develop. Aluminium is in general considered maintenance
free. However, in damp or wet conditions aluminium can be adversely affected by
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being allowed to come into direct contact with dissimilar metals and some building
materials including concrete.
Protection, in general can be provided by painting the contact surface of the

aluminium with 2 coats of bituminous paint. Bolts used for fastening in adverse
conditions should be provided with plastic ferrules and washers for the bolt shank and
under the bolt head and nut.
Unprotected ‘mill finish’ aluminium is highly weather resistant and lasts for many
years even in an exposed environment. Where it is desirable to provide added
protection, anodising the metals to BS 1615 grade AA25 can be considered.
Anodising is an electrolytic process in which the natural oxide layer that is always
present on aluminium is thickened.
9.5.3 Aluminium Products
9.5.3.1 Handrails
Handrails for walkways, platforms and stairs within BSEN ISO 14122-2001 will
generally come under the category of ‘General Duty’ with a loading requirement of
0.3kN/m or heavy duty with a loading requirement of 0.7kN/m.
a) Handrail for General Duty (0.36kN/m)
Handrails and standards shall be of aluminium alloy grade 6082 (T.6. condition for
handrail standards and T.4. condition for handrails), complying with the requirements
of BSEN ISO 14122-2001 (BS 5395:Pt 3: 1985), having top and intermediate rails at
550mm centres. Handrails shall be constructed from 60 o/d tube (minimum 6.3mm
wall thickness), complete with all bends and internal joints. Handrail joints to be of the
internal ferrule type. Handrails shall be supported by tubular type handrail standards
spaced at not greater than 2000mm centres. Standards shall be constructed from
50.8mm o/d tube (minimum 6.35mm wall thickness) and be fitted with a die cast top
tee and a high duty die cast aluminium (LM25) base, secured to shank with 2 no. M8
stainless steel grub screws. Bases shall be purpose made (minimum 170mm x 90mm
x 15mm thick) twice drilled for 2 no. M12 resin anchor bolts, having stainless steel
studs grade 316. Handrail standards to be fitted with stainless steel grub screws to
screw to secure handrails in position. Handrails to platforms, walkways and landings
to be 1100m high and between 900mm and 1000 mm above the pitch line on the
stairs.
Finish: Natural untreated mill finish, powder coated or anodised grade AA25.
b) Handrail for Heavy Duty (0.74 kN/m)
Handrails and standards shall be of aluminium alloy grade 6082 (T.6 condition for
handrail standards and T.4 condition for handrails), complying with the requirements
of BSEN ISO 14122 /2001 (BS 5395:Pt 3 : 1985), having top and intermediate rails at
550mm centres. Handrails shall be constructed from 75 mm o/d tube (minimum 6.25
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Dubai Municipality
mm wall thickness), complete with all bends and internal joints. Handrail joints to be
of the internal ferrule type. Handrails shall be supported by tubular type handrail
standards spaced at not greater then 1500mm centres. Standards shall be
constructed from 50 mm o/d tube (minimum 6.35 mm wall thickness) and be fitted
with a die cast top tee and a high duty die cast aluminium (LM25) base secured to
shank with 2 no. M8 stainless steel grub screws. Bases shall be purpose made
(minimum 170mm x 90mm x 15mm thick) twice drilled for 2 no. M12 resin anchor
bolts, having stainless steel grade 316. Handrail standards to be fitted with stainless
steel grub screws handrails in position. Handrails to platforms, walkways and
landings to be 1100 high and between 900mm and 1000mm above the pitch line on
the stairs.
9.5.3.2 Toe Plates
Toe plates shall provided to all platforms and walkways and shall be of extruded
section minimum height 160mm. Toe plates shall be secured to handrail standards
with clamp plate and strap, to avoid any distortion along its length. All joints in toe
plates shall be made secure with 3mm thick joint plate. All corners shall be complete
with cleat connections, again of bolted construction using grade 316 stainless steel
fixings.
Finish: natural untreated mill finish, powder coated or anodised grade AA25.
9.5.3.3 Ladders (Fixed Vertical or Near Vertical)
Access ladders fabricated from aluminium alloy grade 6082 T.6 shall comply with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985). Ladders shall be
constructed from minimum 65 mm x 10mm stringers, spaced 380mm apart, fitted with
20mm diameter solid or tubular rungs at 250mm centres of all welded/ riveted
construction. Fixing stays shall be provided at centres not greater than 1.8m. Ladders
rising more than 2.2m should be fitted with a safety cage. Handholds shall be
provided to all ladders. Ladders rising above the floor level to which they give access
shall be fitted with safety chains. Where ladders terminate below floor level to which
they give access (manhole type) they shall be fitted with retractable handholds.
Safety cages shall be constructed from 50mm x 8 mm flat hoops, complete with 3
vertical straps. Hoops shall be provided at centres not greater than 750mm and shall
be of bolted constructions, bolts to be M10 stainless steel countersunk type or have
dome heads on the inside of safety cages.
9.5.3.4 Step Ladders
Step ladder shall be of aluminium alloy grade 6082 T.6 and shall conform with the
design requirements of BSEN ISO 14122-2001 (BS 5395:Pt 3: 1985), constructed
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from 130mm x 10mm flat stringers 550mm apart, cleated top and bottom for fixing
and fitted with open type aluminium alloy treads, (or solid treads type), complete with
end plates welded on and twice drilled at each end for fixing to the stringers with M10
stainless steel bolts. A single line handrail shall be provided on each side of the step
ladder, having 50.8 mm o/d x 6.3 mm tubular shanks and purpose made high duty
cast aluminium side palm bases, secured to the step ladder with 2 nos. M12 stainless
steel bolts. Handrails shall be opened out at the top a minimum of 610mm and shall
be turned to form continuity with the platform handrail.
9.5.3.5 Open Type Flooring
Open type flooring shall be of aluminium alloy grade 6082 T6 Deck type having 24%
open area, complying with the requirements of BSEN ISO 14122 – 2001 (BS 5395:Pt
3: 1985), suitable for a super imposed loading of 5kN/m.sq. in accordance with the
requirements of BS4592. The flooring shall be of a reinforced extruded section with
integral inverted ‘T’ section stiffening webs, made up into suitable size panels for
ease of handling and complete with welded on nosing bars. The mass of any
individual panel shall not exceed 40kg. Where floor panels are supported on
structural members, adjustable type fixing clips shall be provided with a minimum of 4
clips per panel, securing each corner. Where floor panels are contained with angle
curbing, fixing clips are not required. Where angle curbing is provided, this shall be
complete with purpose made lugs. Curbing shall provide adequate seating for the
flooring and should match the depth of the floor plate for which it is provided. Floor
plates shall be of a depth to ensure that deflection does not exceed span/200 or
10mm whichever is lower, when fully loaded. All necessary intermediate support
beams shall be provided, including all necessary cleates and fixing bolts to facilitate
easy removal where necessary. Fixing clips shall be aluminium alloy with M8 nickel
head stainless steel fixing screws, spring washer & nut.
9.5.3.6 Solid Floor Plates
Solid floor plates shall be aluminium alloy grade 6082T6 and shall comply with the
requirements of BSEN ISO 14122-2001 (BS5395: Pt 3: 1985). suitable for a super
imposed loading of 5 kN/m.sq. Floor plates shall be of a reinforced extruded section
with integral inverted ‘T’ section stiffening webs. The floor plates shall be supplied in
suitable size panels for ease of handling and complete with welded on nosing bars.
The mass of any individual panel shall not exceed 40kg. Where floor plates are
supported on structural members, adjustable type fixing clips shall be provided with a
minimum of 4 clips per panel securing each corner. Fixing clips shall be aluminium
alloy with M8 nickel head stainless steel fixing screws. Where floor panels are
contained within angle curbing, fixing clips are not required. Where angle curbing is
provided this shall be complete with purpose made lugs. Curbing shall provide
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adequate seating for the flooring and should match the depth of the floor plate for
which it is provided. Floor plates shall be of a depth to ensure that deflection does not
exceed span/200 or 10mm whichever is the lower, when fully loaded. All necessary
intermediate support beams shall be provided, including all cleats and fixing bolts to
facilitate easy removal where necessary. Where cut outs are required in flooring
around pipework or other obstructions, a continuous nosing bar shall be welded to all
load baring bars around the cut out. The clearance around the obstruction shall not
exceed 30mm.
Finish: Natural untreated mill finish, powder coated or anodised AA25.
9.5.3.7 Staircases
Staircases shall be of a aluminium alloy grade 6082 T6, complying with the
requirements of BSEN ISO 14122-2001 (BS 5395: Pt 3 : 1985). Staircases shall have
a rake not exceeding 38 degrees and shall have a width of 800mm or 1 metre as
shown on drawings. Handrails shall be provided on both sides and shall be
continuous with toeplate to horizontal areas (not stringers). Stairs shall be fitted with
open type aluminium alloy treads which shall be complete with end plates welded on
and each twice drilled for M12 stainless steel fixing bolts for attaching to the stair
stingers. The going of each tread shall be 250mm and the maximum rise shall be
190mm. The stair stringers shall be of minimum 180 x 10 mm flat section aluminium
alloy and shall be cleated top and bottom for fixing, stringers at the bottom of the
staircase shall not extend more than 50mm beyond the lowest tread. Stairs shall have
no more than 16 rises or not less than 3. Where stairs have a rise exceeding
3040mm, intermediate landings shall be introduced. Staircases shall be designed for
a uniform distributed loading of 5kN/m.sq.
9.5.3.8 Heat Treatment of Aluminium Alloys Specified.
Material grade 6082 to BSEN 755.
Heat-treated to T4 (H30TB) and T6 (H30TF) condition to BSEN ISO 515.
9.6 GRP MOULDED GRATING AND GRP PULTRUDED SUPPORTS
9.6.1 General
a) GRP grating types shall be open or solid top, slip resistant where indicated in the
drawings.
b) All finished surfaces of GRP items and fabrications shall be resin rich, free or
voids and without dry spots, cracks, or un-reinforced areas. All fiberglass shall be
well covered with resin to protect against their exposure due to wear and
weathering.
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Dubai Municipality
c) All GRP products shall be mechanically secured using holddown clamps and
pannel connections of GR: 316L SS for all grating pannel sections. A minimum of
4 per panel shall be provided.
d) The submittal must be along with the relevant product catalogues / descriptive
literature stating manufacturing process, materials, mill certificates of accessories
and instructions on construction or erection manual, handling.
e) Shop drawing shall be indicated with mesh size, design load parameters,
dimensions, materials, clearances, tolerances, support details, integration of
piping components and anchorage, etc.
f) Manufacturing process shall be open heat moulded, Continuous glass fibres are
placed in the mould in alternating layers and completely wetted out with resin.
This continuous process produces an integral, one piece construction which
provides excellent corrosion resistance as well as bi-directional strength. When
the weaving process is completed, the mould is heated to cure the panel. The
mould will receive the grit before the part is cured. After curing the part is
extracted from the mould.
g) Grating shall be suitable for 100% humidity and > 50C temperature, corrosion
proof, UV stabilized.
h) Sealing: All shop fabricated and field fabricated grating cuts shall be coated with
a resin compatable to grating resin to provide maximum corrosion resistance.
i) The Grating shall be free, as commercially possible, from visual defects such as
foreign inclusions, delamination, blisters, resin burns, air bubbles and pits.
j) Colour of Grating shall be safety yellow pigmented Grey or Green or Orange.
k) After moulding, no dry glass fibres shall be visible on any surface or bearing bars
or cross bars. All bars shall be smooth and uniform with no evidence of fiber
orientation irregularities, interlaminar voids, resin rich or resin starved areas.
l) Moulded grating to be designed to exhibit a minimum of class 1 flame spread

rating less < 25, when tested in accordance with ASTM E-84 flame spread rating
tunnel Test.
m) All openings shall be edge banded.
n) Grating designated as “solid top” shall include a seamless GRP sheet of minimum
thickness 5 mm permanently attached to the bars.
o) Top surface of all open and solid panels shall have a non- skid grit affixed by
baked epoxy resin.
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p) Moulded grating must be designed with superior slip resistant grit top. The grits
must be embedded to the surface before the heating process, which Sprayed
type grit is not allowed.
9.6.2 Construction
a) Glass Content:
Moulded grating is manufactured using a proprietary method enabling a higher

percentage of glass roving to be introduced into the grating. The grating must contain
a 30-35% glass. The corrosion resistance of fiberglass grating is provided by the
resin and the stiffness is provided by the glass. Percentage of glass (by weight) shall
not exceed 40% so as to achieve maximum corrosion resistance, and as required to
maintain the structural requirements of the contract.
b) Resin Selection:
The resin selection is paramount in determining the corrosion resistance of the

finished product. VEFR-25 is a premium vinylester resin with a flame spread rating
less than 25. It provides the most chemical resistant moulded product offered in the
industry. Designed to withstand the harshest chemical environments over a
broadrange of acids and caustics, it shall be primarily used in petrochemical,
wastewater, where the grating is subject to frequent and direct contact with harsh
chemicals.
c) Mesh Selection: shall be as Table 9-5.
Type of Grating Application Specification
Powergrid 38 x 25 x Service and Maintenance Mesh 25 x 150 , depth 38 mm,

150 RM platforms for light, medium Load bar thickness 9.3 mm,
duty equipment, load bar centres 25, open area
Accessories, tools. 56%, Approx. Weight 22.4
kgs/m2.
Powergrid 60 x 38 Service and Maintenance Mesh 38 x 38, depth 60 mm,

SM platforms for heavy-duty load bar thickness 11, load bar
equipment, Accessories, centres 38 mm, open area
tools, Machinery, etc. 58%, Approx. weight
50.4kgs/m².
(i) FIRE RETARDANT
Manufacturer is required to test and provide certification of ASTM E84 test on grating
panels from independent testing laboratory. The data performed only on the base
resin shall not be acceptable.
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(ii) INSTALLATION
1. Sub-contractor shall install gratings in accordance with the

manufacturer’s assembly drawings. Lock grating panels securely in
place with hold-down fasteners.
2. Field cut and drill fiberglass reinforced plastic products with carbide or
diamond tipped bits and blades. Seal cut or drilled surfaces in
accordance with manufacturer’s instructions.
3. Install items specified as indicated and in accordance with

manufacturer’s instructions.
(iii) TOLERANCES
1. The grating tolerance to side of trench is 6 mm,
2. The grating tolerance to wall 10mm.
3. The grating tolerance between panels is 0 mm to 6 mm.
4. The minimum support width is 38mm.
5. The cutting tolerance is +0 mm, - 6mm.
a) All testing and inspection costs if required, shall be born by the contractor.
b) The following min Test reports to be provided by the manufacturer / supplier for
Engineer’s review:
Table 9-6: Minimum Tests Reports to be provided
Sr. Tests on Properties Standard Limits
1. Uniform load testing NSI/ASCE/ACMA Minimum design

FGM-2003 requests
2. Concentrated load testing ANSI/ASCE/ACM "

AFGM 2003
3. Concentrated line load testing ANSI/ASCE/ACM A "
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Dubai Municipality
FGM 2003
4. Barcol hardness ASTM D 2583 > 33
5. Visual inspection ASTM D 2563 Level 1
6. Acid immersion test in 10% ASTM C 581 Shall not show any
Concentrated sulphuric acid for deterioration after
100 days the test.
7. Glass content ASTM D 2584 >30%
Type of Grating Application Specification
Powergrid 38 x 25 x 152 Stair Treads Mesh 25 x 152, depth 38

RM with double bearing mm, load bar thickness
bars at 150 intervals and 6.4, load bar centres 25,
non- skid nosing open Area 56%, weight 23
kgs/m2
Powergrid 38 x 25 x 150 Service and Maintenance Mesh 25 x 150 , depth 43

RM, Covered plate platforms in odour control mm, load bar thickness 9.3
surface area mm. Load bar centres 25 ,
closed top surface,
Approx. Weight 30 kgs/m2
9.6.4 Design Criteria:
a) The criteria of the FRP products including connections shall be in accordance

with governing building codes and generally accepted standards in the FRP
industry.
b) Gratings: Design live loads of the FRP gratings for walkway applications shall be
500 kgs/m2 uniformly distributed load with a maximum deflection of 6 mm or L/120
at the centre of a simple span or a concentrated load of 750 kgs with a maximum
deflections of 6.25 mm at the centre of a simple beam.
c) Stair Treads: Stair treads shall be designed for a uniform load of 500 kgs/m2 at
the centre of a simple span OR a 450 kgs/m of width line load at the centre of the
tread.
d) LOAD DEFINITIONS:
(i) Dead load:
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Dubai Municipality
All structural materials, floors and various permanent elements forming part of the
platform shall be considered as dead loads.
(ii) Live Load:
The design imposed loading shall be as per Table 9-7:
Floor Area Usage Distributed load Kgs/m2 Concentrated load Kgs
Maintenance , and storage 500 750

Area
Heavy equipment, loading 1500 2250

and offloading area, where
forklift is used.
e) DEFLECTION:
Floor Area Usage Max allowable deflection
Maintenance , and storage area L/120
Heavy equipment, loading and offloading L/120

area, where forklifts used
9.6.5 Submittals
a) Submit manufacturer’s shop drawings of all fabricated gratings clearly showing

Materials sizes, types, styles, part or catalogue numbers, complete details for the
fabrication of and erection of components including, but not limited to, location,
lengths, type and sizes of fasteners, clip angles, members sizes and connection
details.
b) Submit the manufacturer’s published literature including structural design data,

Structural properties data, grating load/deflection tables, corrosion resistance
tables, certificate compliance, test reports as applicable and design calculation
manual for pultruded supporting system.
c) Submit sample pieces of each item specified herein, manufactured by the method
used in the work and as quality and colour.
9.6.6 Pultruded Supports
a) A pultruded fiberglass structural shape is comprised of reinforcing fibres and

resin. The fibre reinforcement provides the structural stiffness, and the resin
provides the resistance to the environment, be it ultraviolet resistance, chemical
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Dubai Municipality
resistance, impact resistance. Resins typically contains fillers to assist in

achieving an intended performance characteristic.
b) Reinforced fibres consist of continuous strand mat and continuous stand roving.
Typical structural shapes contain from 45% - 75% fibre reinforcement by weight.
c) Since pultrusion is a low pressure process, fiberglass reinforcement normally

appear close to the surface of the product. This can affect the corrosion
resistance. Surface veils must be added to the laminate construction, and when
used, displaces the reinforcement from the surface of the profile, creating a resin
rich surface.
d) Vinylester resin possess excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly
corrosive environment.
e) Fiberglass will undergo some decay and change of appearance due to prolonged
exposure to outdoor weathering. UV stabiliser will retard the effect of weathering.
UV Stabilised urethane coating shall provide for U.V protection with minimal
change in appearance.
9.6.7 Structural Design Basis
a) Effect of Temperature
When designing fiberglass structures that will be subjected to high heat exposure, the
manufacturer is cautioned to consider the effect of temperature as it relates to the
allowable stresses and to the modulus of elasticity. The result of higher temperatures
on structural fiberglass is a reduction in modulus of elasticity and thus a lowering of
the allowable stresses. The table below provides the retention of modulus of
elasticity.
Temperature Retention of Modulus of Elasticity
37° C 100%
51° C 95%
Temperature Retention of Ultimate Stress
37°C 90%
51°C 80%
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b) Safety Factors
Safety factors are defined as the ratio of the ultimate stress to the allowable stress.
Safety factor (S.F) = Ultimate Stress (U.S) / Allowable Stress (A.S)
The safety factors are chosen to prevent “first deformation of the part”. First
deformation is defined as the first visible deformation including local flange or web
buckling, twisting, crushing, etc.
The recommended design safety factors are:
Loading Type Recommended Safety Factors
Flexural members, beam 2.5
Compression members, column 3.0
Tension members 4.0
Beam Shear 3.0
Connections 4.0
MODULUS
Modulus of Elasticity 1.0
Shear Modulus 1.0
(i) DEFLECTION
As a minimum, all live load deflections of all beams should be limited such that the
deflection over length ratio (Δ / L) does not exceed 1/150. For Cantilevered beams,
the deflection ratio should be limited to 1/100.
The deflection of a fiberglass beam is actually comprised of two components:
 Flexural deflection
 Shear deflection
The shear deflection will and add an additional 10-15% to the deflection.
In short beams subjected to high concentrated loads, shear stress may govern the
beam selection as opposed to the flexural stress.
(ii) FLEXURAL BEAM MEMBERS
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Dubai Municipality
Flexural members have two primary failure modes due to bending:
1. Failure due to pure bending stress, i.e. Compression flange crushing or

tension flange breaking and
2. Failure due to global buckling, i.e. lateral torsional buckling. Proper

design of flexural members required that both of these failures modes
be investigated in the design process. Allowable stresses will be
reduced significantly if the proper bracing scheme is not used. The use
of intermediate beams at the appropriate spacing along the bending
member shall be used to eliminate buckling concerns.
(iii) COMPRESSION COLUMN MEMBERS
The column failure can be categorized into two modes: bearing failure and local/
global instability. The short column generally fail in bearing deformation or local
buckling mode. The long columns generally fail in the global buckling mode. Short
columns with I section fail to due to combination of axial load and bending moment.
Table: 9 -8 Determine the effective length coefficient, k-value
Sr. End connections Recommended K - Value
1. Pinned - Pinned 1.00
2. Fixed - Fixed 0.65
3. Pinned - Fixed 0.80
4. Fixed - Translation Fixed 0.80
5. Fixed - Translation Free 1.20
6. Pinned - Translation Fixed 2.00
(iv) CONNECTION
1. Fiberglass structures are typically designed to be removable, thus all

connections are to be bolted.
2. All connections are to be designed using a safety Factor of 4.0.
3. All bolting hardware used should be SS 316 stainless steel.
4. When designing bolted connections, there are four engineering checks

to be performed,
5. Using the reaction load at the joint:
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Dubai Municipality
a. Check of beam shear on net throat area of a clip angle, S.F = 4.0
b. Check of beam shear on the web areas of the beams, S.F = 4.0.
c. Check of bolt bearing on the web of the beams, S.F = 4.0
d. Check of bolt shear, web of beams through bolt, S.F = 4.0.
Note: The shear factor for a beam analysis performed at a location other than
the connection is 3.0.
9.7 GRP PULTRUDED LADDER
9.7.1 General
a) All finished surfaces of GRP Ladder items and fabrications shall be resin rich, free
of voids and without dry spots, cracks, or un—reinforced areas. All fibreglass shall
be well covered with resin to protect against their exposure due to wear and
weathering.
b) All GRP products shall be mechanically secured using fixings manufactured from
SS316.
c) The submittal must be along with the relevant product catalogues / descriptive
and instructions on construction, handling.
d) Shop drawing shall be indicated with size, design load parameters, dimensions,
materials, clearance, tolerances, support details, etc….
e) Manufacturing process of side rail, rungs is pultrusion process. Cage hoops, and
wall bracket shall produced by open moulded hand lay up method.
f) Ladder shall be suitable for 100% humidity and > 50 C temperature, corrosion
proof, UV stabilized.
g) Sealing: all shop fabricated and field fabricated ladder cuts shall be coated with a
resin comparable to ladder resin to provide maximum corrosion resistance.
h) The ladder shall be free, as commercially possible, from visual defects such as
foreign inclusions, delamination, blisters, resin burns, air bubbles and pits.
i) Colour ladder shall be safety yellow pigmented.
9.7.2 Manufacturing Process
Pultruded fibreglass ladder is comprised of reinforcing fibres and resin. The fibre
reinforcement provides the structural stiffness, and the resin provides the resistance
to the environment, be it ultra-violet resistance, chemical resistance. Resins typically
contain fillers to assist in achieving an intended performance characteristic.
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Dubai Municipality
Reinforced fibres consist of continuous strand mat and continuous stand roving.
Typical structural shapes contain from 45% - 75% fibre reinforcement by weight.
Since pultrusion is a low pressure process, fibreglass reinforcement normally appear

close to the surface of the product. This can affect the corrosion resistance two layers
of surfaces veils must be added to the laminate construction, and when used,
displaces the reinforcement from the surface of the profile, creating a resin rich
surface.
Vinylester resin possesses excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly corrosive
environment.
9.7.3 Construction
The ladder side rail shall be 54 mm square with a wall thickness of 6 mm. the rungs
shall be 32 mm diameter Pultruded structural shapes, continuously fluted to provide a
non-slip surface. Rungs that are gritted as secondary operation shall not be
permitted. Rungs are to be capable of withstanding a pointed load of 500 N applied at
the centre of rug. Ladder wall and floor mount shall be fabricated from hand lay up or
Pultruded angles 10mm minimum thickness.
The ladder cage vertical bars shall be 50mm wide x 15 mm Pultruded channel
shapes to offer protection to workers from exposed hardware.
Type SS 316 stainless steel bolts shall be provided for attaching ladder cage vertical
bars to hoops, ladders hoops to brackets, ladder cage brackets to the ladder and wall
brackets to the ladder.
All rungs shall be both mechanically attached to the ladder with stainless steel rivets
and chemically bonded with epoxy.
9.7.4 Design / Standard
The ladder shall meet the following min requirement of OSHA code, section 1910.27
and project requirement:
a) The minimum design live load shall be a single concentrated load of 300 kgs.
b) The distance between rungs shall not exceed 300mm and the minimum clear
distance between side rails shall be 450 mm.
c) The safety cage is required on ladders of more than 6 m to a maximum unbroken

length of 9m.
d) The safety cage to extend minimum 1050 mm above top of landing.
e) The safety cage to begin minimum 2100 m to maximum 2400 mm above base of
ladder (floor).
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f) The safety cage shall not extend less than 675 mm not more than 700mm from
the centreline of the rungs of the ladder. Cage shall not be less then 675 mm in
width.
g) The distance between hoop cages shall be max 850 mm.
h) The wall mounting brackets shall be spaced at max. 1800 mm.
i) Vertical bars shall be located at a maximum spacing of 40 degrees around

circumference of the cage; this will give a maximum spacing of approximately 138
mm centre to centre.
j) In certain locations, where safety is a major concern, the safety cage shall have a
fibreglass net manufactured by pultrusion process instead of vertical bars,
average thickened 3 mm, green or yellow colour, fixed on the GRP Cage hoops,
to provide extra safety for technicians.
k) When supported horizontally over a span on 1.0 meter with the climbing
uppermost and with a load of 1000N applied at the centre of the span , the ladder
shall:
(i) Not deflect more than 15mm at the point of application of the load.
(ii) Show no permanent deflection after removal of the load.
9.7.5 Submittals
a) Submit manufacture’s shop drawings of all fabricated ladder clearly showing

Material sizes, types, part or catalogue numbers, complete details for the
fabrication of components including, but not limited to, lengths, type and sizes of
fasteners, clip angles, members sizes and connection details.
b) Submit the manufactures published literature including structural design data,

corrosion resistance tables, test reports as applicable, raw material data sheet.
c) Submit sample ladder, safety cage of each item specified herein, manufactured
by the method used in the work and as quality and colour.
9.8 GRP PULTRUDED HANDRAILS
9.8.1 General
a) All finished surfaces of GRP handrail items and fabrications shall be resin rich,
free of voids and without dry spots, cracks, or un-reinforced areas. All fibreglass
shall be well covered with resin to protect against their exposure due to wear and
weathering.
b) All GRP products shall be mechanically secured fixing using SS316.
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Dubai Municipality
c) The submittal must be along with the relevant product catalogues / descriptive
and instructions on construction, handling.
d) Shop drawing shall be indicated with size, design load parameters, dimensions,
materials, clearance, tolerances, support details, etc…
9.8.2 Manufacturing Process
Pultruded fibreglass handrail is comprised of reinforcing fibres and resin. The fibre
reinforcement provides the structural stiffness, and the resin provides the resistance
to the environment, be it ultra-violet resistance, chemical resistance. Resins typically
contains fillers to assist in achieving an intended performance characteristic.
Reinforced fibres consist of continuous strand mat. Typical structural shapes contain
from 45% - 75% fibre reinforcement by weight.
Since pultrusion is a low pressure process, fibreglass reinforcement normally appear

close to the surface of the product. This can affect the corrosion resistance two layers
of surfaces veils must be added to the laminate construction, and when used,
displaces the reinforcement from the surface of the profile, creating a resin rich
surface.
Vinylester resin possesses excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly corrosive
environment.
9.8.3 Construction
a) The Handrail post/rail connection is to be fabricated such that the rail is unbroken
and continuous through the post without the use of packs and splices.
b) The bottom rail is to be installed through the post at a prepared hole made to fit
the outside dimensions of the rail.
c) The top rail is to fit into a machined “U” shaped pocket formed into top of the post
such that the rail is located at the centre of the post. All exposed corners are to be
chamfered and rounded to eliminate sharp edges.
d) The top rail and middle rail size is 44 x 44, the post size is 54 x 54 mm.
e) The rails are to be joined to the post through a combination of bonding and
riveting. No sharp protruding edges to remain after assembly of the handrails.
f) The handrail must have a vertical height of 1100mm from upper surface or as
shown in the Drawing.
g) The stair handrail must have a vertical height of 850 mm from the upper surface
of the top rail to the face of the riser at the forward edge of the tread.
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Dubai Municipality
h) Spacing of the posts should not exceed 1.5 m. For inclined handrail, the spacing
of the posts shall be maximum 1.2 m.
i) The middle rail must be approximately halfway between the top rail and the floor.
j) All Fasteners shapes used in handrail are to be SS 316.
k) Kicker plate shall be securely fastened in place with no more than 6.4 mm
clearance above the walking surface. Kicker plate size shall be 100mm, 3 mm
thick, W shape or M shape.
l) All shop fabricated cuts are to be coated with vinyl ester resin to provide
maximum corrosion resistance. Field cuts are to be similar coated in accordance
with manufacturer’s recommendations.
9.8.4 UV Protection
For outdoor exposure, the optimum method of maintaining surface appearance is to

apply a coating to the surface. UV stabilized Urethane coating must be applied to the
handrail in order to provide protection with minimal change in appearance.
9.8.5 Design / Standard
The complete handrail installation shall meet the following loads requirements of
OSHA standard, section 1910.23 with a safety factor of minimum 2. The handrail
system must withstand the following structural loads.
a) Concentrated load : 890 N applied in any direction at the top rail.
b) Uniform load of 75kg/m applied horizontally.
c) Concentrated and uniform loads shall not be applied simultaneously.
9.8.6 Submittals
a) Submit manufacturer’s shop drawings of all fabricated handrail clearly showing

Layout. Profiles and products components, including anchorage, accessories.
Include details showing plans, elevations, sections, details of components.
b) Submit the manufacturer’s published literature including Corrosion resistance

tables of resin, test reports as applicable, raw material data sheet of (vinylester
Resin, fire retardant additives, UV inhibitor additives, UV urethane coating,
Surface veil)
c) Submit sample handrail 0.5m each item specified herein, manufactured by the
method used in the work and as quality and colour.
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9.8.7 Mock -Up
Mock-up: install at project site a job mock up, assembled handrail 2.5 m long, using
manufacturer approved installation methods. Maintain mock-up during construction
for workmanship comparison.
9.8.8 Delivery, Storage & Handling
a) Ordering: Comply with manufacturer’s ordering instruction and led time

requirements to avoid construction delays.
b) Delivery: Deliver materials with identification labels intact.
c) Storage & Protection: store materials protected from exposure to harmful weather
conditions, at temperature and humidity conditions recommended by
manufacturer.
9.8.9 Project Conditions
a) Field Measurement: manufacturer to verify actual measurements and opening by

field measurement before fabrication; show recorded measurement on shop
drawings. Co-ordinate field measurements and fabrication schedule with
construction progress to avoid construction delays.
9.8.10 Fabrication
Fabricate handrails and railing systems to comply with requirements indicated for
design, dimensions, details, finish and member sizes.
a) Fabricated at supplier /Dealer’s workshop in UAE, and if practical preamble rail

sections prior to transporting to job site. Fabrication includes but not limited to,
cutting, routing and drilling components in accordance but not limited to, cutting,
routing and drilling components in accordance with engineering drawings.
b) Brackets, flanges, fittings and Anchors: Provide manufacturer’s standard

brackets, mounts and anchors for assembly and mounting of rail system.
9.8.11 Installation
a) Ensure mounting surface and substructure are structurally capable of supporting

railing system and application loads.
b) During installation, FRP components shall be carefully handled and stored to

avoid contact with abrasive surfaces.
c) Install handrail as indicated on the drawings provided.
d) List of Approved Supplier for Grating, handrail, Ladder:
(i) Leadertech, UAE
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Dubai Municipality
(ii) Top Glass, Italy
(iii) Strong well, USA
9.9 GLASS REINFORCED, HOT PRESSED, SMC (SHEET MOULDING COMPOUND)

POTABLE WATER TANK
This specification shall apply to the tanks assembled by the Hot pressed Sheet
Moulding Compound (SMC) panels, manufactured from fibre-glass reinforced
polyester compound, filler, unsaturated polyester resin, pressurised and moulded by
hydraulic process where used for
(i) Potable water storage
(ii) Treated Effluent water storage
(iii) Irrigation water storage
Applicable Standards: BSEN 13280, ASTM 3841
9.9.2 General
a) The Product manufacturer shall submit the relevant product

catalogues/descriptive literature stating manufacturing process, material, mill
certificates of accessories, and instructions on construction or erection manual,
handling, periodic inspection and maintenance.
b) The tank capacity shall be as shown in the approved drawing. The product
manufacturer’s Shop drawing shall indicate the capacity as given above, and the
tank type, design load parameters, dimensions, materials, fabrication details,
clearance, field jointing, tolerances, support details, integration of piping
components, anchorage, partition etc.
c) The panel specification sectional design according to tank size and application
flexibility shall be submitted for the approval of the Engineer. These panels shall
be non- toxic, hygienic for water storage and ultra violet protection against algae
growth.
d) The panel thickness to be designed based on (FEM) Finite Element Method study
with a safety factor 6times the actual hydrostatic water pressure according to
BSEN 13280 and the relevant design calculation shall be submitted for engineer’s
review.
e) Tank material shall be virgin reinforced fiber-glass mat ‘E’ type comply with BSEN
3691/BSEN 14118/BS 3396/BS 3749 standards, the mixed filler and unsaturated
polyester resin comply with BS 3532 Type-B & BSEN 14364/BSEN 1796.
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f) The tank shall be suitable for 100% humidity and > 50°C Water temperature,
corrosion proof, UV stabilized, non-toxic, non-staining, smooth inner surface &
algae resistant.
g) The colour of tank panels and components shall be light Grey, pigmented as such
to reduce the heat absorption. The process shall be hot press using SMC
material. Different process like RTM/cold press shall not be acceptable.
h) The SMC Panel structure shall be double skin with foam material heat insulation
type (25 mm Polyurethane, density 40 kgs/m3 with thermoplastic vacuum
moulded cover for top, side panels, and bottom).
i) The tank should be opaque to help reduce evaporation of disinfectant and inhibit
algae growth. Maximum measured light transmission value inside a closure cover
tank shall not exceed 0.05%.
j) Tank exterior frames, pipe fittings, fasteners, supports, etc shall protected against
weather conditions.
k) Interior strengthening reinforcing steel shall be with stainless steel pipe section
min dia 32 mm grade 444 (carbon content < 0.025).
l) Tank shall be erected above ground with General arrangements shown in the
approved drawing and a clear access of not less than 1m all around.
m) Flexible connectors shall be used to avoid stress & vibration transfer to the water
tanks.
n) Manufacturer’s instructions and guidelines concerning storage of tank parts and

accessories general site conditions of tank location, erection method, usage and
operation of the water tanks shall be strictly observed.
o) The water level indicator shall be as recommended by tank manufacturer.
p) Manufacturer’s representative certified and experienced bodies shall fix the tank.
q) The manufacturer must be a member of, or affiliated with quality control or

certification authority, relevant to GRP tanks & fittings proposed for incorporation
in the works. ISO 9001 certification is required for the tank manufacturer.
9.9.3 Construction
a) The tank body shall be configured to quadrilateral panel assembling type and
secure assemblage space and maintenance space around the tank. The Wall
Panel configuration shall be as follows: 1 x 1.5m and 1 x 2 m panels shall be used
at the top part, while 1x1 m panels shall be used at the lower part of the wall.
Example: 2.5m High tank: 1 x 1 (bottom) + 1 x 1.5 (top)
4.0m High tank: 1 x 1 (bottom), 2 nos + 1 x 2 (top)

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Dubai Municipality
b) External and internal reinforcing parts section shall be capable to withstand the
expected load such as water pressure, wind load, live load, etc.
c) Tank roof panel top supporting metal reinforcements shall be installed outside to
avoid the chlorine gas corrosion.
d) Internal / external Reinforcing parts: Internal Reinforcement shall be used at the

lower part of the tank (MATERIAL SUS 444, NO WELDING, SECTION PIPE DIA
32 MM MIN), while the upper part (Large panels 1.5 M, 2 M) must be externally
reinforced with top external stays, vertical external frame and bottom external
bracket due to the following reason: “Chlorine from disinfectant generates rust on
upper part of internal reinforcement material (SS) which are not under water, say
1.5 m section below the ceiling”.
e) Tank accessories, structural reinforcing / frames, fasteners and components shall

be as given in Table 9-9 & 9-10.
Table 9-9 GRP HOT PRESSED SECTIONAL (PANEL) WATER TANKS
Sr. Physical Characteristics Standard Values
1. Specific Gravity ASTM D 792 1.8
2. Tensile Strength (Longitudinal ASTM D 638;BS (1000 Kg/cm2 ±

Transversal) 2782; ASTM D 15%)
2841
3. Flexural Strength ASTM D 790; BS (1900 Kg/ cm2 ±

2782; ASTM D 15%)
3841; BS 5734
4. Impact Strength ASTM D 256;BS (59 kgf.cm/cm2)

2782; BS5734
5. Water Absorption ASTM D 570; BS Not greater than

EN 13280 0.10%
6. Glass Content ASTM D 2584; BS More than 30%

2782
7. Light Transmission < 0.05%
8. Coefficient Of Thermal Expansion ASTM D 696 1.7 x 105 /°C
9. Thermal Conductivity 0.15 kcal/m/hr/°C
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10. Barcol Hardness ASTM D 2583; BS >40

2782
11. Cavity Less than 1%
12. Toxicity BS 6920 Nil
13. Micro- Biological Growth BS 6920 Nil
14. Ultra –Violet Resistance Stabilised /

resistant
15. Opacity BS 2782 / BS EN 0.02

ISO 7686
Contents of the panel tank
Components Standard Items
Tank Panel Hot pressed SMC- grey colour
Material SMC Suitable for storing drinking water
Nuts, Bolts, Washers S/S grade 316L in contact with liquid

water
Sealant / Gasket PVC foam
External Reinforcement
Internal Reinforcement Structural steel hot dipped galvanised
S/S grade 444 angle stays, tie angles or

tie rods
External Ladder Stainless steel 316 grade L
Internal Ladder Stainless steel grade 444
Roof Support 75mm diamter Pipes S.S grade 444
Level Indicator (optional) Mechanical float switch/clear tube/or
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Dubai Municipality
painting
Steel Skid Hot dip galvanised & epoxy coated

structural steel channels
Finishing Smooth internal and external finish
Tie Rods S/S 316L rods diameter 12 mm
Resistance Water temperature upto 50 C
Properties of Insulation (Polyurethane)
Density 38 to 40 Kg/m3
Thermal Conductivity 0.018 to 0.020 kcal/m/hr/C
Closed cells 90 to 95 %
Operation Temperature + 80 C
Insulation Thickness 25 mm
Light transmission 0.00%
Table 9 –10 Panel Tank Accessories
Accessories / Fasteners Material Corrosion Protection
External
Base frame, Wall panel Structural Steel channel Hot dip galvanised and
joints, (Frames, Flanges sections epoxy & Polyurethane
bars, and Roof stays) coated.
External Ladder Stainless steel grade 316L -
Roof access Manholes, GRP , SMC Hinge :Stainless steel

Min. 900 mm dia, clear grade 316L
opening. Equipped with
locking device.
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Bolts, nuts, washers SS 316L -
Fittings Copper alloy / PVC Specified Coating &

Insulation
Ventilation hole, ABS Material with PE UV protection

Screen
Internal
Corner frames, stays, Tie Stainless Steel G 444 -

rods etc.
Roof support (pipe 75mm Stainless steel -

Ø)
Ladder Stainless steel G:444
Bolts, nuts, washers SS 316L -
a) The manufacturer / Supplier shall take necessary measures to satisfy the client
that water tank supplied for use within its domain meets the requirements
detailed. This shall be repeatedly done every five years or as and when called by
the owner during guarantee period.
b) Tanks shall be erected, tested and commissioned for use by the manufacturer/
Local Agent under the supervision of engineer’s representatives.
c) The manufacturer / local agent shall carry out periodic inspection of tank algae
growth and remedial measures.
d) Whenever composition or manufacturing process of particular component part is

changed or modified, the affected component part shall have to be tested in the
presence of Engineer.
e) All testing and inspection costs shall be borne by the contractor.
f) The GRP hot pressed water tank shall comply the requirements of British
Standard BS EN 13280/ ASTM D3841.
g) The tank operating atmospheric pressure shall be tested under ‘tank full’ condition
for water tightness and structural soundness. Water tank shall be subject to a
standing leak test for 24 hours, during which time all joints shall be carefully
examined. Noticed defects shall be rectified immediately and the test to be
repeated.
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h) In house QA/QC records: (mill certificate for SS 444 accessories and SMC) shall
be provided along with tank supply to the site.
i) Upon the completion of the erection, tank shall be cleaned and disinfected by the
contractor, as per the manufacturer’s guideline.
9.9.5 Inlet, Outlet & Over Flow Pipes
UPVC material (socket / flange type). Overflow pipe shall be placed in same level of
inlet pipe. Outlet pipes shall be kept level at least 10cm above the tank bottom.
9.9.6 Drain Pipe
Drainpipe shall be fixed at bottom most level of the tank.
9.9.7 Approval of Local / International Health Authorities
a) The tank manufactured shall be certified by International Authority to meet the

requirements of BS 6920 for products approved for potable water usage. The
following certificates to be provided for engineer’s review and approval.
(i) WRAS (UK) approval up to 50 C
(ii) FDA (USA) approval for SMC material
b) Potable water tank must comply with BS EN 13280 requirements. The following
test reports by Independent Authority is to be provided by the manufacturer for
Engineers review, during submittal stage:
(i) Permanent compressive strain test.
(ii) Sunlight transmission test
(iii) Physical properties test (tensile, Bending, Elastic modulus, Barcol hardness,
Water absorption)
(iv) Leakage test
(v) Deflection test
(vi) Metal toxicity test of Stainless steel in contact with water.
(vii) Test of Sealing gasket in accordance with Japanese Food Sanitation Law
(viii) Opacity Test to BSEN ISO 7686
(ix) Testing of GRP for use in contact with water intended for human
consumption.
c) A guarantee of fitness for storing, effluent water shall be obtained from concerned
local government agencies (Municipality & Town planning / Environment & Health
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Section), and a copy provided to the Engineer. Certificate should cover

accessories and component parts of the Water tank in question.
9.9.8 Guarantee Certificates
Manufacturer, importer or supplier of the water tank shall provide a certificate of

guarantee, against manufacturing and erection defects covering a period of minimum
ten (10) years from the date of erection. During the guarantee period, tank
component parts and accessories found deteriorated, defective shall be replaced by
the manufacturer at his cost.
FOLLOWING ENGINEERING CALCULATIONS TO BE SUBMITTED FOR

ENGINEER’S REVIEW AND APPROVAL:
 STRUCTURAL DESIGN
 HYDROSTATIC PRESSURE
 WIND LOADING
 SEISMIC LOADING
 MAINTENANCE ACCESS
LOADING
a) List of Approved Supplier
 LG HITANK - South Korea

 BALMORAL - UK
 AC PLASTIC - UK
9.9.9 GRP Baffles
a) Material
(i) Fibreglass reinforced polyester resin composite laminate shall exhibit the
following minimum properties:
Property Test Method Minimum Requirement
Impact Notched , Izod ASTM D 256 13.5 Nm
Heat Distortion ASTM D 384 79°C
Water Absorption after 24 ASTM D 570 Max 0.20%

hours
Tensile Strength ASTM D 638 62 MPa
Thermal Expansion ASTM D 696 10.5 x 10-6 mm/mm/°F
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Flexural Strength ASTM D 790 110 Mpa
Flexural Modulus ASTM D 790 6 Gpa
Barcol Hardness ASTM D 2583 40
(ii) “ECR” glass fiber and vinylester Epoxy resin shall be used in full laminate.
(iii) Perform hardness tests on the resin-rich surfaces of the test samples.
(iv) Prepare test coupons in accordance with appropriate ASTM test method.
(v) The manufacturer shall maintain a continious quality control program and
upon request shall furnish certified test results of the physical properties.
(vi) Laminate shall be 75 mm thick and shall contain a gel-coat on each surface
a minimum of 20 mils thick.
b) Components
(i) The Baffle System component shall be as shown in the Drawing.
1. Each segment shall be moulded using gel-coated exterior surfaces,

vinyl resin and fibreglass reinforcement (ECR “C” glass).
9.10 GLASS REINFORCED PLASTIC TANKS FOR CHEMICAL STORAGE
9.10.1 General
9.10.1.1 Scope of Work
Furnish all labour, materials, equipment, and incidentals required to install, field test,
complete and make ready for service vertical, flat bottom, seamless, fiberglass tanks
for chemical storage and make-up, as shown on the Drawings and as specified
herein.
9.10.1.2 Related Work
a) Field painting external as specified in protective coating schedule or pigmented

coating recommended by the manufacturer.
b) Chemical feed pumps are as shown in the drawing.
c) Instrumentation is as shown in the drawing.
d) Piping, valves and appurtenances and pipe hangers and supports are shown in
the drawings.
e) Process mixers are as shown in the drawing.
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f) The chemical compatibility of the liner internal proposed shall be based on the
process fluid storing inside.
g) The size and capacity of the tank shall be as shown in the drawing.
h) The geometry and supports of the tank shall be as shown in the drawing.
9.10.1.3 Submittals
a) Submit to the Engineer the shop drawings showing details of construction and
erection as follows:
(i) The type and category of tanks shall be related to the three categories given
in Table 2 of BS4994: 1987 to suit the various chemicals storing inside.
(ii) The chemicals storing inside the tanks are Ferric chloride, caustic &
Polymer.
(iii) Dimensions of tank, fittings and attachments.
(iv) Wall thickness (shell, head and base).
(v) Location of fittings, attachments and joints.
(vi) Width and thickness of joint overlays.
(vii) Resin used and complete description of chemical resistance for all materials
that will come in contact with material stored.
(viii) Weight of tanks and fittings.
(ix) Statement that fabrication is in accordance with these Specifications.
(x) Complete structural calculations for each tank, including all accessories and
tank supported appurtenances to be furnished by others.
(xi) Description of fabrication method.
(xii) Laminate samples.
(xiii) Description of hold-downs.
(xiv) Description of nozzles showing details of construction and attachment to

tank.
(xv) Instructions for handling, storage and installation of tanks.
(xvi) Installation list of tanks with similar applications.
b) Samples
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Representative laminate samples of both the filament wound cylindrical shell and the
heads shall be furnished. These samples shall be from plant production and shall be
representative of actual construction, workmanship, appearance and surface
hardness of tanks to be furnished. The Engineer may reject any tank which does not
meet the standard of the representative samples.
c) In the event that it is impossible to conform to certain details of the specifications

due to different manufacturing techniques, describe completely all non-
conforming aspects.
d) Drawings shall be approved by the Engineer prior to start of fabrication. Approval

of Drawings by the Engineer shall not release the Contractor of responsibility of
compliance with specifications. All proposed changes in specifications shall be
stated in writing. No fabrication may start prior to approval of proposed changes
by the Engineer.
e) Submit shop inspection and test records as specified herein.
9.10.1.4 Reference Standards
a) American Society for Testing and Materials (ASTM).
(i) ASTM D3299- Standard Specifications for Filament-Wound Glass-Fiber¬

Reinforced Thermo set Resin Chemical-Resistant Tanks.
(ii) BS 4994:1987 Design and construction of vessels and tanks in reinforced

plastics.
(iii) BS 476-7.
(iv) ASTM C 581
(v) ASTM C 582
(vi) ASTM D 4097
b) Occupational Safety and Health Administration (OSHA).
9.10.1.5 Quality Assurance
a) Tanks shall be constructed by a single manufacturer that has at least 10 years

prior experience in construction of fiberglass tanks for similar applications.
b) Should equipment which differs from these Specifications or as shown on the

Drawings be offered and determined equal to that specified and shown, such
equipment shall be acceptable only on the basis that any revisions to the design
and/or construction of the structure, piping, appurtenant equipment, etc., required
to accommodate such a substitution shall be made at no additional cost to the
client and be as approved by the Engineer.
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9.10.1.6 System Description
a) The tanks shall be constructed of fiberglass reinforced polyester with chemical

resistant backing layer internal and shall be vertical, cylindrical, flat bottom,
furnished with all accessories as specified herein.
b) Tank accessories and fittings shall be of the sizes and arrangement as detailed
on the Drawings.
9.10.1.7 Delivery, Storage and Handling
a) The Contractor shall require the manufacturer to assume responsibility for

packaging to prevent damage to the tanks during normal transit and handling.
b) Flange faces shall be protected from damage. All openings are to be securely
covered to prevent entrance of dirt, water and debris.
c) Tanks shall be mounted on skids or protective framework so constructed as to

provide for easy handling for fork truck or similar device and be provided with
lifting lugs, cleats, etc. to permit handling by crane, nozzles manholes, or other
fittings shall not be used for lifting.
d) Tanks shipped horizontally shall be supported by cradles supporting 120 degrees

of the tank circumference.
e) Instructions shall be provided for unloading and installation of the tanks.
9.10.2 Products
9.10.2.1 General
a) The use of manufacturer's name and model or catalogue number is for the
purpose of establishing the standard of quality and general configuration desired.
b) Like items of materials, equipment shall be the end products of one manufacturer
in order to provide standardization for appearance, operation, maintenance, spare
parts and manufacturer's service.
c) Hold-down devices shall be provided by the manufacturer.
9.10.2.2 Materials
a) Resins used for the tanks shall be a commercial-grade corrosion-resistant thermo

set, fully tested and acceptable for the service conditions. Resins shall not contain
fillers, pigments, dyes, or colourants. A chemotropic agent that does not interfere
with either visual inspection of laminate quality or with corrosion resistance of
laminate, may be used.
b) Clear ultraviolet absorbers shall be used in final resin coats.
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9.10.2.3 GRP Tanks
a) The GRP tanks shall be manufactured strictly in accordance with the specified
standards.
b) The GRP tanks shall be constructed using the filament winding process and shall
be capable of storing the chemicals specified above at service temperatures in
excess of 82°C. The manufacturer shall be responsible for the design and
structural integrity of the tanks. All glass reinforcement used shall be 'ECR' type
only.
c) The type of chemical barrier to be used shall be agreed between the

manufacturer and the Engineer prior to manufacture the tank where a thermo set
lining is used it shall be as specified in CL 7 & 8 of BS 4994: 1987.
d) All parts shall be designed and proportioned as to have lateral strength and
stiffness, to especially adapted for the work to be done. Ample room and facilities
shall be provided for access.
e) Tanks shall be non-insulated suitable for vertical installation in an enclosed

thermally controlled or outdoor environment as specified. Tanks shall be designed
so that no external bracing, ribs, hoops, or support wires are required. Top of tank
must be capable of supporting weight of maintenance personnel.
f) There shall be no vertical joints (in axial direction) in the cylindrical shell. The
entire thickness of the cylindrical shell (inner surface, interior layer and exterior
layer) shall be built up prior to removal of the shell from the mandrel.
g) The longitudinal strength of the cylindrical shell shall be at least 25 percent of the
hoop strength.
h) Regardless of the theoretical design requirements, the minimum total laminate

thickness of the filament wound tank shall NOT BE LESS THAN 10mm with
stiffeners external. The tank wall thickness shall be designed by the manufacturer
in accordance with BS 4994/ ASTM D 3299 and relevant calculations shall be
provided for engineer’s review.
i) Where a tank is intended to contain flammable fluids the external surface layers
shall be modified so as to have a surface spread of flame characteristic which at
least complies with class 1 requirements of BS 476-7.
j) The knuckle radius of the top and bottom heads shall be a minimum of 40-mm.
k) Heads may be fabricated integrally with the shell or may be fabricated separately.
Heads fabricated separately shall be moulded with an integral skirt. The minimum
skirt length shall be l00-mm. The entire head including knuckle radius and skirt
shall be fabricated in one piece.
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l) Tanks shall be completely fabricated in the shop. No field assembly is permitted.
m) All surfaces exposed to chemicals shall be resin rich with "c" glass and the
thickness of this inner most layer shall be a minimum of 0.5mm.
n) A backing layer of 2mm thick normally containing a minimum of 1.2 kg/sq.m

"CSM" between 25% - 33% glass content by mass with epoxy based vinyl ester
resin.
o) The heat distortion temperature of the fully cured resin system used for the GRP
laminate shall not be less than 20 degree C higher than the design temperature of
the tank when determined as described in BS 2782 method 121A.
p) The exterior layer of laminate shall consists two layers of "C" glass resin rich outer
liner and the minimum thickness shall be 1 mm.
q) The structural layers shall be with ECR glass and ISO resin and no sand filler
Shall be used. The laminate shall consist of Hoop glass, CSM, glass cloth &
woven roving as necessary. External ribs shall be used to meet the stiffness
requirements not less than 10,000 N/SQ.M.
r) No paints or pigmented, coloured or dyed resins shall be used on the outside

surface of the tank.
s) The tanks shall be made with machine made shaft liner.
t) Tanks specified herein to require interior baffles shall be sized and oriented within
the tank as recommended by the mixer manufacturer. Tank baffles shall be of
GRP attached to the tank walls by Gusseted Brackets, at the locations
recommended by the mixer manufacturer.
u) Accessories
(i) The fibreglass tanks shall be equipped with the accessories as shown on
the drawings.
(ii) Each tank shall have an identification label laminated to the exterior surface
which shall indicate manufacturers name, address, model number, and date
of manufacture, capacity, design temperature and the pressure operating
and vacuum.
v) Installation
The contractor shall install the tanks in accordance with the drawings and the
manufacturer's instructions.
w) Compliance
The manufacturer shall provide a compliance statement for the products supplied in
accordance with relevant standards given in 9.10.1.4.
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Test Requirements
(i) Degree of cure of the laminate by Barcol hardness in accordance with

ASTM D 2584.
(ii) Chemical resistance of the resin in accordance with ASTM C581
(iii) Wall thickness in accordance with ASTM D 3567.
(iv) The glass content of the inner liner and the interior layer combined in
accordance with STM D 2584.
(v) The surface spread of flame characteristic in accordance with BS 476-7. All
test result should comply with the relevant standard requirements.
x) Field Testing
After installation the tank shall be field tested by filling with water. The tank & fittings
shall hold water without loss, evidence of weeping or capillary action for a period of
24 hrs prior to acceptance.
y) Guarantee
The finished product shall be guaranteed for a minimum of 50 years design life.
z) Inspection
Should any defects become evident during inspection, testing or within the guarantee
period the contractor shall repair or replace the tank or fitting as approved by the
Engineer.
aa) Additional Labelling
All tanks shall be labelled with the name of relevant liquid content proposed,
operating and safety instructions and other warning if necessary.
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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 10
SAFETY PROCEDURES
DM/SRPD Section 10 Safety Procedures Rev 00 June
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DM/SRPD Section 10 Safety Procedures Rev 00 June Page i of ii
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SECTION 10
SAFETY PROCEDURES
CONTENTS
10 SAFETY PROCEDURES ................................................................................................... 1
10.1 GENERAL...................................................................................................................... 1
10.2 FAMILIARISATION WITH SAFETY PROBLEMS......................................................... 1
10.3 SAFETY OFFICER ........................................................................................................ 1
10.4 SAFE WORKING CONDITIONS AT THE SITE ............................................................ 2
10.5 SAFETY EQUIPMENT................................................................................................... 3
10.6 USE OF ROADS & HIGHWAYS ................................................................................... 4
10.7 SAFETY PROCEDURES............................................................................................... 5
10.7.1 General ................................................................................................................. 5
10.7.2 Atmosphere Monitoring ......................................................................................... 6
10.7.3 Atmosphere Ventilation ......................................................................................... 6
10.7.4 Safety Harness ..................................................................................................... 7
10.7.5 Emergency Breathing Apparatus .......................................................................... 7
10.7.6 Active Confined Space Entry ................................................................................ 7
10.7.7 Washing Facilities ................................................................................................. 7
10.7.8 Communication ..................................................................................................... 7
10.7.9 Lighting ................................................................................................................. 7
10.8 TRAFFIC CONTROL ..................................................................................................... 8
DM/SRPD Section 10 Safety Procedures Rev 00 June Page ii of ii
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10 SAFETY PROCEDURES
10.1 GENERAL
a) The Contractor shall be responsible for the safety of personnel and the public
during the contract period and compliance with safety requirements stated herein
shall not relieve the Contractor of his responsibility or liability under the Contract.
b) Prior to the commencement of the Works, the Contractor shall submit a safety
policy for the Contract detailing all proposed specific safety arrangements for the
agreement of the Engineer. This shall include but not be limited to the
requirements set out in this section.
c) If at any time safety requirements are not being met by the Contractor, the
Engineer shall have the right to instruct the Contractor on the necessary safety
provisions and the Contractor shall comply with such instructions forthwith.
d) The Contractor shall notify the Engineer immediately of any accident that occurs
whether on or off site in which the Contractor is directly involved which results in
any injury to any person whether directly concerned with the site or whether a
third party. Such initial notification may be verbal and shall be followed by a
written comprehensive report within 24 hours of the accident.
e) Particular problems of health and safety may arise with respect to microtunnelling
/ pipe jacking non-destructive methods of trenchless construction employed for
new pipeline construction or for pipeline replacement or manhole renovation. In
this respect the Contractor must ensure that adequate precautions and
satisfactory working practices are adopted in the execution of such Works to
protect the health and safety of all personnel engaged in executing the Works and
in their supervision.
10.2 FAMILIARISATION WITH SAFETY PROBLEMS
The Contractor shall make himself familiar with the condition of the site before
tendering in order to assess the nature of safety problems he is likely to encounter
and the safety requirements.
10.3 SAFETY OFFICER
a) The Contractor shall appoint a Safety Officer who shall be responsible for all
aspects of safety. He shall be conversant with and experienced in all general civil
engineering construction and sewer safety techniques and emergency
procedures, and shall be on site at all times operatives are working. He shall
enforce and supervise the safety procedures at all places of works and make sure
that adequate safety equipment, required under Clause 10.5, is available in good
working condition and at all places of works at the time works are on-going.
DM/SRPD Section 10 Safety Procedures Rev 00 June Page 1 of 8
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b) The Safety Officer shall also be responsible for organizing, implementing and
maintaining any road closures, traffic diversions, removal of parked cars causing
an obstruction, etc., in adequate time to ensure compliance with the Contract
programme.
10.4 SAFE WORKING CONDITIONS AT THE SITE
a) The Contractor shall provide Method Statements detailing proposed safe methods
of work with the Tender. The Contractor is specifically required to provide method
statements/risk assessments for the following activities, but not limited to;
(i) Work in Excavations including shoring, dewatering
(ii) Work in the vicinity of Underground Services
(iii) Use of Excavators & Micro-tunnelling Machines
(iv) Working in the vicinity of Overhead Services
(v) Working adjacent to active Roadways
(vi) Manual Handling
(vii) Use of Scaffolding
(viii) Demolition Work
(ix) Working with Sewage/Hazardous substances
(x) Pit Excavations
(xi) Borehole Drilling
(xii) Entry into Confined Spaces
(xiii) Working at Heights
b) The methods should generally follow the recommendations of the following

publications:
(i) Code of Construction Safety Practice as published by the Dubai

Municipality.
(ii) Administrative Order No. 330 in connection with Safety Manual of Dubai
Municipality.
(iii) Health and Safety Guideline No. 2, Safe Working in Sewers and at Sewage
Works as published in the United Kingdom.
c) Accident procedures and emergency procedures shall be fully detailed.
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d) No persons shall be allowed to enter a confined space until the safe methods of
work have been agreed upon and fully implemented to the satisfaction of the
Engineer.
10.5 SAFETY EQUIPMENT
a) The Contractor shall make sure, prior to commencement of works on site that
adequate safety equipment, apparatus and devices are available, and that as a
minimum the following equipment and devices are available at each entry point to
a confined space:
Sr. Type of equipment No. required
1 Safety harness and ropes 2
2 Lifting frame and tackle for safety harness 1
3 Gas detector (suitable for H2S) 2
4 Approved mechanical air blower and power supply 1
5 Emergency breathing apparatus 2
6 Atmosphere monitoring device, capable of monitoring
oxygen levels, and levels of toxic and flammable gas 1
7 Washing facilities with disinfectants, toiletries As required
8 Communication facilities As required
9 Lighting (explosion proof) As required
10 Fire Extinguishers As required
b) All personnel working on, visiting or inspecting any part of the Works shall be
provided with and be required to wear appropriate protective clothing or
apparatus. This may include:-
(i) Safety helmets, coats, gloves, footwear, goggles, ear muffs, breathing
apparatus and any other protective apparel or any other equipment deemed
necessary by the Engineer.
(ii) Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle,
used in the Works shall be thoroughly examined by a competent person at
least once every 6 months and shall be test loaded to 150% of the safe
working load and shall then be tagged with the safe working load and the
date of successful testing by an authorised testing authority.
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c) All parts and working gear whether fixed or movable, including the anchoring and
fixing appliances of every crane and lifting machine shall be of good construction,
sound material, and adequate strength and shall be properly maintained. All
parts and gear shall be examined at least once every twelve months.
d) A register of all such equipment and examinations shall be kept up to date by the
Contractor and be available for inspection by the Engineer.
10.6 USE OF ROADS & HIGHWAYS
a) The Contractor shall provide a Traffic Control Plan and give four weeks notice in
writing to the Employer of his intention to commence Works on any public road
(which shall include unmade rights of way) or highway.
b) The closure of public roads or highways will not be permitted without the written
permission of Dubai Municipality, the Dubai Traffic Police, Roads and Transport
Authority (RTA) any other relevant Authority and the Employer.
c) The Contractor shall submit five no. copies of his proposals for diverting traffic,
indicating positions of all signs, cones, lights and anything else which may be
necessary. The Contractor shall comply with any specifications for traffic
diversion, including surfacing requirements, safety and control laid down by the
Authorities and shall be responsible for continuous maintenance. Where a
temporary diversion of the public road or highway is approved which will be
utilized by public traffic then the route shall have an asphalt surface.
d) No Works will be permitted on a public highway verge, central reservation or

garden without the signed approval of the respective Authorities copies of which
must be handed to the Employer before such Works commence.
e) The Contractor's Works shall be arranged so that use of the roads or highways
affected by the Works shall be restored to the public with the minimum of delay.
Laying of the pipelines, backfilling, testing of the pipelines, temporary
reinstatement and clearance of the Site shall follow closely behind excavation
and, unless written permission is obtained, the Contractor shall not occupy more
than a 100 meters length of highway at any one location at any time.
f) The Work shall be carried out in such a manner as to cause minimum

interference with the public use of highways, footpaths and other thoroughfares,
and only such Plant, Materials, tools, etc., as from time to time required for
immediate use, shall be deposited thereon. Storage depots, offices, etc., shall be
sited elsewhere.
g) The Contractor shall maintain those parts of the roads or highways, etc., not
temporarily occupied by the Works in a clean, passable and safe state.
h) Suitable temporary roads shall be provided by the Contractor to allow access to

all Sections of the Works at all times. Suitable precautions will be taken to prevent
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misuse of site roads by the general public. The Contractor shall be responsible for
reinstating these areas to their original condition after completion of the Works.
10.7 SAFETY PROCEDURES
10.7.1 General
a) All excavation shall be adequately supported against collapse and provided with
protective safety barriers and appropriate warning signs and bunting.
b) Suitable and sufficient scaffolds shall be provided and properly maintained for all
work that cannot safely be carried out from the ground or from part of the
structure or from a ladder. Every scaffold shall be of good construction, of
suitable and sound material and of adequate strength for the purpose for which it
is used. Unless designed as an independent structure, every scaffold shall be
rigidly connected to a part of the structure which is of sufficient strength to afford
safe support. Protective headgear shall always be worn.
c) All manufacturer’s instructions and recommendations for the use, application,

erection or construction of any material or item of equipment or plant shall be
followed precisely.
d) Special care shall be taken to protect all employees when using power tools or
materials which will produce a fine dust and in particular all asbestos based
products. The operator should stand upwind of the operation and wear an
approved respirator and goggles. Wherever possible overalls should be worn and
should consist of 60% polyester fibre and 40% cotton.
e) Transportation of any material by the Contractor shall be in suitable vehicles

which when loaded does not cause spillage and all loads shall be suitably
secured. The Engineer shall have the right to instruct the withdrawal from the site
of any vehicle which does not comply with these requirements or any of the Dubai
or UAE traffic regulations and laws.
f) The Contractor shall adopt the safety procedures as proposed by him as per
Clause 10.4 for entry into a manhole or other confined space. However, the
following safety procedures are outlined as a guide only. The Contractor shall,
where appropriate, use these procedures in addition to his proposed procedures
while entering into a manhole or a confined space. Also included is additional
information on safety procedures for manhole entry in Appendix 3 contained in
these Specifications for his guidance and use where appropriate.
g) It shall be explicitly understood that safety is the responsibility of the Contractor

and use of any of these procedures as outlined under this clause or in Appendix 3
shall not relieve him of any of his contractual responsibilities.
h) The manhole or confined space shall be thoroughly vented by mechanical air

blower prior to entry.
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i) A full gas check is to be undertaken prior to entry. If the level of toxic or explosive
gases is above the safe level (maximum acceptable for hydrogen sulphide is 10
ppm) or the level of oxygen is below a safe level (18%) then entry is not permitted
without the use of full breathing apparatus.
j) All persons entering a manhole or a confined space shall wear a safety harness
properly rigged to the lifting frame.
k) The mechanical air blower shall be kept close by the manhole or confined space
which has been entered.
l) The hydrogen sulphide level in the manhole or confined space shall be

continuously monitored. If the level rises above 10 ppm then the manhole or
confined space shall be evacuated immediately.
m) At least two people shall be available close to the point of entry to operate the air
blower and lifting tackle in the event of an emergency and who shall note the
location of the nearest telephone in working order and the telephone number of
the nearest hospital before entry is permitted.
n) No smoking shall be permitted and ‘no spark’ tools shall be used.
10.7.2 Atmosphere Monitoring
a) When any person is in a confined space, the atmosphere at the work place and at
the base of the access manhole or pit shall be continuously monitored by a
Monitoring Device to detect oxygen deficiency, flammable gas and toxic gases.
The monitoring equipment shall be designed to be lowered into the work place or
access manhole and shall not depend on a sample draw tube from the surface.
The monitoring equipment shall be the first piece of equipment to be lowered into
the place of work and shall be the last piece of equipment removed.
b) The Contractor shall provide, maintain and calibrate the approved monitoring
equipment in accordance with the manufacturer's instructions. The Contractor
shall provide adequate numbers of monitoring devices to fully cover all proposed
work places and open manholes or access pits with adequate spare devices,
parts and batteries as needed to ensure complete monitoring of all sites of work
at all times throughout the construction period. No entry into a confined space
shall be allowed until the monitoring devices have been properly placed at the
work place or access site and the readings indicate that the atmosphere is safe.
Operatives are to be fully trained in the use of the monitoring equipment and in
the necessary response to alarm conditions.
10.7.3 Atmosphere Ventilation
Before any person is allowed to enter a confined space, the atmosphere shall be
adequately ventilated. As a minimum, both ends of the sewer section or work place
shall be opened to the atmosphere either by removing the manhole covers or through
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open access pits. Positive ventilation shall be provided at all times when a person is
in a confined space, even if the atmosphere monitoring equipment indicates that the
atmosphere is safe for access.
10.7.4 Safety Harness
Each person entering a confined space shall wear a harness at all times. The
harness shall be designed such that it will enable an unconscious person to be lifted
to the surface in a vertical posture.
10.7.5 Emergency Breathing Apparatus
Each person in a confined space shall have emergency breathing apparatus available
and ready for use within the confined space. The breathing apparatus shall have a
minimum capacity of 2 litres and a working pressure of 200 bar and shall be tested
daily, prior to starting work.
10.7.6 Active Confined Space Entry
Before any person is allowed to enter a confined space that is in active service, the
Contractor shall ascertain the schedule of sewage flows which can be anticipated
over the duration of the work. This shall include average and peak gravity sewage
flows and the discharge flows from all upstream pumping stations. Should the
combined gravity and pumped flows exceed safe working conditions at the work
place, then the Contractor shall prepare a plan for the control and diversion of flows
around or away from the work place. The method of flow diversion shall be as
approved by the Engineer and by the Dubai Municipality. A "permit to work" system
shall be employed for work on sewers where incoming flows (from pumping or
diversion) are controlled by people remote from the work site.
10.7.7 Washing Facilities
Every work place where persons are entering a confined space shall be provided with
facilities for washing.
10.7.8 Communication
The Contractor shall provide a means of communication, appropriate to the safe

system of work, between ground level and any work place within the confined space.
10.7.9 Lighting
When permanent works are being constructed or inspected, the confined space shall
be adequately lit. The lighting apparatus shall operate at a voltage not exceeding 50
Volts. The circuit shall be protected against overload. No transformers, switches,
fuses, contact breakers, etc., shall be taken into the confined space. Bulbs shall be
protected against damage.
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10.8 TRAFFIC CONTROL
a) Prior to initiating any work at a site, the Contractor shall prepare, for the approval
of the Engineer, a plan for the diversion and control of traffic around the work site.
The approved traffic control plan shall be submitted to Roads & Transport
Authority and Dubai Traffic Police for review. Work at the Site may not commence
until the traffic control plan has been approved by the Roads & Transport
Authority and Dubai Traffic Police.
b) The traffic control plan shall include a street plan of the work site showing all
traffic lanes and building access drives that will be affected by the work. The
proposed system of traffic diversions and the manner of control shall be clearly
illustrated, including the location and types of traffic cones, warning signs and
warning lights to be used. The plan should indicate the anticipated schedule of
works for which traffic must be diverted. Road diversions and road signs shall
conform to Clause 1.3.5 and to Appendix 1 contained in the Specifications.
c) The traffic control plan shall take into consideration the requirements of the work
crew for access to the work site, for positioning and parking of vehicles needed
for the work and for the temporary storage of equipment and materials.
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 11
PIPELINES RENOVATION, REPLACEMENT AND

ABANDONMENT
DM/SRPD Section 11 Pipelines Renovation, Replacement and Rev 00 June

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DM/SRPD Section 11 Pipelines Renovation, Replacement and Rev 00 June Page i of iii
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SECTION 11
PIPELINES RENOVATION, REPLACEMENT AND
ABANDONMENT
CONTENTS
11 PIPELINES RENOVATION, REPLACEMENT AND ABANDONMENT ............................ 1
11.1 GENERAL...................................................................................................................... 1
11.1.1 Renovation, Replacement and Abandonment Works ........................................... 1
11.1.2 Use of Approved Specialist Firms / Sub-Contractors ........................................... 2
11.1.3 Health and Safety ................................................................................................. 2
11.1.4 Materials ............................................................................................................... 2
11.1.5 Diversion of Sewage Flows .................................................................................. 6
11.1.6 Flow Control .......................................................................................................... 6
11.1.7 Maintaining Clean Conditions ............................................................................... 7
11.1.8 Sewer Pre-Renovation Surveys ............................................................................ 7
11.1.9 Cleaning of Sewers ............................................................................................... 8
11.1.10 Traffic Control and Diversion ................................................................................ 8
11.1.11 Manhole Connections ........................................................................................... 8
11.1.12 House Connections .............................................................................................. 8
11.2 PIPELINE RENOVATION - SLIPLINING ...................................................................... 9

11.2.1 General ................................................................................................................. 9
11.2.2 Slip-Lining Execution ............................................................................................ 9
11.2.3 Grouting .............................................................................................................. 10
11.3 PIPELINE RENOVATION - DEFORMED PIPE LINING .............................................. 11

11.3.1 General ............................................................................................................... 11
11.3.2 Materials - HDPE or HPPE Pipe ......................................................................... 12
11.3.3 Further Site work Preparation ............................................................................. 12
11.3.4 Pipeline Obstructions .......................................................................................... 13
11.3.5 Sewer Lining Execution ...................................................................................... 13
11.3.6 Guarantee ........................................................................................................... 15
11.3.7 Finishing to Manholes ......................................................................................... 15
11.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING ....................................... 15

11.4.1 General ............................................................................................................... 15
11.4.2 Materials ............................................................................................................. 16
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11.4.3 Inversion Type Resin System ............................................................................. 17

11.4.4 Tests ................................................................................................................... 17
11.4.5 Soft Lining Design ............................................................................................... 18
11.4.6 Sewer Lining Execution ...................................................................................... 19
11.4.7 Guarantee ........................................................................................................... 21
11.5 PIPELINE REPLACEMENT - PIPE BURSTING ......................................................... 22

11.5.1 General ............................................................................................................... 22
11.5.2 Pipe Bursting - Execution ................................................................................... 23
11.5.4 Obstructions ........................................................................................................ 25
11.6 PIPELINE ABANDONMENT ....................................................................................... 25

11.6.1 General ............................................................................................................... 25
11.6.2 Grout and Grouting for Abandoned Pipeline ....................................................... 25
11.7 SEWER CLEANING AND CCTV SURVEY ................................................................. 25

11.7.1 General ............................................................................................................... 25
11.7.2 Sewer Cleaning .................................................................................................. 26
11.7.3 Survey and Operational Equipment .................................................................... 27
11.7.4 Performance of Survey ....................................................................................... 28
11.7.5 Survey Data Reporting ....................................................................................... 30
11.7.6 Drawings ............................................................................................................. 31
11.7.7 Metric Measurement ........................................................................................... 31
11.7.8 Photographs ....................................................................................................... 31
11.7.9 Equipment Standards ......................................................................................... 32
11.7.10 Quality Control .................................................................................................... 33
DM/SRPD Section 11 Pipelines Renovation, Replacement and Rev 00 June Page iii of iii
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11 PIPELINES RENOVATION, REPLACEMENT AND ABANDONMENT
11.1 GENERAL
11.1.1 Renovation, Replacement and Abandonment Works
The Contractor shall provide the labour, material and equipment and perform the
work necessary to renovate, replace or abandon the sewers indicated on the Contract
Drawings and as directed by the Engineer.
Where downsizing has been indicated the renovation of existing sewers or rising
mains shall be undertaken using slip-lining technology. Alternatively subject to the
approval of the Engineer and prior to mobilization to the works site, renovation of the
pipeline may be by using either a deformed pipe lining system or an inversion type
soft lining system.
Where up-sizing or replacement has been indicated the existing pipeline may be
replaced using conventional open cut methods or where such methods are
unacceptable or impractical, a non-disruptive method using pipe bursting techniques
shall be adopted.
All renovation or replacement operations shall be conducted from within existing

manholes without long lead in trenches unless otherwise approved by the Engineer.
The selection of insertion and reception locations shall be such as to minimize
disruption of normal traffic and inconvenience to the public.
Design calculations and method statement for each method proposed shall be
submitted to the Engineer at least 35 days prior to the intended date of
commencement of the work on site.
The Contractor shall inspect each location for proposed pipeline renovation to confirm
or determine the following:
1) The length and size of pipeline to be renovated.
2) The access available to the pipeline at either manholes or chambers.
3) The location of existing services together with any additional services not shown
on the drawings.
4) The number of house connections to the pipeline and their location.
Where there is infiltration of groundwater at pipe joints, cracks and other defects, the
infiltration shall be sealed off prior to the installation of any lining. The materials and
method of sealing shall be submitted to the Engineer for approval.
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11.1.2 Use of Approved Specialist Firms / Sub-Contractors
The Contractor shall engage specialist Firms / Sub-Contractors to carry out / execute
each of the specialized category of works such as:
a) Pipeline Renovation - Slip lining, deformed pipe lining, and soft lining.
b) Pipeline Replacement - Pipe bursting
All specialist Firms/Sub-Contractors are subject to approval for each aspect of work
on this project in the field of their respective specialization. Only those companies that
can demonstrate successful experience on projects similar to that required for this
work (scope, size, conditions, and program) shall be proposed by the Contractor for
consideration and approval. Companies proposed for approval shall demonstrate the
necessary registration as a contractor licensed to work in Dubai either directly or
through a legal association with a registered contractor.
11.1.3 Health and Safety
The contractor shall provide and agree with the Engineer a written statement detailing
safe systems of work (see clause 10.4 & 10.7 ‘Safety Procedures’ of the General
Specification).
The Contractor shall provide and maintain on site suitable and sufficient safety
equipment and the necessary personnel trained in its use, for the safety and
protection of employees, the general public and systems and property of Dubai
Municipality.
The Contractor is responsible for the safety of all personnel as well as for the safety
of the public during the performance of the work and is responsible for maintaining
safe conditions in and around the work area. This is specified in more detail in
Section 10.
11.1.4 Materials
11.1.4.1 Polyethylene and uPVC Pipe
a) General
uPVC sewer lining pipe shall comply with the provisions of clause 4.3.1 of this
specification.
Polyethylene (HDPE or HPPE) sewer lining pipe shall comply with the relevant
provisions of Clause 4.3.2 of this specification.
Short length sections shall be used for slip lining and pipe bursting technique
between manholes where no long lead in trenches is permitted.

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The short sections shall be of such a length as to enable insertion from within the
smallest diameter manhole in the applicable sections of the sewerage system.
Winching forces on PE and uPVC pipes during jointing and installation processes
shall be restricted so as not to exceed the maximum permissible short term tensile
stress specified by the pipe manufacturer at the appropriate temperature.
b) Storage, Handling and Transport
uPVC, HDPE or HPPE pipe shall be stored, handled and transported generally as
specified in clause 4.5.3 & 4.5.5 for Thermoplastic / HDPE pipes .
Black polyethylene pipe may be stored either under cover or in the open. Natural
polyethylene pipe, however, shall be stored under cover and protected from direct
sunlight.
Straight lengths shall be stored on horizontal racks giving continuous support to

prevent the pipe taking on a permanent set.
If, due to unsatisfactory storage or handling, a pipe is damaged or kinked, the

damaged portion shall be cut out completely
Transport vehicles shall be provided with a flat bed free from nails or other projections
which might cause damage to the pipe by abrasion.
All lining pipes shall be inspected before being taken into store and again before
being taken underground for infiltration.
c) Jointing
Short section pipes shall be capable of jointing by fusion welding techniques or,
alternatively, by mechanical type joints including screw type joints or snap on locking
connectors. Details of jointing systems shall be provided to the Engineer prior to
procurement of the pipe.
Linings shall be cut using methods approved by the Engineer. Precautions shall be
taken to avoid delaminating or spalling.
Jointing - Butt Fusion Welding
The Contractor shall supply the Engineer with the pipe manufacturers welding
instructions.
Welding shall be undertaken in clean conditions and an appropriate cover shall be

provided to prevent rain or airborne particles from contaminating the pipe faces
prepared for welding. If necessary, the pipe ends shall be plugged or covered to
prevent internal cooling. Only electric heating plates shall be used for butt fusion
welding.
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Pipe jointing shall conform to the pipe manufacturers recommended procedures. The
weld bead is to be checked to ensure that it is uniform in shape, smooth in
appearance and bead width conform to the manufacturers allowable limits. The bead
height shall not be greater than half the bead width.
Any unacceptable weld, and at least 250mm length of pipe on either side of that weld,
shall be cut off and discarded.
Internal and external weld beads shall be removed to a minimum protrusion of 1mm
from the pipe wall after the outside of the joint has cooled to 35°C or below.
Welds shall be sampled, as directed by the Engineer, and shall meet the
requirements of PE tensile weld test.
Jointing - Mechanical Type
The Contractor shall use either Snap Lock, Clear line or other approved mechanical
joint system and shall satisfy himself that loads applied during the slip lining operation
are within the accepted limits for the joint as provided by the manufacturer. The joint
shall be capable of withstanding the grouting pressure or the standard pipeline water
or air test, whichever is greater.
The Contractor shall provide calculations of the loads expected during installation and
during service and the manufacturers recommended allowable loads to the Engineer
prior to purchase of the pipe.
11.1.4.2 Annulus Grout
a) General
Cement for annulus grout mixes shall be sulphate resisting Portland cement
complying with the provisions of BS 4027. The use of pfa with sulphate resisting
cement shall not be permitted.
Sand for annulus grout mixes shall meet the relevant requirements of BS 882 or BS
1200.
Admixtures for annulus grout mixes shall meet the relevant requirements of BS 5075,
but shall not be used without the written approval of the Engineer.
Any admixture shall be measured using a proprietary dispenser and shall be mixed
with the full amount of water required for each batch and the combined water /
admixture mixed with the dry constituents.
Admixtures shall be stored and used strictly in accordance with the manufacturer’s
instructions.
Mixing water for annulus grout mixes shall be of potable quality.
Full details of the proposed grout mix shall be submitted to the Engineer for approval.
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Trial mixes of the grout type proposed shall be undertaken to establish the properties
of the grout. The following properties shall be determined and the results shall form
the control values for quality control purposes.
1) Density using the Baroid Mud Balance or similar approved equipment.
2) Workability using either the Concrete Flow Trough or the Marsh Cone with 10mm
orifice.
3) Compressive strength. Grout cubes shall be prepared and tested as follows :-
Cube moulds shall be 100mm or 70.7mm with all joints sealed to prevent leakage.
Moulds shall be overfilled and air bubbles removed by lightly tapping the mould. After
leaving for 30-60 minutes, the excess grout shall be struck off and the moulds
covered with plastic sheeting. Moulds shall be stored at 20°C± 5°C for 24 hours or
until the grout has attained sufficient strength to allow the cube to be stripped from
the mould whichever is the greater.
The cubes shall be removed from the moulds, marked and stored in water at a
temperature of 20° C± 1°C until tested. The Contractor shall test the grout cubes at
28 days after casting. Grout cubes shall have a minimum compressive strength of
3N/mm2
4) Bleeding. The amount of bleed water shall be determined by filling a 100mm

diameter container to a depth of 100mm with grout, covering to avoid evaporation and
removing the bleed water after 3 hours. The amount of bleed water shall be
expressed as the percentage ratio of the volume of bleed water to the original grout
sample volume.
5) The percentage by volume of bleed water after 3 hours shall not exceed 5
percent (5%).
b) Grouting
Grout shall be injected from the downstream end of the renovated sewer.
A minimum of two air vents shall be provided. Vent holes shall be plugged when all
air, water and contaminated or watery grout has been released. The pressure shall
be continuously monitored by a suitable gauge fitted at the injection nozzle. The
injection pressure shall not exceed 50kN/m2. The gauge shall have a full-scale
reading of not more than 200 kN/m2.
Means of immediate communication between the nozzle operator and the pump
operator shall be maintained during the grouting and a means of rapidly stopping the
grout flow shall be provided.

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The quantity of grout injected at each injection point and the maximum pressure at
the nozzle at each injection point shall be recorded and the records made available to
the Engineer.
The grout shall be mixed in the proportions specified in Clause 3.2.8 for Class G3
cement grout.
The dry constituents shall be thoroughly mixed using the minimum quantity of water
to ensure the necessary fluidity and to render it capable of penetrating the work. All
grout is to be used within one hour of mixing.
Sulphate resisting cement shall not be used as a constituent of grouts containing pfa
Immediately after each grouting operation, the Contractor shall inspect the pipeline
and clean out any excess grout. All excess grout shall be disposed of in a manner
acceptable to the Engineer such that it does not contaminate any sewer or
watercourse.
Unacceptable grout and any grout wash water shall be disposed of by the Contractor
in a manner acceptable to the Engineer such that it shall not contaminate any sewer
or watercourse.
The Contractor shall make three (3) grout cubes from samples taken from every 5m3
of grout or after every 50 meters of grouted pipe, whichever is the smaller, as detailed
in the previous section.
The density and workability of every batch shall be determined. The density shall not
differ by more than 5 percent from the specified density. The workability shall not
differ by more than 125mm or 5 seconds (through or Cone test respectively) from the
specified workability.
11.1.5 Diversion of Sewage Flows
The Contractor shall provide the equipment, materials and labour necessary to divert
flows around the work site during the lining operation. The pipe section to be lined
shall be isolated from sewage flow by plugging or blocking the line in the upstream
and downstream manholes.
The flow diversion system shall be designed and installed in such a manner as to
minimize disruption of traffic and inconvenience to the public. The Contractor shall
submit his proposed diversion details to the Engineer for approval prior to mobilizing
onto the site.
11.1.6 Flow Control
The Contractor shall use flow control methods and procedures as required to ensure
the safety or personnel and to facilitate completion of the work. Control measures
shall include plugging or blocking of the sewage flow or bypass pumping where

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appropriate. The Contractor shall provide, operate and maintain all equipment
needed to properly control flows during the work.
Where the flow is to be blocked or plugged temporarily, the equipment shall remain in
place until the work has been completed and inspected. It is to be removed in such a
manner that permits sewage flow to gradually return to normal without surge,
surcharging or causing other disturbances downstream.
The Contractor shall provide, operate and maintain a bypass system to conduct
sewer flows around the work area when flow cannot be controlled by blocking or
plugging or when it is necessary to maintain system sewer flow around the work area.
The bypass system is to be of sufficient capacity to handle existing normal sewer

flows plus any additional flow, which may occur during a rain event should the work
take place during the rainy season.
Flow control and bypassing methods and procedures must result in minimum
inconvenience and disturbances to the public, and prevent damage to public and
private property due to flooding, surge or excessive surcharging.
11.1.7 Maintaining Clean Conditions
As noted elsewhere in this Section, the Contractor shall maintain clear conditions in
and around the work area at all times. All material removed from the manholes shall
be taken from the site immediately and disposed of in a safe and approved manner.
Removed material and debris shall not be stored at the work area. The manner and
location of disposal of material shall be approved by the Engineer and employer prior
to the commencement of work.
Construction material and equipment shall be brought to the work area only as
needed and shall be stored on site in a safe and proper manner. The Contractors
equipment and material at the work site shall result in minimum inconvenience and
disturbance to the public.
During the performance of the work, the Contractor shall ensure that no removed
materials or debris, nor any construction material or equipment is permitted to enter
the sewerage system. The Contractor shall provide suitable screening and other
means of trapping and blocking as required in the downstream manhole to prevent
material from passing downstream.
The screened, trapped or blocked material shall be promptly removed from the
manholes by suitable means, placed in suitable containers, removed from the site
and disposed of properly.
11.1.8 Sewer Pre-Renovation Surveys
The existing sewer shall be CCTV surveyed prior to any renovation or repair work.
Refer to Section 11.7 for CCTV survey requirements.
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11.1.9 Cleaning of Sewers
All deposits of debris that are likely to jeopardize the performance of the lining
operation or of the finished pipe lining shall be removed. This may include, but not be
limited to sand, grease accumulations, construction rubble and other debris in the
sewers as well as root and other hard protrusions. Cleaning shall be carried out by
approved methods.
All debris removed from the sewer shall be disposed of in a safe manner. The method
and location of disposal shall be submitted to the Engineer for approval prior to
beginning cleaning operations. The Contractor shall take all precautions to prevent
debris from being carried downstream of the work place. Refer to Section 11.7 for
Sewer Cleaning Requirements
11.1.10 Traffic Control and Diversion
The Contractor shall submit his plans for the diversions of traffic around the site of the
work to the Dubai Municipality and the Dubai Traffic Police for approval prior to
mobilizing on site. The Contractor shall provide all traffic barricades, lights, signs and
all other equipment or personnel necessary to control traffic safely around the work
site. For road-diversions and road-signs refer to Appendix 1 and Appendix 4, Part 3 of
3 of the Specifications.
11.1.11 Manhole Connections
Where a renovated or replacement sewer connects to a manhole the channels and

benching shall be modified in accordance with Section 12.2 ‘Manhole Renovation to
suit the new pipe sizes and / or arrangements.
The design and installation shall be such as to ensure that groundwater is not
permitted to enter the sewer or manhole.
Compatibility between materials for sewer renovation or replacement works and

manhole materials shall be ensured.
11.1.12 House Connections
House connection work including the re-routing of existing house connections is not
All house connection work shall be designed by the Contractor and approved by the
Engineer. This design work shall include a full survey and investigation for each
individual house connection together with drawings and calculations for submission to
the engineer for approval.
House connections to existing manholes that will be abandoned shall be re-routed to

the most suitable alternative new or existing manholes.

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Where the main sewers to be renovated or replaced have house connections directly
connected to the sewer by a “Y” connection, the existing house connections shall be
abandoned and replace with new house connections and transition chambers, if
necessary. The new house connections shall be constructed connecting to the
nearest existing manhole or house connection chamber. House connections and
chambers shall conform in shape, size, dimensions, materials and other aspects to
the details indicated on the Contract Drawings or as ordered by the Engineer.
House connection works shall be carried out in accordance with Section 4 of the
Specification.
11.2 PIPELINE RENOVATION - SLIPLINING
11.2.1 General
The renovation of existing sewers or rising mains where down-sizing has been
indicated shall be undertaken using slip-lining technology, The slip-lining pipe is to be
manufactured from unplasticised polyvinyl chloride (uPVC), high density polyethylene
(HDPE) or high performance polyethylene (HPPE). The annular space between the
existing pipe and the new slip-lined pipe shall be filled with grout.
The slip lining work shall include, but not be limited to the following operations.
1) Initial sewer cleaning prior to CCTV Survey
2) Initial CCTV survey and logging
3) Submission by Contractor to Engineer of proposed slip lining method based on

the initial CCTV survey and minimum disruption.
4) Full sewer cleaning prior to slip lining.
5) Slip lining
6) Grouting
7) Manhole Refurbishment as per clause 11.1.11
8) Testing of slip lined pipe
9) Temporary blocking off and over pumping and diverting of all contributing flow as
required during operations (1) through (8) above.
10) proving pig down the length to be relined to confirm the minimum annulus size.
11.2.2 Slip-Lining Execution
Slip-lining shall use uPVC, HDPE or HPPE pipe lining.
Immediately prior to installation of the pipe lining, the Contractor shall pass a proving
pig down the length to be relined to confirm the minimum annulus size.
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The proving pig shall have solid ends of sufficient rigidity and length to be
representative of the proposed lining system.
The pipe lining shall be installed by winching (or other approved method) the
assembled pipe through the existing sewer. Details of the proposed method of
winching must be submitted to the Engineer for approval at least seven (7) days
before the proposed insertion date.
The joints shall be watertight during winching of the pipes and in their final positions.
The joints shall be designed to withstand the external pressure applied to the joint
during annulus grouting and to prevent any leakage of grout into the liner pipe.
The winch shall be fitted with a direct reading load gauge to measure the winching
load. At the end of each days winching, the Contractor shall provide the Engineer with
copies of the forces recorded in winching or each approved method at the start of any
pull and during the pull at increments of 20 meters of winching distance and at any
restart after temporary stops.
The Contractor shall supply sufficient cable in one continuous length so that the pull
may be continuous between approved winching points.
The winch cable and cable drum must be provided with safety cage and supports so
that it may be operated safely without injury to persons and property.
The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.
A nose cone shall be fixed to the first pipe to be inserted and shall be fitted with a
swivel attachment to reduce the twist transmission between the winch cable and nose
cone.
Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.
Linings shall be cut using methods as recommend by the manufacturer or approved

by the Engineer. Precautions shall be taken to avoid de-lamination or spilling.
11.2.3 Grouting
The annular space between the existing sewer pipe and the newly installed lining is to
be filled with cementitious grout as per clause 11.1.4.2. The Contractor shall take all
necessary precautions to ensure continuous operations between manholes or drive
pits and that any delay due to blockage or mechanical breakdown is minimized so as
not to affect the performance of the placed grout.

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The selection of the grout material and the method for grouting the annular space
shall be such as to prevent the flotation of the pipe during the grouting operation. As
a minimum, the newly installed pipe lining, shall be capped and filled with water.
11.2.3.1 Treatment of End of Lining
At the upstream end of the lining, the existing invert is to be broken out and the lining
lay on a suitable mortar bed so that the inverts are level. At all other points, the
existing sewer shall be suitably prepared and a smooth transition made with suitable
mortar.
Where existing benching and channels require modification to suit the new pipe sizes
and arrangements, then prior to sewer lining being carried out, the manhole shall be
thoroughly cleaned; the existing benching and channels scrabbled. All loose scale
aggregate and dust removed and any large holes filled with 3:1 sand cement mortar.
The channel invert and sides shall be broken out to a depth sufficient to permit a
minimum of 10mm thickness of epoxy mortar or 7mm thickness of GRP laminate to
be applied in accordance with Section 7 of this specification after completion of the
renovation works.
Alternatively, with the approval of the Engineer, the benching and channel may be
broken out and reconstructed with Class 30/20 concrete to profiles suitable for the
new pipe sizes and arrangements and which will enable application of the minimum
thickness of laminate as detailed in Section 7 of this specification .
11.3 PIPELINE RENOVATION - DEFORMED PIPE LINING
11.3.1 General
Where downsizing has been indicated on the Drawings and where the existing pipe is
not suffering from excessive deformation, the Contractor may propose to renovate the
existing sewer using deformed pipe lining systems. In such instances, the Contractor
must indicate which line he proposes to renovate using deformed pipelining
techniques and obtain approval from the Engineer prior to mobilizing labour, materials
and equipment to the work site.
The deformed pipe lining works shall include but not be limited to the following
operations:
1) Initial sewer cleaning prior to CCTV survey.
2) Initial CCTV survey
3) Submission by Contractor to Engineer of proposed deformed pipe lining process

to be used based on the initial CCTV survey.
4) Preparation of manhole per clause 11.3.7

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5) Full sewer cleaning prior to deformed pipe sewer lining.
6) Deformed pipe sewer lining
7) Testing of lined pipes.
8) Final jetting and CCTV survey
9) Temporary blocking off, over pumping and diverting of all contributing flows as
required during operations (1) to (8) above.
11.3.2 Materials - HDPE or HPPE Pipe
Pipeline renovation by deformed pipe techniques shall use high-density polyethylene

(HDPE) or high performance polyethylene (HPPE) pipe as specified in Section 4 of
these specifications.
The HDPE or HPPE pipe shall be supplied in coils or on reels as recommended and
provided by the manufacturer.
11.3.3 Further Site work Preparation
The Contractor shall obtain the field measurements of the existing pipe profiles at the
accessible points such as manholes.
In addition to vertical and horizontal measurements of the pipe diameters, the

Contractor shall obtain measurements of the inner circumference of the pipe. From
the inner circumference measurements a round pipe theoretical outer diameter shall
be computed and compared to measured diameters. The horizontal and vertical
diameters measured shall be used by the Contractor to make necessary decisions
about the overall conditions for the new pipe cross sections.
The Contractor will make a determination concerning the lower and upper ranges of
the pipe’s diameters. The Contractor shall use the circumferences measured from
inside the pipe as a governing measure while the two perpendicular diameters will be
used as supporting measurements. The Contractor shall compare the inside
circumference of the pipe with the outside circumference for the liner pipe. By
subtracting one from the other, the Contractor will determine what matching pipe
should be selected for the work.
The Contractor shall ensure that the replacement pipe shall match the existing pipe to
provide a tight fit after the deformed pipe has been reverted to its full size.
The pipe shall be determined and ordered in the cold state and the Engineer shall
approve the size requirements for the pipe using the methods described above.

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11.3.4 Pipeline Obstructions
The Contractor shall repair or remove from the pipeline all obstructions (e.g.
sediments, protruding service laterals and collapsed pipe sections), that can prohibit
insertion of the pipe. A high speed rotating hydraulic cutter shall be used to cut
protruding service laterals, offset joints, roots, barnacles, concrete or other
obstructions. The cut will be made flush with the wall of the pipe to be restored and
the debris will be flushed down the pipe to the downstream manhole. If an obstruction
cannot be removed by conventional methods and/or mechanical equipment remotely
controlled, then the Contractor shall, by excavation, remove or repair the obstruction.
Such excavation shall be considered as separate measurement item and must be
approved in writing before commencement. The difficult or special cases shall be
evaluated by the Engineer and Contractor prior to excavation. All loosened material
must be removed at the downstream manhole.
The pipeline shall also be checked immediately before lining for the presence of
collapses occurring subsequent to cleaning by passing sewer rods between
manholes, shafts or chambers. If a collapse is detected its position shall be
determined and an additional shaft shall be excavated if the debris cannot be
removed.
Where a collapse has occurred subsequent to cleaning the cost of excavation to clear
the blockage shall be paid at the appropriate billed rates.
If deformed pipe lining is delayed for a period in excess of 7 days after cleaning and
initial inspection the pipeline shall be reinspected. The cost of this work will be borne
by the Contractor if he is responsible for the delay as determined by the Engineer.
11.3.5 Sewer Lining Execution
All blocking off of sewers and house connections and over pumping shall be carried
out to the approval of the Engineer.
11.3.5.1 Pipe Insertion
The pipe reel or coil shall be positioned at the upstream manhole. The pipe will be
installed by pulling it, through the pipe to be restored, directly from the reel or coil,
through the upstream manhole in one single section without any excavation.
The pipe shall be winched through the existing pipe with due care to avoid snagging
or damage to the manholes. Guides or rollers shall be fitted within the manholes to
avoid the risk of snagging.
If it is necessary to reclaim the pipe from its position in the pipeline, this should be
done immediately the decision is made. Preferred methods are vacuum collapsing
the pipe or mechanically pulling the pipe, if the friction is not prohibitively high.
Excavation should be used as a last resort in the process of recovering the pipe.

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11.3.5.2 Manifold Installation
Processing manifolds to enable head and steam to revert the deformed pipe shall be
fixed at each end of the pipe.
11.3.5.3 Processing the Pipe
The Contractor shall install temperature and pressure measuring devices at the
upstream and downstream manholes. The temperatures sensors shall be fixed as far
as possible inside the pipe at the inlet and outlet points.
A steam heat source, operated in conjunction with the pressure, such as is generated
from the steam generator, shall be utilized to supply steam to the pipe during the
processing period. The steam generating equipment shall have a capacity of not less
than 102°C (215°F) nor more than 177°C (350°F). This capacity should be sufficient
to reach a downstream manhole. These measurements will be gauged at the
upstream manhole. The internal pressure range, which will be used in the pipe’s
processing, will not be less than 1.36 bars (20 psi) or more than 1.70 bars (25 psi) for
normal processing. The equipment must have the capacity to provide at least this
quoted pressure range.
11.3.5.4 Cooling Process
After the pipe has been fully processed or it has reverted to its circular shape
pressurized air shall replace steam at a gradual rate. Further cooling shall be carried
out using water.
11.3.5.5 Finishing Work
The pipe shall be cut flush at the inlet and outlet prior in the manhole by using the
rotary cutter.
11.3.5.6 Equipment General Specifications
Steam rated pressure and temperature gauges to be fitted to the steam generator
and processing gauge stations and manifold shall be at least 125mm in diameter and
shall be clearly readable at a distance of 2 metres. All such gauges shall have the
capacity to measure from 10 to 260°C.
The remote steam gauges shall be attached to the downstream processing gauge
station.
The high pressure steam hoses and fittings shall be rated for 200 psi or higher
working steam pressure.
The pulling winch shall be equipped with a tension gauge, capable of running at
constant and controlled speed. The operator must have the ability to increase or
decrease the pulling speed. The Contractor will prepare computations for approval by
the Engineer of the size of the winch necessary for a particular job.
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11.3.6 Guarantee
The Contractor must provide a 10 year guarantee for the deformed pipe sewer lining.
11.3.7 Finishing to Manholes
A. Prior to deformed pipe lining work being carried out, the manholes shall be
thoroughly cleaned, the existing benching and channels scrabbled and all loose
scale, aggregate and dust removed and any large holes filled with a 3:1 sand cement
mortar. The invert and sides of the main channel shall be broken out to a minimum
depth of 10mm with a chase 75mm x 15mm deep being formed in the sides of the
main channel just before springer level. A layer of epoxy mortar 10mm thick shall be
formed in the main channel up to springer level to give a uniform fall across the
manhole.
B. On completion of the deformed pipe sewer lining process and removal of

equipment, the lining pipe shall be neatly cut and trimmed to suit the benching profile
in each manhole. The free edge of the cut liner shall be dressed with epoxy mortar
into the performed chase in the channel sides and a 10mm minimum thickness of
epoxy mortar or 7mm thickness of GRP laminate shall be applied to the whole of the
benching and exposed channel and over the free edge of the cut pipe as specified in
Section 7 of these specifications.
C. At the point of entry of the lining pipe to a manhole the lining pipe is to be cut at
the crown 25mm from the inside of the manhole finish and the junction between the
pipe and manhole lining is to be sealed with a compatible material giving a similar
degree of protection to the manhole liner.
D. In manholes where two dissimilar lining pipe section adjoin, the channel between
the lining pipes shall be broken out to a depth to allow 10mm minimum thickness of
epoxy mortar or 7mm minimum thickness of GRP laminate to be applied between the
lining pipes, and a 75mm wide 15mm deep chase shall be formed around the channel
into which the bonding edge of the lining pipe shall be dressed with epoxy mortar or
GRP laminate. The entire channel shall then be applied with a minimum of 10mm of
Epoxy Mortar or GRP laminate as per Section 7 of these specification .
11.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING
11.4.1 General
Where down sizing has been indicated on the drawings and where the existing pipe is
not suffering from excessive deformation, the Contractor may propose to renovate the
existing sewer using inversion type soft lining techniques. In such instances, the
Contractor must indicate which lines he proposes to renovate using inversion lining
techniques and obtain approval from the Engineer prior to mobilizing labour, materials
and equipment to the work site.

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The inversion sewer lining works shall include, but not be limited to the following
operations:
1) Initial sewer cleaning prior to CCTV survey
2) Initial CCTV survey.
3) Submission by Contractor to Engineer of proposed liner design based on the

initial CCTV survey.
4) Full sewer cleaning prior to lining.
5) Inversion sewer lining
6) Testing of soft lined pipes
7) Manhole refurbishment as per clause 11.4.8
8) Final jetting and CCTV Survey
9) Temporary blocking off and over pumping and diverting of all contributing flows
as required during operations (1) to (8) above.
11.4.2 Materials
The inversion type soft lining pipe material shall be of the following types: -
1) A composite tube, consisting of one or more layers of polyester or acrylic needle

felt with an integral external coating of polyurethane, polyethylene, PVC or nylon,
impregnated with an approved thermosetting resin, which, after inversion into a pipe,
will bed against the pipe wall with the coating on the inside.
2) On or more layers of a continuous glass fibre reinforcement impregnated with an

approved thermosetting resin, which, after inversion into a pipe will bed against the
pipe wall.
For the purposes of this project, only soft lining systems which provide structural
strength liners capable of resisting ground and traffic or groundwater loadings as
necessary upon curing will be considered. The resin system and the lining thickness
shall be selected to meet the chemical resistance and structural requirements for the
lining.
A trial section must be carried out and test performed as detailed in clause 10.4.3 to
prove the Contractor’s proposed resin, handling technique, and the amount of resin
required.
The Contractor must supply the Engineer with full details of recommended usage,
curing method, pot times, life, mechanical properties and chemical resistance or the
resin he proposes to use.

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The Contractor must provide evidence that the proposed resin or polyethylene
material will have strength, stability and resistance to corrosion in an environment
which may comprise any combination of the following factors for a design life of 50
years: -
1) Immersion in septic sewage at up to 35°C.
2) Exposure to hydrogen sulphide gas derived from septic sewage to temperatures

up to 35°C
3) Immersion in saline water at temperatures up to 35°C
4) Deposits of free sulphur on exposed surfaces
5) Exposure to 10% sulphuric acid at up to 35°C
Note: For items 1 through 3, refer to the 100-day ASTM test C581.
A preliner shall be used to prevent migration of resin into connections. The preliner
shall be composed of a polymeric membrane and may be integral with the in-situ
tube. This form of construction will be used in all applications of inversion type lining
systems.
11.4.3 Inversion Type Resin System
The inversion type soft lining systems shall use a resin system using an isophthalic
polyester resin or a proven alternative with equivalent or higher performance
characteristics than the isophthalic polyester resins. The resin systems may contain
only those additives approved by and only up to the limits defined by the resin
manufacturer to control viscosity and pot life.
The thermosetting resin system shall cure with a minimum of volumetric shrinkage
and shall have viscosities suitable for good impregnation and defined processing
characteristics at ambient temperatures between 20-50°C (Middle Eastern and
tropical conditions must be accommodated).
The resin system shall cure under water and must also cure in the presence of tar
residues and dirt in the pipelines. The resin system shall not be affected by sun
radiation usually prevailing when inverting the impregnated felt tube.
In addition to the requirements of BS3532 the heat distortion temperature of castings

of fully cured resin (as opposed to felt/resin matrix) when determined in accordance
with BS2782: Method 121A, shall be not less than 20 C above the expected
maximum service temperature of the lining.
11.4.4 Tests
The Contractor shall, when directed, periodically provide results of tests carried out
on the cured in-situ lining material by an approved testing laboratory. These tests are

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to confirm the physical properties of the cured in-situ lining material. Tests shall be
carried out in accordance with Appendix 2 of this Specification. The properties to be
tested are given below: -
• Flexural modulus
• Flexural strength at first break
• Tensile strength
• Compressive strength
The Contractor will be required to initiate with an approved testing laboratory a test to
substantiate the 50 year creep modulus of the In-situ form material at the working
temperature in the pipe.
11.4.5 Soft Lining Design
Following the initial CCTV survey the contractor shall supply calculations to
demonstrate the ability of the in-situ pipe to withstand design loading. These
calculations shall be comprehensive and should not be based on empirical
relationships found by the Contractor. They shall be based on a design life of 50
years. They shall cover all pipe diameters noted in the contract documents.
The liner shall be designed assuming no adhesion between the cured liner and the
walls of the existing pipe.
Approval by the Engineer of the use of any particular in-situ pipe thickness shall not
release the Contractor from his obligations under the Contract.
11.4.5.1 Liner Thickness Design
The liners for soft lining shall be designed as structural liners i.e. as chemically
protective liners with structural capability to withstand continuous inside and outside
pressure at an elevated temperature of up to 50°C.
The following parameters shall be reviewed from CCTV survey record for evaluation
of the existing sewer as to its soundness structurally.
1) Infiltration of ground water accompanying soil, bedding material through joints,

open joints, breaks and missing sections.
2) Degree of corrosion due to corrosive effluent and corrosive environment.
3) Overall condition of the sewer - any visible cracks, protrusion of rubber rings at
open joints, intrusion of the tree roots etc.
The finished cured liner thickness design shall be based on: -
1) Loading criteria such as ground and water pressures, highway loading.

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Note: Water pressure shall be assumed to be from ground level. Highway loading
shall be assumed from Sewer Rehabilitation Manual
2) A Standard Dimensional Ration (SDR) as shown:
Nominal inner pipe diameter (mm)SDR
250 35 – 40
300 40 – 50
350 40 – 50
400 40 – 50
500 40 – 50
750 50 – 60
1000 40 – 55
Note:
For pipes less than dia 250mm, the liner (cured) thickness shall be minimum 4mm,
but shall not exceed 6mm.
11.4.5.2 Liner Tube Fabrication
The lining bag or tube shall consist of one or more layers of needle interlocked
polyester felt or woven glass fibre and shall be fabricated to provide the required
length and thickness of in-situ pipe and shall be of a diameter such that on inversion it
expands to fit the profile of the pipe to be renovated. The required thickness of liner
tube may be achieved by fabrication in successive layers each formed by sewing or
flame bonding. Where the liners thickness is built-up using more than one layer of
polyester felt, the joints in the felt shall be offset to prevent excessive thickening on
the completed lining. The thickness of the finished pipe shall be at least minimum
specified and may be up to 15% greater, except where felt layers overlap in which
case it may exceed this value. The outer layer shall be made from coated felt and a
covering strip shall be bonded over the flame bonded or sewn seams. The diameter
of the tube shall allow for any variation in the diameter of the pipe to be lined such
that voids or wrinkles do not occur in the finishing lining.
11.4.6 Sewer Lining Execution
All blocking off of sewers and house connections and over pumping shall be carried
out to the approval of the Engineer.

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Pipe connections (if any) protruding into the sewers to be renovated shall be cut off
neatly using an approved cutting technique
11.4.6.1 Equipment
The Contractor shall provide the expertise, personnel and equipment necessary to
perform in-situ soft lining of sewer pipes. The Contractor shall be responsible for the
provision, transport, storage, insertion and curing of the pipe lining as specified. The
Contractor shall supply all equipment, tools, materials and labour required to
efficiently perform the soft lining work within the specified schedule.
11.4.6.2 Impregnation
The liner tube shall be laid flat and a vacuum applied by means of a vacuum pump
and the resin injected. The resin shall be impregnated evenly throughout by means of
rollers. Both ends of the in-situ tube shall then be sealed. The volume of resin shall
be such that on completion of inversion and curing the specified in-situ pipe thickness
is achieved.
Immediately after impregnation the liner tube shall be placed in storage at or below a
maximum temperature recommended by the resin manufacturer and approved by the
Engineer and this temperature shall be maintained until the inversion procedure
commences on site using ice and cold storage vehicles as necessary. The maximum
time of storage after impregnation shall be as recommended by the resin
manufacturer and approved by the Engineer.
11.4.6.3 Transport and Storage
The lining system materials shall be transported to the site under controlled
environmental conditions according to the manufacturer’s recommendations.
The lining manufacturer shall be familiar with the changes in viscosity, gel time, etc.,
which may occur during transport and storage of the resin, especially in the climatic
conditions in the U.A.E., and shall make appropriate allowances in the lining
manufacturing process. Resin stored in original, unopened containers shall not be
used after the resin manufacturers stated keeping period.
11.4.6.4 Inversion and Curing
The lining shall be inverted into the prepared pipeline using the unheated water or
compressed air. The medium used for the insertion should be as cool as possible
considering the climatic conditions in the U.A.E. and may require timing the insertion
during the night time hours and providing means for keeping the insertion water cool.
Equipment shall be such that there is adequate head to ensure proper inversion of
the in-situ tube.

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The in-situ tube shall be clamped around the inversion ring or elbow and inverted into
the pipe. Water or compressed air shall be pumped into the in-situ tube at a rate such
that inversion proceeds under an adequate head.
A water hose with discharge holes along its length, or a draw rope for subsequently
pulling in light cure lamps shall be attached to the in-situ tube rope end so that on
completion of the inversion it shall occupy the full length of pipe being renovated.
On completion of inversion, curing shall be effected by the application of heat or by

the application of ultra violet light of the correct wavelength and intensity.
Heat shall be applied by means of circulating the water contained in the in-situ pipe
through a boiler and the water hose until the optimum curing temperature is attained
throughout the length of the pipe being renovated. The rate of temperature rise and
fall shall not exceed 10 C/min. The optimum curing temperature is to be as
recommended by the manufacturer and approved by the Engineer. The water
temperature shall be automatically controlled. The resin temperature shall be
monitored using thermocouples on the inner and outer faces of the lining installed
where applicable. The boiler inlet and outlet water temperature shall be recorded.
During cure, the curing reactions become exothermic which may show up on the
temperature monitor as a peak. The curing temperature shall be maintained until the
exothermic reaction is witnessed, indicating a properly cured liner.
Ultra violet light shall be applied by drawing suitable lamps along the length of the in-
situ tube at a rate compatible with the resin system. For all installations the curing
parameters required must be agreed with the resin manufacturer and approved by
the Engineer.
After curing, the water in the in-situ pipe shall be released provided that the
temperature of the water is within 10°C of ambient and provided always that this
temperature is within the safe permissible limits of temperature to allow the
Contractors employees to carry out this work in safety. The curing water must be
allowed to cool naturally and the full inversion head must be maintained throughout
cooling.
In the event that local repairs to the in-situ pipe are required the Contractor shall
submit proposals for such repairs to the Engineer. The Contract shall however take
all necessary steps and precautions to obviate the need for such repairs during
manufacture and installation of the liner.
11.4.7 Guarantee
The Contractor must provide a 10-year guarantee for the in-situ sewer lining. The
Contractor should note, however, that the design life of the lining should be 50 years
as stated in clause 11.4.1

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A. Prior to in-situ lining work being carried out, the manholes shall be thoroughly
cleaned, the existing benching and channels scrabbled and all loose scale, aggregate
and dust removed and any large holes filled with a 3:1 sand cement mortar. The
invert and sides of the main channel shall be broken out to a minimum depth of
10mm with a chase 75mm x 15mm deep being formed in the sides of the main
channel just above springer level. A layer of epoxy mortar 10mm thick shall be
formed in the main channel up to springer level to give a uniform fall across the
manhole.
B. On completion on the in-situ sewer lining process and removal of inversion

equipment, the in-situ pipe shall be neatly cut and trimmed to suit the benching profile
in each manhole. The free edge of the cut in-situ liner shall be dressed with epoxy
mortar into the preformed chase in the channel; sides and a 10mm minimum
thickness of epoxy mortar or a 7mm minimum thickness of GRP laminate shall be
applied to the whole of the benching and exposed channel and over the free edge of
the cut in-situ pipe as specified in Section 7 of this specification .
C. At the point of entry of the in-situ pipe to a manhole the in-situ pipe is to be cut at
in-situ pipe and manhole lining is to be sealed with a compatible material giving a
similar degree of protection to the manhole liner.
D. In manholes where two dissimilar in-situ pipe sections adjoin, the channel
between the in-situ pipes shall be broken out to a depth to allow a 10mm minimum
thickness of epoxy mortar or 7mm minimum thickness of GRP laminate to be applied
between the in-situ pipes, and a 75mm wide 15mm deep chase shall be formed
around the channel into which the bonding edge of the in-situ pie shall be dressed
with epoxy mortar of GRP laminate. The entire channel shall then be applied with a
minimum of 10mm of epoxy mortar or 7mm of GRP laminate as per Section 7 of this
specification.
11.5 PIPELINE REPLACEMENT - PIPE BURSTING
11.5.1 General
The Contractor shall select a suitable pipe bursting method and equipment to perform
the specified pipe upsizing and replacement. The Contractor shall specify the method
and equipment to be used in his tender submittal.
Pipe bursting operation shall be conducted from within existing manholes without long
lead in trenches unless otherwise approve by the Engineer. The selection of drive
and reception locations shall be such as to minimize disruption of normal traffic and
inconvenience to the public.

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The Contractor’s design shall include for all dewatering or other ground water and soil
support systems, necessary to prevent any adjacent ground from being adversely
affected during and after pipe bursting activities.
The pipeline replacement by pipe bursting works shall include, but not be limited to
the following operations:
1) Initial sewer cleaning prior to CCTV survey.
2) Initial CCTV survey
3) Submission by contractor to Engineer of proposed pipe bursting technique based

on the initial CCTV survey.
4) Full sewer cleaning prior to pipe bursting.
5) Preparations of manholes prior to pipe bursting
6) Pipe replacement by pipe bursting
7) Testing of new pipes.
8) Manhole refurbishment per clause 11.5.3
9) Final jetting and CCTV survey
10) Temporary blocking off and over pumping and diverting of all contributing flows
are required during operations (1) to (9) above.
11.5.2 Pipe Bursting - Execution
The details of the method of pipe replacement to be used shall be submitted by the
Contractor to the Engineer in the form of a detailed method statement for approval
prior to mobilization to the site. The details shall include but not be limited to the
method of pipe bursting, method of jointing and if necessary, debeading the pipe
internally and externally, the location of driving and reception pits and the necessary
temporary works.
Pipe bursting shall use HDPE or PPE pipe. HDPE or PPE pipe shall be installed by
winching (or other approved method) the pipe bursting assembly and jointed pipe
through the existing sewers. Details of the proposed method of winching must be
submitted to the Engineer for approval at least 7 days before the work is intended to
be performed.
The winch shall be fitted with a direct reading load gauge to measure the winching
load. At the end of each working day, the Contractor shall provide the Engineer with
copies of the winching forces recorded for each approved method at the start of any
pull and during the pull at increments of 20 meters of winching distance and at any
restart after temporary stops.

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The Contractor shall supply sufficient cable in one continuous length so that the pull
may be continuous between approved winching points.
The winch cable and cable drum must be provided with safety cage and supports so
that it may be operated safely without injury to person and property.
The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.
The pipe bursting assembly shall be fixed to the first pipe to be inserted and shall be
fitted with a swivel attachment to reduce the twist transmission between the winch
cable and nose cone.
Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.
Cutting of Linings
Linings shall be cut using the methods approved by the Engineer. Precautions shall
be taken to avoid delaminations or spalling.
A. Prior to pipe bursting work being carried out, the manholes shall be thoroughly
cleaned, the existing benching and channels scrabbled, and all loose scale,
aggregate and dust removed and any large holes filled with a 3:1 sand cement
mortar. The invert and side of the main channel shall be broken out to accommodate
the outer dimensions of the new pipe to be installed plus a minimum additional 10mm
depth. A layer of epoxy mortar 10mm thick shall be formed in the main channel up to
springer level to give a uniform fall across the manhole.
B. Prior to pipe bursting work being carried out, the existing pipe penetrations
through the manhole wall shall be broken out to accommodate the outer dimensions
of the new pipe to be installed. The Contractor shall prevent groundwater flow into the
manhole by the use of hydrophilic gel injection around the existing pipe penetrations
or by dewatering around the manhole, or by such other method as shall be approved
by the Engineer.
C. On completion of the pipe bursting process, and removal of the equipment, the
new pipe shall be neatly cut and trimmed to suit the benching profile in each
manhole. A 10mm minimum thickness of epoxy mortar or a 7mm minimum thickness
of GRP laminate shall be applied to the whole of the benching and exposed channel
and over the free edge of the new pipe as specified in Section 7 of this specification.
D. At the point of entry of the new pipe into a manhole, the new pipe is to be cut at

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new pipe and the manhole lining is to be sealed with a compatible material giving a
similar degree of protection to the manhole liner.
11.5.4 Obstructions
The contractor may encounter section of existing pipe where a concrete surround has
been used. In these situations, the pipe bursting technique may not be capable of
fracturing the pipe and concrete surround. The Contractor shall endeavour to identify
the possible locations of such obstructions through review of Dubai Municipality
records and discussions with Municipality personnel.
Where obstructions are known to exist, or where such obstructions are encountered
during the execution of pipe replacement work, the Contractor shall excavate at the
site and remove the obstruction. Following completion of the pipe replacement
through the affected section, the Contractor shall place pipe bedding and backfill and
complete reinstatement of pavements.
11.6 PIPELINE ABANDONMENT
11.6.1 General
The Contractor shall clean and fill by the method of continuous grout injection, the
asbestos cement sewer pipelines to be abandoned as indicated on the Contracts
Drawing(s) and as specified herein. uPVC pipes to be abandoned will be fully cleaned
as per Section 11.7 and left in place. The abandonment works must be scheduled
and co-ordinate with the renovation of existing sewers and construction of new
sewers so as to avoid conflicts between work crews, to facilitate rapid completion of
the work, and to limit disturbances to the area.
11.6.2 Grout and Grouting for Abandoned Pipeline
Grout for abandoned pipeline shall be as the annulus grout specified in clause
11.1.4.2
The asbestos cement sewers to be abandoned will be fully cleaned as specified in

Section 11.7 immediately prior to grouting.
11.7 SEWER CLEANING AND CCTV SURVEY
11.7.1 General
The Contractor, where required to conduct a closed-circuit television survey (CCTV)

of sewers, shall perform a series of surveys as detailed below:
11.7.1.1 Extent of the Survey
The Contractor shall conduct an initial CCTV survey and logging on all existing
gravity sewers within the project area prior to the renovation and replacement of any

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line. A (Post Renovation) survey shall be conducted on completion of renovation and

replacement operations all as described herein.
Initial Survey/Condition Survey
An initial survey shall be carried out on all pipelines to be renovated or replaced or as

otherwise required by the works. This survey shall be carried out as soon as possible
to check the condition of the pipe and to confirm proposed method of replacement.
This survey shall be carried out in addition to the survey immediately prior to
renovation/replacement whilst the sewer is operating under actual flow conditions.
The maximum flow in the pipe should be not more than 10%.
A light source shall be placed at the other end of the line to be surveyed to verify the
alignment of the pipe. The light may be removed once observed by the camera, the
location in the pipe length from which the light is first observed shall be recorded.
Pre-Renovation Survey
Immediately prior to the renovation of any pipe, a CCTV survey (Pre-Renovation

Survey) shall be conducted.
Post Renovation Survey
As soon as practical after the renovation/replacement of the pipe a CCTV Survey

(Post Renovation Survey) shall be carried out.
11.7.2 Sewer Cleaning
All sewers including manholes prior to rehabilitation, renovation, replacement or

abandonment shall be cleaned as per the requirements of this section.
a) Prior to beginning the CCTV survey in any section of sewer, the Contractor shall
have the sewer section including manholes thoroughly cleaned and prepared for the
survey. The Contractor shall provide all necessary vehicles, equipment, materials and
labour, in proper condition and in sufficient numbers, to carry out the cleaning of the
sewers and manholes in a timely and expeditious manner.
The Contractor shall arrange for the disposal of all material and debris in a safe
manner, as approved by the Engineer and the relevant authorities.
b) Sewer and manhole cleaning shall be carried out mainly by water jetting.
Water jetting shall be carried out using purpose built jetting tankers. Jetting tankers
shall be equipped with at least 150m of suitable 25mm diameter hose with jetting
heads. The water pressure at the jetting head shall be variable between 100 bars and
170 bars. The minimum flow rate at 100 bars will be 2.5 l/s.

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The hose shall be mounted on a power operated drum reel having variable speed
and direction controls. The hose system shall incorporate a suitable method of
meterage indication. A calibrated hose is an acceptable method for measuring
meterage. The hose must be equipped with a variety of nozzles, including rear jets
only (15½ to 30½), rear plus forward jets, and rear plus side jets or other
configuration to ensure adequate cleaning of the pipelines.
Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.
c) Along with water jetting, sewer and manhole cleaning shall include the following :
i. blocking off sewer lengths and over pumping where required
ii. bucket and winch dredging where required
iii. flushing from downstream manhole only using potable water. Debris and sand
jetted or dredged from the sewers shall be collected by silt traps or screens installed
in the downstream manhole.
iv. removal and disposal of all collected debris and sand.
v. wire brushing of manholes
vi. such other methods and works as may be required to clean the sewers and
manholes to a satisfac¬tory standard.
d) Initial sewer cleaning, prior to the initial CCTV survey, shall be carried out in such
a manner as to avoid damage to the sewers, which are likely to be in poor structural
condition. Jetting pressure will be limited to 100 bars for initial cleaning.
During initial cleaning sewers must be cleaned to a standard such that an effective
CCTV survey of their structure can be carried out. Manholes shall be similarly
cleaned to permit visual surveys.
e) Full cleaning shall be performed prior to lining or abandonment of sewers and

manholes and will include all operations necessary to remove all grease, slime and
loose material from the pipes and manholes.
Sewers and manholes must be cleaned to a standard such that the sewer lining can
be effectively in¬stalled.
Where the initial CCTV survey indicates that the sewers are in poor structural
condition jetting pres¬sure will be limited to 100 bars. Care must be taken, generally,
to avoid damage to the sewers. Any sewer collapses caused by jetting shall be
rectified by the Contractor immediately at his cost.
11.7.3 Survey and Operational Equipment
The surveying equipment shall be capable of surveying a section of sewer up to 350

meters in length where entry to the sewer may be obtained at each end, up to 30
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meters by rodding. Where entry is at one end of the section only, the equipment shall
be capable of survey¬ing a section of sewer up to 150 meters in length using a self-
propelled unit.
The Contractor shall maintain this equipment in full working order and shall satisfy the
Engineer at the beginning of each working shift that all items of equip¬ment have
been provided and are in full working order.
Each survey unit shall contain a means of transporting the CCTV camera in a stable
condition through the sewer under inspection. Such equipment shall ensure that the
CCTV camera position is maintained on or near to the central axis of the sewer.
Where the CCTV camera is towed by winch and bond through the sewer, all winches
shall be stable with either lock¬able or ratcheted drums. All bonds shall be steel or of
an equally non-elastic material to ensure the smooth and steady progress of the
CCTV camera. All winches shall be inherently stable under loaded conditions.
Each survey unit shall carry sufficient numbers of guides and rollers such that, when
surveying, all bonds are supported away from pipe and manhole structures and all
CCTV cables and/or lines used to measure the cameras location within the sewer are
maintained in a taut man¬ner and set at right angles, where possible, to run through
or over the measuring equipment.
Each unit shall carry a range of flow control equipment, as opposed to over pumping
equipment, for use in control¬ling flow during the survey. A minimum of one item of
each size of equipment ranging from 150 mm to 450 mm diameter inclusive shall be
carried.
11.7.4 Performance of Survey
11.7.4.1 Camera Position
The camera lens shall be positioned centrally within the sewer, looking along the axis
of the sewer. A position¬ing tolerance of ± 10 % of the vertical sewer dimension shall
be allowed.
11.7.4.2 Camera Speed
The speed of the camera in the sewer shall be limited to 0.1m/s for sewers of
diameter less than 200 mm, 0.15 m/s for sewers of 200 mm diameter up to 315 mm
diameter, and 0.20 m/s for sewers exceeding 315 mm in diameter. The camera shall
be stopped whenever defects are being noted or photographed.
11.7.4.3 Linear Measurement
The CCTV monitor display shall incorporate an automati¬cally updated record, in

meters and tenths of a meter, of the linear measurement of the camera position from
the cable calibration point.

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The Contractor shall use a suitable metering device, which enables the cable length
to be accurately measured, with a tolerance of ± 1% or 0.3m, whichever is greater.
The Contractor shall demonstrate that this tolerance is being complied with using one
or both of the following methods:
i. - use of a cable calibration device, or
ii. - use of a tape measurement of the surface between manholes.
If the Contractor fails to meet the standard of ac¬curacy, the Engineer shall instruct
the Contractor to provide a new metering device and may, at his discre¬tion, instruct
in writing, the Contractor to resurvey those lengths of sewer first inspected with the
original metering device.
11.7.4.4 Data Display, Video Recording and Start of Survey
At the start of each sewer length being surveyed, the length of sewer from zero
chainage up to the cable calibration point shall be recorded and reported in or¬der to
obtain a full record of the sewer length.
The meter reading entered on to the data display at the cable calibration point must
allow for the distance from the start of the survey to the cable calibration point such
that the meterage at the start of the survey is zero. In the case of a survey through a
manhole where a new header sheet is required, the meterage shall be set at zero
with the camera focused on the outgoing pipe entrance.
The camera operator shall ensure that the metreage counter starts to register
immediately the camera moves.
At the start of each manhole length, a data generator shall electronically generate
and clearly display on the viewing monitor and video recording a record of data in
alpha-numeric form containing the following minimum in¬formation:
Automatic update of the camera's metreage position in the sewer line from adjusted
zero,
i. Sewer dimensions,
ii. Sewer use,
iii. Manhole reference numbers,
iv. Date of survey,
v. Road name and planning area number,
vi. Direction of survey, and

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vii. Time of start of survey.
The size and position of the data display shall be such as not to interfere with the
main subject of the picture.
Once the survey of the manhole length is under way, the following minimum data
shall be continuously displayed:
i. Automatic update of the cameras metreage position in the sewer line from
adjusted zero,
ii. Sewer dimensions,
iii. Manhole reference number, and
iv. Direction of survey.
Correct adjustment of the recording apparatus and monitor shall be demonstrated by

use of the test tape or other device approved by the Engineer. Satisfactory
performance of the camera shall then be demonstrated by the recording of the
appropriate test device at the commencement of each day for a minimum period of 30
seconds.
The test device(s) shall be provided on site at all times to enable practical
demonstration of compliance with the requirements of this section.
All video cassette tapes shall be supplied by the Con¬tractor and shall be best quality
high grade (HG) new and unused prior to the recording and shall be of a Video Home
Systems (VHS) format.
11.7.5 Survey Data Reporting
The Contractor shall record and present the survey data in a format acceptable to the
Engineer. The report should generally be in accordance with the format presented in
the WAA/WRC "Manual of Sewer Condition Classification" 2nd Edition, published
1988.
The Contractor shall supply the various numbers of copies and types of report for
each item listed, within the time period stated in the schedule for each section of
sewer.
Reports submitted by the Contractor shall be prepared by a qualified, trained and

certified Operator. The Operator shall be a signatory to each report.

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11.7.6 Drawings
One clean set of drawings showing manhole reference numbers which coincide with
the reporting format and tapes, shall be returned to the Engineer at the comple¬tion
of each section of the survey and shall be clearly annotated to show any significant
errors noted in the course of the survey. Such errors shall be brought to the attention
of the Engineer during the survey.
11.7.7 Metric Measurement
All dimensions shall be metric. For the purpose of metrication, inch sizes shall be
converted on the basis of 1 inch = 25.4 mm. Measurement shall be on nominal
diameter dimensions quoted to the nearest mm.
11.7.8 Photographs
The Contractor shall provide colour photographs. The photographs shall be durable
and shall be approximately 89 mm X 125 mm. Photographs should be high resolution
and computer generated by the CCTV system and printed on photographic quality
paper.
Photographs shall be taken of the internal condition of the sewers at the following
locations:
i. All defective junctions and connections,
ii. At defects including cracks, fractures, broken pipes, deformations, collapsed

pipes and severe joint displacement,
iii. For continuous defects, at the beginning and end of the defect,
iv. Wherever else the Engineer may direct.
Where photographs are not otherwise required, general condition photographs shall
be taken of each manhole length.
The photographs must clearly and accurately show what is displayed on the monitor,
which shall be in proper adjustment.
Photographs must be clearly identified in relation to the location, survey direction,

metreage, photograph number and date when the photograph was taken. The
annotation shall be clearly visible and in contrast to its background, shall have a
figure size no greater than 5 mm and shall be type printed. The annotation shall be so
positioned so as not to interfere with the subject of the photograph.
The photographs shall be supplied in suitable A4 sized plastic holders and bound in
ring binders or lever arch files. The photographs shall be presented in chronologi¬cal
order and each file shall contain a contents page providing clear cross-referencing to
the report.

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11.7.9 Equipment Standards
11.7.9.1 Picture Quality
The Contractor will provide a colour CCTV system.
The electronic systems, television camera and monitor shall be of such quality as to
enable the following to be achieved:
Shades of Grey. The grey scale shall show equal changes in brightness ranging from
black to white with a minimum of five clearly recognizable stages.
Colour. With the monitor control adjusted for correct saturation, the six colours plus
black and white shall be clearly resolved with the primary and complementary colours
in order of decreasing luminance. The grey scale shall appear in contrasting shades
of grey with no tint.
Linearity. The background grid shall show squares of equal size, without convergence
or divergence over the whole of the picture. The centre circle should appear round
and have the correct height to width relationships within a tolerance of ± 5 percent.
Resolution. The live picture must be clearly visible with no interference and must be
capable of registering a minimum number of TV lines per picture height lines. In the
case of a tube camera, 350 lines, and in the case of a CCD type camera, 250 lines.
Colour constancy. To ensure the camera shall provide similar results when used with
its own illumination source, the lighting shall be fixed in intensity prior to commencing
the Survey. In order to ensure colour constancy, generally no variation in illumination
shall take place during the Survey.
The Contractor shall note that the Engineer may periodically check both the live and
video picture colour consistency against the colour bar. Any differences will
necessitate re-survey of these new length affected at the Contractor's expense.
11.7.9.2 Video Playback
Video playback shall be capable of a resolution of a minimum of 250 lines recorded at

standard VHS speed.
11.7.9.3 Focus, Iris and Illumination Adjustment
The camera shall have pan and tilt facilities with zoom; capable of 360° rotation. The
adjustment of focus and iris shall allow optimum picture quality to be achieved and be
remotely operated. The adjustment of focus and iris shall be suitable for conducting a
360° rotational joint survey for a minimum pipe diameter of 150 mm. The range shall
extend to infinity. The distance along the sewer in focus from the initial point of
observation shall be a minimum of twice the vertical height of the sewer.

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The illumination shall be such as to allow an even distribution of the light around the
sewer perimeter without loss of contrast, flare out of picture or shadowing.
11.7.9.4 Equipment Testing
All equipment used shall be factory calibrated and conduct a self-test on start-up. The
self-test should confirm all aspects of picture quality and general operation. In the
event of calibration discrepancies, the Contractor shall resurvey all affected lines at
his own expense.
11.7.10.1 Contractor's Quality Control Procedure
The Contractor shall operate a quality control system, to be approved by the

Engineer, which will effectively gauge the accuracy and consistency of the survey
report produced by the operator from the monitor picture.
The system shall be such that the accuracy of reporting shall be a function
particularly of:
i. the number of faults not recorded (omissions),
ii. the correctness of the coding and classification of each fault recorded.
The Engineer shall be entitled to audit periodically the control system and be present
when assessments are being computed.
When requested by the Engineer in writing the Contractor shall forward to the
Engineer sufficient details and information for this audit assessment.
If any report fails to achieve the specified percentages for a particular sewer length,
the Engineer shall require the Contractor to re-code and re-submit the report. If the
accuracy check fails, the Contractor shall repeat the full quality control check on 10
surveys, 5 surveys either side of the survey which has failed. If any further failures
are found to be outside the tolerances laid down in clause 11.7.10.5 within these
additional checks, the process shall be repeated until the acceptable standard has
been reached. Any reports that have failed shall be re-coded by another Water
Training qualified surveyor and submitted to the Engineer to replace those in his
possession.
11.7.10.2 Random Selection
Quality selection shall be achieved by using two parameters:
i. Population: the anticipated number of surveys carried out by one surveyor over a
period of time.

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ii. Sample size: the number of surveys required to be checked to satisfy the quality
control validity.
The sample surveys for quality control shall be selected by the use of computer
generated random numbers (ERNI) or other such equivalent method and shall be 5%
of the total population. Each surveyor shall have a different set of random numbers,
which are sorted into chronologi¬cal order, and are renewed once the population size
has been reached. The random numbers shall not be disclosed to the surveyor until
they have been used up.
11.7.10.3 Survey Extraction
On site the surveyor shall log the information on the surveys and the "in-office" staff
shall then count through the surveys that have taken place and copy those reports
that coincide with the random numbers.
A copy of the relevant section of video tape shall also be made.
Information on the new tape and its contents shall be entered on a survey selection
log.
11.7.10.4 Checking
Header information - All header information shall be checked to ensure that left and
right justified entries are correctly entered, alpha or numeric symbols are correctly
used and all compulsory boxes filled in. The percentages of accurate entries shall be
ascertained and any that fall below the value stated in clause 11.7.10.5 shall be
rejected. All decimal percentage points shall be rounded down to the nearest whole
number.
Detail information - Each error/omission shall be treated on an equal basis whether or

not it is a minor or major error or omission. During the checking each error/omission
shall be highlighted on the report from which the following totals shall be calculated
for each survey report:
i. the number of actual entries that should have been made.
ii. the number of actual errors/omissions made.
These totals shall be entered on the right of the survey report being checked.
Individual column totals shall also be calculated and entered on to the survey
accuracy log.
The accuracy of each survey shall be arrived at by taking the number of actual
errors/omissions away from the number of actual entries that should have been made
and dividing the result by the number of actual entries that should have been made
and multiplying by 100 to create a percentage.
Note:
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The Contractor shall have the option to employ quality control methods other than
those outlined in clauses 11.7.10.2 through 11.7.10.4 of this specification with the
11.7.10.5 Accuracy for Quality Control
The minimum level of accuracy to be obtained under the quality control procedure
shall be as follows:-
Standard for this Contract
i. Header accuracy 95%
ii. Detail accuracy 85%
iii. lowest acceptable tolerance 75%

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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 12
MANHOLE RENOVATION & ABANDONMENT AND

PUMP STATION AND RISING MAIN ABANDONMENT
DM/SRPD Section 12 Manhole Renovation & Abandonment and Rev 00 June

Pump Station and Rising Main Abandonment
2016

Dubai Municipality
DM/SRPD Section 12 Manhole Renovation & Abandonment and Rev 00 June Page i of ii
2016

Dubai Municipality
SECTION 12
MANHOLE RENOVATION & ABANDONMENT AND
PUMP STATION AND RISING MAIN ABANDONMENT
CONTENTS
12 MANHOLE RENOVATION & ABANDONMENT AND PUMP STATION AND
RISING MAIN ABANDONMENT........................................................................................ 1
12.1 GENERAL...................................................................................................................... 1
12.1.1 Flow Control .......................................................................................................... 1
12.1.2 Maintaining Clean Conditions ............................................................................... 1
12.1.3 Safety.................................................................................................................... 2
12.2 MANHOLE RENOVATION ............................................................................................ 2

12.2.1 General ................................................................................................................. 2
12.2.2 Cleaning of Manholes ........................................................................................... 3
12.2.3 Inspection of Manholes ......................................................................................... 3
12.2.4 Manhole Inspection Report ................................................................................... 5
12.2.5 Manhole Renovation ............................................................................................. 5
12.2.6 Covers and Frames .............................................................................................. 5
12.2.7 Corbelling.............................................................................................................. 7
12.2.8 Concrete Access Shaft, Top Slab and Barrel ....................................................... 7
12.3 MANHOLE ABANDONMENT ..................................................................................... 10

12.3.1 General ............................................................................................................... 10
12.3.2 Manhole Abandonment ....................................................................................... 10
12.4 PUMPING STATION AND RISING MAIN ABANDONMENT ...................................... 11

12.4.1 General ............................................................................................................... 11
12.4.2 Pumping Station and Rising Main Abandonment ............................................... 11
DM/SRPD Section 12 Manhole Renovation & Abandonment and Rev 00 June Page ii of ii
2016

Dubai Municipality
12 MANHOLE RENOVATION & ABANDONMENT AND PUMP STATION AND RISING

MAIN ABANDONMENT
12.1 GENERAL
12.1.1 Flow Control
The Contractor shall use flow control methods and procedures as required to ensure
the safety of personnel and to facilitate completion of the work. Control measures
shall include plugging or blocking of the sewage flow or bypass pumping where
appropriate. The Contractor shall provide, operate and maintain all equipment
needed to properly control flows during the work including standby equipment in case
of plant failure.
Where the flow is to be blocked or plugged temporarily, the equipment shall remain in
place until the work has been completed and inspected. It is to be removed in such a
manner that permits sewage flow to gradually return to normal without surge,
surcharging or causing other disturbances downstream.
The Contractor shall provide, operate and maintain a bypass system to conduct
sewer flows around the work area when flow cannot be controlled by blocking or
plugging or when it is necessary to maintain system sewer flow around the work area.
The bypass system is to be of sufficient capacity to handle existing normal sewers

flows plus any additional flow which may occur during a rain event should the work
take place during the rainy season.
Flow control and bypassing methods and procedures must result in minimum
inconvenience and disturbances to the public, and prevent damage to public and
private property due to flooding, surge or excessive surcharging.
12.1.2 Maintaining Clean Conditions
The Contractor shall maintain clean conditions in and around the work area at all
times. All material removed from the manholes and pump stations shall be taken
from the site immediately and disposed of in a safe and approved manner. Removed
material and debris shall not be stored at the work area. The manner and location of
disposal of material shall be approved by the Engineer and Employer prior to the
commencement of work.
Construction material and equipment shall be brought to the work area only as
needed and shall be stored on site in a safe and proper manner. The Contractors
equipment and material at the work site shall result in minimum inconvenience and
disturbance to the public.
During the performance of the work, the Contractor shall ensure that no removed
material or debris, nor any construction material or equipment is permitted to enter
the sewerage system. The Contractor shall provide a suitable screening and other
DM/SRPD Section 12 Manhole Renovation & Abandonment and Rev 00 June Page 1 of 12
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Dubai Municipality
means of trapping and blocking as required in the downstream manhole to prevent

material from passing downstream.
The screened, trapped or blocked material shall be promptly removed from the
manhole by suitable means, placed in containers, removed from the site and
disposed of in an approved manner.
12.1.3 Safety
The Contractor is responsible for the safety of all personnel as well as for the safety
of the public during the performance of the work and is responsible for maintaining
safe conditions in and around the work area. This is specified in more detail in
Section 10 under “Safety Procedures”.
The Contractor shall provide and agree with the Engineer a written statement
detailing safe systems of work and shall provide and maintain on site suitable and
sufficient safety equipment and the necessary personnel trained in its use, for the
safety and protection of employees, the general public and systems and property of
Dubai Municipality.
12.2 MANHOLE RENOVATION
12.2.1 General
The extent of renovation works shall be as indicated on the drawings and as

determined by the Engineer during the Contract Period from the manhole condition
survey.
The Contractor shall provide all labour, materials and equipment and perform the
works necessary to renovate existing manhole as shown on the drawings or in the
specification or as directed by the Engineer.
A work method description and a proposed programme of manhole renovation works

shall be submitted to the Engineer for approval by the Contractor not less than 14
days prior to the commencement of renovation works.
The manhole condition survey shall be preceded by manhole cleaning which should
be co-ordinated with the sewer cleaning works to be conducted prior to the CCTV
surveys as specified in Section 11.7.
The manufacturer’s instructions on application and safety procedures for all

equipment and materials shall be strictly followed, and where it is deemed necessary
by the Engineer the whole or any part of the application shall be carried out or
supervised by specialists.
The Contractor shall provide the Employer with a written guarantee for the materials
and performance of the manhole renovation works for a minimum period of ten years
commencing on the date of completion of renovation works.
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All manhole renovation works shall be carried out by in-situ lamination methods
unless otherwise instructed.
To minimize disruption to vehicular traffic no manhole cover slabs shall be removed

to undertake the work unless such cover slab is determined to be structurally
unsound by the Engineer.
The Contractor shall keep accurate records of the location and nature of works
carried out to each manhole.
12.2.2 Cleaning of Manholes
Prior to commencing the detailed inspection of any manhole, the manhole shall be
visually inspected for evidence of any accumulations of sand, grease or debris which
may impede the progress or thoroughness of the detailed inspection.
Any accumulations of sand, grease or other debris shall be cleaned from all surfaces
of the manhole prior to commencing the detailed inspection. Manhole walls benching,
corbelling and roof slab shall be cleaned by means of water jetting. Where absolutely
necessary steam may be used to remove obstinate grease and other deposits where
the use of steam is permitted, adequate precautions to protect the operative and
general public from air borne pollution shall be observed. In general, the use of such
methods shall be kept to a minimum. Where directed, additives for cleaning and
disinfecting shall be used.
No sand, grease and other debris in the manhole shall be allowed into the
downstream portions of the sewerage system and shall be removed immediately from
the site. The removed material shall be disposed of in a safe manner and as
12.2.3 Inspection of Manholes
The Contractor shall prepare a manhole inspection program and submit the proposed
program to the Engineer for approval prior to commencing work. The submittal shall
indicate the methods and procedures to be used to evaluate the condition of the
manholes, equipment to be used, the reporting forms to be used to record the results
of the inspection, and the schedule of work. The work schedule must be coordinated
with the schedule of work for the CCTV surveys.
At a minimum, the Contractor shall evaluate the manhole condition against the
following parameters for each manhole:
1) The type and condition of the existing manhole cover and frame. The cover and
frame should conform to the DM standard type and be free from corrosion and
damage. The cover shall also be checked as to its proper seating in the frame so as
to prevent rocking under traffic and to its level relative to the surrounding surface
when in road or footpath.
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2) The presence of and condition of the GRP sealing plate.
3) The condition of the brick corbelling courses under the manhole frame. The
bricks shall be checked for evidence of damage from corrosion and should be
structurally sound. The mortar should be in good condition and the bricks should be
properly seated.
4) The condition of the interior face of the concrete access shaft, barrel and roof
slab. The concrete shall be inspected for evidence of corrosion, pitting, spalling and
loss of material. Exposed reinforcing steel in the top of slab should be noted. Any
evidence of leakage, as indicated either by an active leak or by staining on the interior
face of the concrete, shall be noted.
5) The structural soundness of the concrete access shaft, manhole barrel walls and
roof slab. The structural soundness shall be tested by non-destructive means from
inside the manhole. The testing methods shall be as approved by the Engineer but
shall include :-
Core (100mm dia) strength, BS 1881: P. 1 core per every 10 sq. meter (If the core
120 strength is less than 1.12 times the
required compressive strength additional
cores will be taken).
Water absorption of concrete BS 1881: P. 1 test per every 10 sq. meters.

122
Sulphate content of concrete, BS 1881: - do -

P.124
Cement content in concrete, BS 1881: 1 test per every 10 sq. meters

P.124
Chloride content of concrete, BS 1881: - do -

P.124
Alkali content in concrete, BS 1881: - do -

P.124
Determination of concrete cover depth
Determination of reduction in steel cross

sectional area
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Dubai Municipality
6) The material and condition of the existing liner where present in the shaft and
barrel of the manhole.
7) The type and condition of any fittings inside the manhole including manhole
ladders, manhole steps or rungs, flap valves, safety chains or any other
appurtenance. The report shall note the type of fittings, their number, material of
construction, their location in the manhole, their condition and the manner of their
installation in the manhole.
8) The condition of the benching. The benching shall be inspected for evidence of
corrosion, pitting and loss of material as well as any physical damage. The invert
shall be checked for uniformity and for the smooth transition form the upstream to
downstream pipe and from any branch into the mainline.
9) The pipe entrances and exists to the manhole shall be inspected for damage to
both the manhole wall and to the pipe material.
12.2.4 Manhole Inspection Report
The Contractor shall submit the results of the manhole inspections to the Engineer for
review. The report shall include notes on the visual inspection of the manhole
parameters listed in preceding Clause 12.2.3 “Inspection of Manholes” and any
drawings or sketches necessary to adequately convey the results of the inspection to
the Engineer. The report text shall be clearly legible and typewritten in a format
previously agreed upon with the Engineer.
An inspection report shall be submitted for each manhole as work progresses within
48 hours of completion of the inspection on that manhole or as otherwise agreed
upon with the Engineer.
The Engineer will review the manhole inspection reports and determine the action to
be taken for each manhole; the actions to be recommended include renovation of the
manhole, either wholly or in part, complete replacement of the manhole or no action.
12.2.5 Manhole Renovation
The Contractor shall renovate existing manholes as shown on the contract drawings
and where directed by the Engineer. The renovation work must be scheduled and
coordinated with the renovation or rehabilitation of the existing sewer pipeline so as to
avoid conflicts between work crews, facilitate rapid completion of the work and to limit
the disturbance to the area.
12.2.6 Covers and Frames
Where the manhole cover and frame are found not to conform to the DM standard
type (refer to Clause 4.10 headed “DM Standards for Covers and Gratings”), or if
either the existing cover or the frame are found to be corroded or otherwise damaged,
the Engineer will direct the Contractor to remove the existing cover and frame, which
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Dubai Municipality
shall be taken from the site and disposed of as directed by the Engineer. The
Contractor shall immediately install a new cover and frame conforming to the DM
standards.
Manholes covers and frames which are in the opinion of the Engineer in serviceable
condition, but are not in accordance with current Dubai Municipality requirements,
shall be removed and transported to the Dubai Municipality Drainage Section store.
New covers and frame complying with DM standards shall be installed by the
Contractor.
Where in the opinion of the Engineer, the existing manhole cover and frame may be
retained and of the DM Standard type, then refurbishment of the cover and frame
shall comprise the following :-
1) Removal of the cover followed by cleaning and sand blasting to remove all
grease, rust and scale.
2) Painting of the cover in accordance with the requirements of Clause 4.10 “DM
Standards for Covers and Gratings” appropriate for sewerage environment.
3) Where in the opinion of the Engineer the frame can be removed, items 1. and 2,
shall also apply to the frame.
4) Where the frame is to be left in place, all exposed parts shall be thoroughly
cleaned to remove all grease, rust and scale and then painted in accordance with the
requirements of clause 4.10 “DM Standards for Covers and Gratings” appropriate for
sewerage environment.
5) If there is an existing GRP sealing plate and this is in a damaged condition the
Contractor shall provide and install a new and identical GRP sealing plate to replace
the damaged unit and to suit the cover and frame in which it is to be installed.
6) If there is no existing GRP sealing plate, the Contractor shall provide and install
a new GRP sealing plate to suit the cover and frame in which it is to be installed. The
Contractor shall submit detailed drawings of each type of GRP sealing plate to
demonstrate how it will fit each type of existing cover and frame.
The new or rehabilitated manhole covers and frames shall be set with the tops
conforming to the finished grade of pavement or ground surface unless otherwise
indicated, specified or directed by the Engineer. The manhole frame shall be set
concentric with the top of the manhole access shaft and cantered over the opening.
The frame shall be set in specified mortar all around and on top of the bottom frame
flange. The mortar shall be smoothly finished and provided with a sloping, rounded
surface all as shown in the drawings.
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12.2.7 Corbelling
Depending on the extent of the damage, if any, to the brick or block corbelling, the
Engineer may direct the Contractor to replace individual bricks or block work, to point
up deteriorated or missing mortar or to replace the entire brick or block corbelling.
Where necessary due to differences between manhole cover and surrounding

surfaces the Engineer may direct the Contractor to replace the entire brick or block
corbelling.
12.2.8 Concrete Access Shaft, Top Slab and Barrel
a) Leak Sealing
Any visible leaks or areas showing evidence of leakage shall be sealed as directed by
the Engineer.
The Contractor shall carefully drill a hole from the interior of the manhole through the
thickness of the wall at each leakage point. Suitable approved non-shrink grout or
sealing material shall be injected through the hole into the surrounding soil to form a
permanent seal from outside of the leaking area. The Contractor shall select and use
suitable equipment to provide an effective watertight seal and ensure that the
grouting pressures do not damage the manhole structures.
When the injection of the sealing grout is complete, the equipment shall be removed
and any sealing material cleaned from the inside surfaces of the hole in the manhole
wall. After the leak sealing operations are complete and the sealing grout has
achieved its set, the manhole shall be inspected in the presence of the Engineer. If
the leak sealing operations are successful and to the satisfaction of the Engineer, the
hole shall then be filled with an approved sewage resistant epoxy mortar.
b) In-Situ Lining
The Contractor shall form an approved in-situ laminated GRP liner to cover the
internal surfaces of the access shaft if applicable, the manhole top slab, the
underside of the roof slab and the barrel walls. The liner shall be by hand application
of an approved resin and glass fibre reinforcing mix onto the prepared surfaces. All
GRP linings shall be in accordance with Section 7.1.6 “In-Situ Laminations”.
The Contractor shall engage personnel with proven expertise in the field of
application of the lining material onto existing surfaces and shall utilize equipment
appropriate to the work and for the conditions under which the work shall be
performed.
All manholes shall be adequately ventilated or otherwise made safe to work without
breathing equipment.
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Prior to forming the liner, the interior surfaces shall be thoroughly cleaned as per
Clause 12.2 and all interior appurtenances removed. The cleaned surfaces shall then
be scabbled using a pneumatic needle hammer or similar to prepare the surfaces for
bonding with the liner material and to ensure that any remaining unsound material is
removed.
Any voids left after the removal of interior appurtenances or from the scabbling
operation shall be filled with an approved epoxy mortar. The final surface of the
internal walls shall be made uniform and to conform to the original contour and levels.
c) Preformed Liner
Where cover slab replacement is necessitated by structural deterioration of the

member or for renovation of the manhole barrel, the Contractor shall install an
approved preformed GRP liner to cover the internal surfaces of the barrel walls. (All
GRP linings shall be in accordance with Section 7.1.5).The diameter of the liner for
the barrel walls shall be 100-150mm less than the existing wall. The liner shall be
formed with spacers to maintain a constant annulus between the liner and the
concrete wall.
Where cover slab replacement involves removal of the access shaft construction of
any replacement shaft shall incorporate a preformed liner with concrete surround, all
as indicated on the drawings.
The preformed liner for the cover slab shall be as shown on the drawings or as
All manholes shall be ventilated or otherwise made safe to work without breathing
equipment.
Prior to installing the liner, the interior surfaces shall be thoroughly cleaned as per
Clause 12.2 and all interior appurtenances removed. The cleaned surfaces shall then
be scrabbled using a pneumatic needle hammer or similar to prepare the surfaces for
bonding with the liner material and to ensure that any remaining unsound material is
removed.
Any voids left after the removal of interior appurtenances or from the scrabbling
operation shall be filled with an approved epoxy mortar.
A rebate shall be prepared in the benching to receive the GRP liner. The rebate shall
be prepared along the perimeter of the manhole where the benching meets the
manhole wall. The rebate shall measure 100mm deep by 100mm wide at the top and
90mm wide at the bottom.
After insertion of the liner, the rebate remaining between the liner and the existing
wall face shall initially be sealed with grout and allowed to set. In addition, the rebate
in the benching shall be filled with cement mortar.
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Dubai Municipality
After sealing the base of the liner the remaining annulus between the liner and the
existing wall face shall be filled with approved non-shrink grout, care being taken not
to deform or disturb the liner due to excessive or uneven pressures. Upon completion
of the grouting the rebate shall be filled with cement mortar and the surface of the
benching shall be repaired .
After the benching has been repaired a 25mm wide and 35mm deep rebate shall be
formed along at the perimeter between the liner and the benching, as detailed in the
drawings for new manholes.
The joint between the wall lining and the cover slab lining shall be sealed effectively
by an approved method.
d) Benching and Channel
The existing benching and channel are to be removed to a sufficient depth to conform
to the new pipe size with an allowance for a 10mm thick epoxy mortar or 7mm GRP
laminate liner. Any material below the required level that is unsound shall also be
removed until sound material is reached. The resulting depression shall be brought to
the proper level and contour using an approved epoxy mortar mix. The benching and
channel surfaces shall be thoroughly cleaned and scrabbled using a pneumatic
needle hammer or similar.
After the benching and channel have been brought to the proper level and contour
and the liner has been installed, an epoxy mortar or GRP laminate liner as specified
in Clause 7.1.7 and 7.1.5 shall be applied to all surfaces of the benching and
channel.
Where epoxy mortar is used a rebate shall be prepared in the benching as specified
to form a satisfactory joint to the internal lining. The material removed from the
benching and channel for resurfacing and from the benching for preparation of the
rebate shall be immediately removed from the manhole and disposed of in a safe and
approved manner and location. Under no circumstances shall debris be allowed into
the downstream sections of the sewer.
The rebate shall be tightly packed with approved sealant which shall be pouring
grade polysulphide suitable for cold application. It shall comply with the requirements
of BS 4254 (amended) and/or USFS TT-S-227 or DIN 18550:1973.
Prior to application of the sealant the rebate shall be made clean, dry and free from
dirt, dust and loose material. The sealant shall be applied and finished strictly as per
the manufacturer’s instructions.
Where in-situ GRP lamination is used, a 50 x 50 mm fillet shall be formed using vinyl
ester paste along the perimeter of the benching at the wall lining. The lamination to
the benching shall be extended to form a 100mm wide overlap to the wall lining
above the chamfer.
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Dubai Municipality
Any holes required in the liner for pipework shall be carefully cut to the outside
diameter of the pipe. A 25mm x 25mm rebate shall be formed in the concrete around
the pipe and this shall be sealed with an approved sealant.
The sealant shall be durable, resistant to microbiological attack, contact with sewage
and sewage gases, weathering and immersion. The rebate shall be primed with
appropriate primer prior to application of the sealant. The sealant shall be applied
strictly in accordance with the manufacturer’s instructions.
12.3 MANHOLE ABANDONMENT
12.3.1 General
The Contractor shall provide the labour, materials and equipment and perform the
work necessary to abandon existing manholes as indicated on the Contract Drawings
and as specified herein. The abandonment work shall be scheduled and co-ordinated
with the renovation of existing sewers and construction of new sewers so as to avoid
conflicts between works crews, facilitate a rapid completion of the work and to limit
the disturbance to the area. Manhole abandonment may commence only after
pipeline abandonment work has been completed at any manhole.
12.3.2 Manhole Abandonment
Covers, frames, all brick or block corbelling together with concrete haunching, shall
be removed from the manholes to be abandoned. All brick and block corbelling and
concrete debris shall be removed from the site and disposed of in a manner approved
by the Engineer.
Where the manhole covers and frames are found not to conform to the DM Standard
type (refer to Clause 4.10), or if either the existing covers or frames are found to be
corroded or otherwise damaged, the Engineer will direct the Contractor to remove the
existing covers and frames from the site and dispose of in an approved manner.
Where the existing manhole covers and frames are found to be in good condition, of
the DM Standard type and are approved by the Engineer, the covers and frames shall
be rehabilitated in accordance with Clause 12.2.6 and delivered to DM stores.
After removal of the cover, frame and corbelling and any undesirable material from
within the manhole, the manhole shaft/barrel walls shall be broken-out to a depth of
1.5m below finished ground level. All undesirable material and concrete rubble shall
be removed or disposed of in a manner approved by the Engineer. After approval by
the Engineer, the Contractor shall fill the entire remaining volume of the manhole
concrete barrel and access shaft, and the excavated area with an approved well
graded natural sand or gravel as specified for Structural Filling in Section 2. Structural
filling is required within road corridors and/or wherever a structure is to be supported
on the fill and where settlement is required to be minimal.
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Where the abandonment of manholes involves the disruption of existing road

surfaces, pavement or tiled areas the affected surfaces shall be reinstated as
specified in Appendix 1 and Appendix 4 of the Specification.
12.4 PUMPING STATION AND RISING MAIN ABANDONMENT
12.4.1 General
The Contractor shall provide all labour, materials and equipment and perform the
work necessary to abandon existing pumping stations as indicated on the Contract
Drawings and as specified herein. The abandonment work shall be scheduled and
co-ordinated with the renovation of existing sewers and construction of new sewers
so as to avoid conflicts between work crews, facilitate a rapid completion of the work
and to minimize disturbances to the area.
Where existing pumping stations are to be demolished, the Contractor shall give
Dubai Municipality Sanitary Sewers Maintenance Team a minimum of two weeks
notice of the intent to commence demolition in order that the Municipality can arrange
for removal of all mechanical and electrical equipment by their personnel and
establish isolation of the power supply to ensure the whole area is safe.
Pumping station abandonment may commence only after pipeline abandonment work
has been completed in the pumping stations catchment area.
12.4.2 Pumping Station and Rising Main Abandonment
The work shall include, but not be limited to, the following:
i. Demolition of kiosk, plinth, wet wall and valve chamber top slab and walls to a
depth of at least 1.5 meters.
ii. Flushing and grouting of rising main
iii. Filling of wet well, valve chamber and excavated area, and
iv. Reinstatement, where necessary.
Access hatches, manhole covers and frames shall be removed from the pumping
station structures to be abandoned. Where the hatches, covers and frames are found
not to conform to the DM Standard type (refer to Clause 4.10), or if either the existing
covers or frames are found to be corroded or otherwise damaged, the Engineer will
direct the Contractor to remove the existing covers and frames from the site and
dispose of in an approved manner.
Where the existing access hatches, covers and frames are found to be in an
acceptable condition, of the DM standard type and are approved by the Engineer, the
covers and frames shall be rehabilitated in accordance with Clause 12.2.6 and
delivered to DM stores.
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Dubai Municipality
The kiosk plinth, top slab and walls of the valve chamber and wet well shall be
removed to a minimum depth of 1.5 meters below ground surface. All concrete and
other material shall be removed from the site and disposed of in a manner approved
by the Engineer.
The Contractor shall flush the rising main with clean water. All flushing water shall be
collected at the discharge end of the rising main to be abandoned and disposed of in
a manner approved by the Engineer. If the rising main is within 1.5 meters from the
surface, the pipe shall be removed for a distance of at least 0.5 meters from the
exterior wall of the valve chamber and then to the next pipe joint. After flushing of the
rising main and if required, after removal of any pipe lengths, the rising main shall be
permanently filled with cement grout all as specified in Section 11.6
The Contractor shall prepare the inlet sewer length for abandonment as provided in
Section 11.6. All sewer lengths from the proposed abandoned pumping station to the
first manhole to remain in service are to be abandoned.
The Contractor will inspect and remove any undesirable material from the pumping
station structures. After approval by the Engineer, the Contractor shall fill the entire
volume of the structures and the excavated area with an approved well graded
natural sand or gravel as specified for Structural Fill in Section 2. Structural filling is
required within road corridors and/or wherever a structure is to be supported on the
fill and where settlement is required to be minimal.
Where the abandonment of pumping station involves the disruption of existing road
surfaces, pavement or tiled areas, the affected surfaces shall be reinstated as
specified in Appendix 1 and Appendix 4, of the Specification.
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 13
PILES AND PILING
DM/SRPD Section 13 Piles and Piling Rev 00 June
2016

Dubai Municipality
DM/SRPD Section 13 Piles and Piling Rev 00 June Page i of iii
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SECTION 13
PILES AND PILING
CONTENTS
13 PILES AND PILING............................................................................................................ 1
13.1 SCOPE........................................................................................................................... 1
13.2 GENERAL...................................................................................................................... 1
13.2.1 Related Specifications .......................................................................................... 1
13.2.2 Record of Condition of Existing Structures ........................................................... 2
13.2.3 Record of Existing Services .................................................................................. 2
13.2.4 Specialised Contractors ........................................................................................ 2
13.3 MATERIALS .................................................................................................................. 2

13.3.1 Permanent Casings .............................................................................................. 2
13.3.2 Temporary Casings .............................................................................................. 2
13.3.3 Concrete for Piling ................................................................................................ 3
13.3.4 Reinforcement ...................................................................................................... 3
13.3.5 Execution of Work ................................................................................................. 3
13.3.6 Pile Head Protection / Water Proofing System ..................................................... 4
13.4 DESIGN ......................................................................................................................... 5

13.4.1 Design Criteria ...................................................................................................... 5
13.4.2 Spacing ................................................................................................................. 5
13.4.3 Submittals ............................................................................................................. 6
13.5 WORKMANSHIP ........................................................................................................... 6

13.5.1 Substandard Work ................................................................................................ 6
13.5.2 Obstruction or Changes in Condition .................................................................... 6
13.5.3 Handling ................................................................................................................ 7
13.5.4 Lengthening of Piles ............................................................................................. 7
13.5.5 Pile Location Identification .................................................................................... 7
13.5.6 Setting Out and Tolerances .................................................................................. 7
13.5.7 Piling Records ....................................................................................................... 8
13.6 TESTING OF CONCRETE ............................................................................................ 8

13.7 LOAD TESTING OF PILES ........................................................................................... 8
13.7.1 General ................................................................................................................. 8
13.7.2 Negative Skin Friction ......................................................................................... 10
13.7.3 Preliminary Pile Tests ......................................................................................... 10
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13.7.4 Working Pile Tests .............................................................................................. 11

13.7.5 Test Failure Criteria ............................................................................................ 12
13.7.6 Fluctuating Load Tests ....................................................................................... 12
13.7.7 Completion of a Test ........................................................................................... 12
13.8 PILE INTEGRITY TESTING ........................................................................................ 13

13.9 CALLIPER LOGGING OF PILE BORE ....................................................................... 14
13.10 DYNAMIC PILE TESTING ........................................................................................... 14
13.11 TEST REPORTS.......................................................................................................... 15
13.12 AS-BUILT DRAWINGS ............................................................................................... 16
DM/SRPD Section 13 Piles and Piling Rev 00 June Page iii of iii
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13 PILES AND PILING
13.1 SCOPE
a) This Specification deals with the general requirements for the materials, design,
workmanship and testing of bored piles of all types. Generally cast insitu (bored)
piles with temporary casing method will be allowed. The type of equipment
adopted shall be selected with consideration of any noise regulations imposed by
the Local Authorities/ Employer.
b) The Contractor shall visit the site to familiarise with the site conditions and
existing services in locations where the piling works has to be carried out and
accordingly make allowance in the price.
13.2 GENERAL
13.2.1 Related Specifications
a) The piling works are to be carried out in accordance with the Institution of Civil
Engineers Specification for Piling and Embedded Retaining Walls (SPERW,
1996). The piles are to be constructed by bored and cast in place techniques. Pile
tests will be required to confirm the design assumptions made and the load
settlement characteristics of the piles.
b) The Contractor shall perform the works with reference to the following codes of
practice
BS 1377 Methods of Test for Soils for Civil Engineering Purposes.
BS 1881 Methods of Testing Concrete.
BS 5930 Code of Practice for Site Investigations.
BS EN 1997-1 Foundations.
CP 2011 Safety Precautions in the Construction of Large Diameter

Boreholes for Piling and other Purposes.
BS EN 1992-1-1 The Structural Use of Concrete.
BS 5950 Structural Use of Steelwork
BS 8102 Code of Practice for the Protection of Structures against

Water from the Ground
CIRIA R144 Integrity Testing in Piling Practice
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13.2.2 Record of Condition of Existing Structures
a) Prior to commencing work the Contractor shall examine and note all existing
cracks or other damage in adjacent structures and bring them to the attention of
the Engineer. This survey shall be submitted to the engineer in report form prior to
the commencement of the works. The report shall include a record of size and
location of all cracks.
b) These surveys shall be carried out by a qualified structural engineer at the Piling
Contractor's expense.
c) It is the responsibility of the Contractor to ensure that no damage occurs to

existing structures, roads or services for the duration of the piling works.
d) If during execution of the work, damage is, or is likely to be caused to any part of
adjacent buildings including finishes etc. and any equipment etc. within the
building the Contractor shall submit his proposal for avoidance of such damage to
the Engineer.
13.2.3 Record of Existing Services
Prior to commencing work, records of drains, cables, piles and other services shall be
made by the Contractor, to ensure that no piles or piling equipment causes damage
to these services. The Contractor is liable for any damage to services occasioned by
or arising out of his work on site.
13.2.4 Specialised Contractors
The works shall be carried out by a specialised piling contractor, well experienced in
the types of piling being specified, and suitably staffed and equipped to carry out such
work in the United Arab Emirates in accordance with this specification.
13.3 MATERIALS
13.3.1 Permanent Casings
For soils in areas classified as category 5 according to BRE Digest 363, permanent
casings shall be provided. The permanent casing length shall be 2.0m below ground
surface. Should the ground water table be at 2.5m below ground level, casing will be
extended to become 3.0m below finished ground surface. This procedure shall be
applicable for areas not affected by tidal effects. For areas affected by tidal effects,
casings shall project 0.5m below the lowest water level anticipated. Permanent
casings shall be of steel, thickness not less than10 mm External surface to be coated
with 2 coats of coal tar epoxy with an overall thickness no less than 300 micron.
13.3.2 Temporary Casings
a) Temporary casings shall be free from significant distortions. They shall be of

uniform cross-section throughout each continuous length. During concreting they
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Dubai Municipality
shall be free from internal projections, debris and encrusted concrete which might
prevent the proper functioning of the pile, or formation of a monolithic pile shaft
free of defects.
b) For temporary casing, a method statement shall be submitted to the Engineer for
approval.
13.3.3 Concrete for Piling
a) Cement to be used shall be selected according to the recommendations of the

soil Investigation Report.
b) The minimum grade of concrete for all piles shaft be C60.
c) Maximum Free WCR shall be 0.35.
d) The minimum cementicious content shall not be less than 400 kg/m³ and the
maximum specified cement content in any mix shall not exceed 475 kg/m³.
Concrete design mix shall be submitted to the Engineer for approval.
e) Concrete is to be placed by a tremie under water the slump shall be 175mm +/-
25mm (Type C) for each pile. Concreting shall be a continuous operation and no
(cold) joint shall be permitted.
f) Certificates and test cube results for the materials and the concrete shall be
supplied to the Engineer for Approval.
13.3.4 Reinforcement
Reinforcement anchorage lengths shall be considered as tension anchorages. The

reinforcement shall be stored to ensure it is clean and free from debris at all times.
13.3.5 Execution of Work
a) Cast insitu (bored) piles with temporary/permanent steel casing will be permitted
for execution. Casing shall extend to a minimum of one metre below the solid
strata of soil as shown in the soil investigation report. Immediately after drilling,
the reinforcement shall be placed and the pile cast. Tremie pipe shall be used for
concrete casting. The internal diameter of the tremie pipe shall not be less than
150mm and it shall extend to the bottom of the pile prior to commencement of
concreting. A minimum embedment of 3.00 m in the concrete shall be maintained
so as to ensure that no mud or debris enters the pile. Concreting shall continue
until sound uncontaminated concrete is present at ground level. The hopper and
tremie shall be fully charged at all times.
b) During withdrawal of temporary casings a sufficient head of wet concrete shall be

maintained within them to prevent the inflow of ground water or collapse of
unstable soil. Excavation around the piles to assist in the extraction of temporary
lining tubes will not be permitted. The level of the concrete after removal of each
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 14
MICROTUNNELLING AND PIPE JACKING
DM/SRPD Section 14 Microtunnelling and Pipe Jacking Rev 00 June
2016

Dubai Municipality
DM/SRPD Section 14 Microtunnelling and Pipe Jacking Rev 00 June Page i of ii
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SECTION 14
MICROTUNNELLING AND PIPE JACKING
CONTENTS
14 MICROTUNNELLING AND PIPE JACKING ..................................................................... 1
14.1 GENERAL...................................................................................................................... 1
14.1.1 Scope.................................................................................................................... 1
14.1.2 Applicable Standards / References ...................................................................... 1
14.1.3 Definitions ............................................................................................................. 3
14.1.4 Submittals ............................................................................................................. 4
14.2 EQUIPMENT and PIPE MATERIALS ......................................................................... 16

14.2.1 Equipment ........................................................................................................... 16
14.2.2 Pipe Materials ..................................................................................................... 19
14.2.3 Joint Packing ...................................................................................................... 26
14.2.4 Joint Seal ............................................................................................................ 26
14.2.5 Dewatering Equipment ....................................................................................... 26
14.3 EXECUTION ................................................................................................................ 27

14.3.1 General ............................................................................................................... 27
14.3.2 Examination ........................................................................................................ 27
14.3.3 Cavity Grouting ................................................................................................... 27
14.3.4 Shafts, Jacking and receiving Pits ...................................................................... 28
14.3.5 Tunnelling / Pipe Installation ............................................................................... 32
14.3.6 Constructions Shift Records ............................................................................... 34
14.3.7 TBM Real Time Monitoring ................................................................................. 34
14.3.8 Guidance and Control System ............................................................................ 35
14.3.9 Drilling Fluid Tests .............................................................................................. 36
14.3.10 Grouting .............................................................................................................. 37
14.3.11 Tolerances .......................................................................................................... 38
14.3.12 Dewatering .......................................................................................................... 38
14.3.13 Slurry Separation Plant ....................................................................................... 41
14.3.14 Protection of existing Structures and Services ................................................... 41
14.3.15 Monitoring Ground Surface Movement ............................................................... 41
14.3.16 Pipe Testing ........................................................................................................ 42
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14 MICROTUNNELLING AND PIPE JACKING
14.1 GENERAL
The following Specifications are for the Microtunnelling and Pipejacking requirements.
The Contractor shall perform non-disruptive techniques in accordance with the
provisions of this Section.
14.1.1 Scope
The Contractor’s scope includes , but is not limited to , providing all labour, tools,
materials, equipment and incidentals required to design and complete the installation
of pipelines using micro-tunnelling or pipe jacking methods as and where indicated on
the Drawings and as specified, including surveying, instrumentation and dewatering.
The Contractor shall be responsible for the design of the Temporary Works,
Permanent Works, jacking pipe and for the selection of the tunnel boring machine
and the tunnel construction systems.
14.1.2 Applicable Standards / References
All activities related to this section of the specifications shall comply with the
followings or approved equivalent standards:
AASHTO HS20 44+100%-Surcharge loading.
BS 1377 Methods of test for soils for civil engineering purposes.
BS 5228-1 Code of practice for basic information and procedures for

noise control.
BS 5228-2 Guide for noise control legislation for construction and

demolition , including road construction and maintenance.
BS 5911-1 Concrete pipes and ancillary concrete products. Specification

for unreinforced concrete pipes ( including jacking pipes) with
flexibe joints.
BS 5930 Code of practice for site investigations.
BS 6164 Code of practice for safety in tunnelling in the construction

industry.
BS EN 681-1 Elastomeric seals. Material requirements for pipe joint seals

used in water and drainage applications.
BS EN 1916 Concrete pipes and fittings , unreinforced , steel fibre and
DM/SRPD Section 14 Microtunnelling and Pipe Jacking Rev 00 June Page 1 of 42
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Dubai Municipality
reinforced.
ISO 9000 Quality management systems.
BS EN 12620:2002 Aggregates for Concrete.
BS EN 12889:2000 Trenchless construction and testing of drains and sewers.
BS EN 206-1:2000 Concrete. Specification, performance, production and

conformity.
BS EN 14364:2006 Plastic piping systems for drainage and sewerage with or

without pressure. Glass reinforced thermosetting plastics
(GRP) based on unsaturated polyester resin (UP).
Specifications for pipes, fittings and joints’
BS EN 14364:2006 Plastics piping systems for non-pressure drainage and

sewerage. Glass-reinforced thermosetting plastics (GRP)
based on unsaturated polyester resin (UP). Fitness for
purpose of the joints.
BS6164: 2011 Code of Practice for Safety in Tunnelling in the Construction

Industry.
ASTM D4161-01 Standard Specification for "Fiberglass" (Glass-Fiber-

Reinforced Thermosetting-Resin) Pipe Joints Using Flexible
Elastomeric Seals’.
ASTM D638 Standard test methods for tensile properties of plastics.
ASTM D 6783 Standard Specification for Polymer Concrete Pipe.
ASTM C 579 Standard test method for compressive strength of chemical

resistant mortars, grouts, monolithic surfacing and polymer
concretes.
DIN 54815-1 Pipes made of filled polyester resin moulding materials -

Dimensions, material and marking.
DIN 54815-2 Pipes made of filled polyester resin moulding materials -

Requirements and testing.
British Tunnel Society: Model specifications for Tunneling’

2001.“Specification for Tunnelling 3rd Edition”: The British
Tunnelling Society and The Institution of Civil Engineers:
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Dubai Municipality
Thomas Telford Ltd 2010.
CIRIA C577 Guide to the construction of reinforced concrete in the

Arabian Peninsula.
Pipe Jacking Association, UK.
Guide to best Practice for installation of pipe Jacks and

Microtunnel (Concrete Pipe Association and the Pipe Jacking
Association, UK - 1995)
An Introduction to Pipe jacking and Microtunneling design.
Dubai Municipality – Guidelines and Requirements for

Planning and Design of Non Disruptive Road Crossings.
14.1.3 Definitions
The following definitions shall apply to words and phrases utilised in this Section:
a) “Pipe Jack” is defined as a pipeline constructed by thrusting specially designed

pipes or other permanent lining of preformed units progressively into the ground
by means of jacks or similar equipment while excavation proceeds at the leading
edge.
b) The use of the term ‘‘tunnelling’’ herein refers to excavation and installation of
pipe by either pipejacking or microtunnelling methods, or other similar trenchless
method. The term ‘tunnel’ shall be taken to mean the installed pipeline, whether
during or after the completion of the installation.
c) “Pipejacking” is a trenchless technology of installing underground pipelines

(between 900mm and 3500mm in diameter) by means of jacking specially
designed pipes through the ground from a jacking pit or shaft. The excavation is
achieved by using a shield at the forward end of the pipeline. Unless otherwise
approved by the Engineer, all shields shall be capable of providing continuous
support to the face by slurry or earth pressure balance methods.
d) “Microtunnelling” is a trenchless technology for construction of pipelines (between

200mmm and <900mm in diameter). It is a remotely-controlled, guided,
pipejacking process that provides continuous support to the face (via a full-face
micro-TBM) without requiring personnel entry into the tunnel.
e) “Tunnel Boring Machine (TBM)” refers to the mechanised cutting unit, shield and
ancillary equipment, whether it is for microtunnelling or pipejacking applications.
f) “Face Control” refers to complete mechanical support of the excavated face at all
times.
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Dubai Municipality
g) “Earth Pressure Balance” refers to pressure applied to the cutting face equals the
pressure of the earth against the cutting face.
h) “Drill String” refers to a series of joined individual pipes which is used to advance
the excavation equipment.
i) “Annular Space”: The void between the outside diameter of the installed casing
pipe and the outer limits of the bore being excavated for the casing pipe. The
annular space also refers to the space between the casing pipe and the smaller
diameter carrier pipe installed within the casing.
j) “Hydraulic Fracturing”: Shall mean fractures produced by pressurised drilling

fluids or grout in weak or unconsolidated areas of the soil matrix resulting in
excessive fluid loss or upwelling of fluid to the surface.
14.1.4 Submittals
14.1.4.1 Products and Material Approvals
The Contractor shall submit information for all products and materials used in the
Works to the Engineer for approval in advance of their use in accordance with the
contract programme allowing for ordering and approval times. Information to be
submitted shall comprise but not necessarily be limited to:
a) The manufacturers design calculations, complete and detailed specification and

test results of the proposed pipes and fittings required for the Works including
manufacturer’s certificates of compliance in accordance with specifications.
Information shall be given for every diameter in each class of pipe.
b) Should any details of the pipes and fittings be altered in any way during
manufacture from those proposed and approved by the Engineer, submit for the
Engineer’s approval the revised details and test results.
c) Submit to the Engineer the results of all quality control tests carried out on the
manufactured pipes and fittings as soon as practicable after testing and in any
case not later than the time of delivery of the relevant pipes and fittings to the site.
d) Pipe manufacturer’s guarantee that the pipe and its materials are suitable for its
Intended use.
e) Joint materials and gaskets.
f) Concrete protection systems.
g) Provide from the manufacturer a certificate of the bentonite powder showing the
properties of each consignment delivered to the site. Ensure that this certificate is
available to the Engineer on request. The properties to be given by the
manufacturer are the apparent viscosity range in pascal seconds and the gel
strength range in pascals for solids in water.
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Dubai Municipality
h) The Contractor shall submit a schedule for the submission of working drawings
and specifications for review. This schedule shall be agreed with the Engineer.
i) The Contractor shall submit a detailed schedule of manufacture/supply of TBMs,

back-up plant and equipment including delivery dates and testing dates. The
Contractor shall update progress on a weekly basis and comment on future
necessary action to maintain delivery date.
j) Within 8 weeks after the Commencement Date, the Contractor shall provide all
details of the TBMs and back-up equipment, including all items specified herein.
k) The Contractor shall demonstrate that the TBM manufacturer has manufactured
at least three TBMs of similar type, size, and complexity, used in successfully
completed similar size projects.
l) The Contractor shall submit to the Engineer information on all proposed drilling
fluids, additives, lubricants and conditioning agents. Submittals must include
material safety data sheets on each material along with a description of where the
material will be used and its purpose in the construction process. All drilling fluids
and lubricants shall be bio-degradable.
m) Prior to the commencement of the Works the Contractor shall submit calculations
showing the estimated maximum jacking force for each drive. The calculations
shall take into consideration the frictional characteristics of the ground and the
pipe material, the type of lubricant, the depth and the diameter of the pipe and the
required length of the drive.
n) Prior to commencement of works, the Contractor shall design the pipes for
adequate strength for NDM (non-disruptive method) works considering ground
characteristics and jacking force, etc. Contractor shall submit the design
calculations for Engineer’s approval.
o) The Contractor shall submit the details, method statements and specifications for
the final pipe systems selected for construction, for approval of the Engineer.
These shall include: pipe materials; collar and joint systems; corrosion protection
lining; grouting; intermediate jacking stations and locations in drives; break in/out
from shafts, soft eyes and seals.
p) The Contractor shall prepare a Gas Characterisation Programme, detailing the

methods and frequencies for monitoring of hazardous gases.
14.1.4.2 Submittals for Dewatering
a) The following submittals shall be forwarded to the Engineer for approval a

minimum of 6 weeks before any work referred to in the submittals is scheduled to
commence.
b) Water Control Plan:

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(i) The Contractor shall submit a Water Control Plan (WCP).
(ii) The WCP shall include, as a minimum, descriptions of proposed

groundwater and surface water control facilities including, but not limited to,
equipment; installation, operation, and removal methods; standby
equipment and power supply, silt removal facilities, pollution control
facilities, discharge locations to be utilized.
(iii) The WCP shall contain provisions for measuring discharge flow from the
dewatering system, a program for measuring groundwater level during
dewatering system operations, and a program for sampling and testing
ground water quality.
(iv) The Contractor shall be required to submit full details to demonstrate that
settlement due to dewatering operations will not exceed the allowable
amounts specified for settlement due to microtunnelling or pipe jacking
operations. The Contractor shall also demonstrate that all buildings,
structures and services within the zone affected by the dewatering
operations shall not be affected by the dewatering. The Contractor shall
submit full details of the numbers and locations of piezometers required to
monitor the extent and magnitude of the drawdown caused by the
dewatering, and of settlement points and other instrumentation to verify that
the settlements are being maintained within allowable tolerances. The
Contractor shall also provide full details of how to monitor both the rate of
abstraction of water from all the wells and the quality of the water
abstracted.
(v) The WCP shall include projected pumping rates based on information
established in the Geotechnical Data Report, Geotechnical Interpretative
Report, and Geotechnical Assessment Report for the project. The WCP
shall also include projected drawdown curves, recharge rates, and other
hydro-geologic information and calculations developed to support the
proposed dewatering systems and methods.
c) Shop Drawings:
(i) The Contractor shall submit shop drawings showing locations, dimensions,
and relationships of elements of each dewatering system. The submittal
shall include design calculations demonstrating adequacy of proposed
dewatering or isolation systems and water wells and their components. The
Contractor shall provide manufacturer's literature describing installation,
operation, and maintenance procedures for all components of the
dewatering system and water wells.
(ii) The Contractor shall provide installation records of all components of the
dewatering systems proposed in the WCP including drawings showing the
installed location of each component of the dewatering system installed.
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d) Quality Control Submittals: The Contractor shall submit weekly to the Engineer,
tabulated water level elevations recorded daily in observation wells and
piezometers.
14.1.4.3 Method Statements
The contractor shall submit method statements to the Engineer for approval 4 weeks
in advance of commencing the site activity in accordance with specifications. These
shall compromise but not necessarily limited to:
a) Geotechnical investigation report to include all information related to geotechnical

and geophysical investigation undertaken and recommendations for tunnelling
technique to be adopted , excavation support, and soil stabilisation if required
including grouting of cavities if any.
(i) Geotechnical Design Report, which:
1. May be separated into the different elements (based on geographic

location and type of pipejacking or microtunnelling);
2. Includes any additional geotechnical investigations and testing (factual

data) undertaken by the Contractor post award;
3. Summarises the anticipated ground conditions for each work shaft and
pipeline drive;
4. Presents the basis for the selection of particular TBM’s and cutter face
arrangements;
5. Presents the basis of design for all work shafts;
6. Presents the requirements and basis of design for all dewatering and
ground improvement;
7. Includes estimates of ground surface movements associated with the

excavations and pipeline construction
8. Presents geotechnical risks and mitigations applicable to the works.
b) List of all equipment and resources and programme of work showing allocation of
equipment and resources.
c) No work shall commence on shaft excavation and support activities until the
following method statement submissions have been approved by the Engineer:
(i) Shaft excavation and support: Shaft excavation method(s) and methods of
installing shaft support system(s) for temporary work shafts (6 weeks).
(ii) Authority approvals: Plan identifying the requirements of and for obtaining
approvals from all relevant agencies and authorities (4 weeks).
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d) Typical shift performance report.
e) Detailed step by step procedure describing how work will be carried out in
particular how the different aspects of pipe jacking are monitored , such as
angular deflection , jacking pressures , face pressures , packers etc. and then
managed so that the interjacks are installed as required , deflection controlled and
jacking pressures minimised.
f) Submit independently authenticated test results to demonstrate that the joint

packing complies with the specification. Include a graph of the stress/strain
relationship over the range of conditions which will be encountered during the
works.
g) Method of excavation and removal.
h) Methodology for correcting line and level.
i) Support of existing services and adjacent structures.
j) Safety arrangements for compliance with safety requirements.
k) Arrangement for dealing with ground water, taking due regard to controlling the
loss of material and preventing settlement around pits/shafts, pipe/pit interfaces
and tunnel face.
l) Dealing with different ground conditions.
m) Locking pipe in position during insertion of the next pipe.
n) Sealing working shafts and reception pits during exiting and entering of pipe.
o) Control of over break.
p) Grouting of cavities where applicable.
q) Grout mix design and method of grouting.
r) Details describing the measures to be taken to avoid the development and

transfer of grout shrinkage or expansion stresses to the pipe and to avoid any
adverse chemical reaction between the pipe and the concrete, grout or other
materials comprising the pipeline.
s) Handling and fixing of the inner line pipe in the case of tunnelling with oversize
casing pipes.
t) Reuse/dumping of cuttings and slurry.
u) Layout of monitoring points for detection of surface movement.
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14.1.4.4 Drawings and Calculations
The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the specification. These shall
comprise but not necessarily be limited to:
a) Working drawings showing on plan and section the method of supporting

excavations.
b) The location of all pits/shafts including those indicated as permanent works in the
design drawings, having due regard to existing services, minimising disruption to
traffic and pedestrian movements and achieving the required system layouts, as
shown on the tender drawings.
c) Foot print plans showing the working site areas at the thrust and reception
pits/shafts, control room, pipe storage area, craneage area, slurry tank, generator
etc.
d) Plan showing proposed traffic and pedestrian diversion proposals around all
pits/shafts.
e) No work shall commence on shaft excavation and support activities until the
following submissions have been approved by the Engineer.
(i) General arrangement drawing of pipejack/microtunnel jacking sites and

reception shaft sites showing layout of all temporary and permanent works,
including site offices, stores, etc (6 weeks).
(ii) Design submittals including calculations demonstrating that the design of

the shaft support system will adequately support the shaft excavation
throughout all stages of construction and until the shaft is either backfilled or
a permanent lining or structure is installed within the shaft (10 weeks)
(iii) Preliminary design drawings for temporary work shafts (10 weeks).
f) Details of entry and exit pipe seals and seal rings in pits/shafts.
g) Longitudinal profiles from thrust to reception pits/shafts showing location of pipe

joints, location of existing services and surface levels.
h) Calculations for thrust and reception pits/shafts which shall be designed to resist
external soil and water pressure and stresses resulting from the jacking machine.
i) Calculations justifying allowable deflections at joints to limit damage to the joint

from eccentric loading under drive and sealing limits and to ensure a completed
pipeline with no visible leaks and within infiltration allowances.
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j) Pipe calculations showing capability of pipe to resist jacking and friction forces in
the axial direction and earth, AASHTO HS20 traffic, and surcharge loadings in the
vertical direction.
k) Calculations for friction loads, face loads, interjacks, jacking pressures etc. for
the complete system, including thrust walls, which demonstrate how the pipes
will be installed with no damage.
l) Calculations giving predicted settlements along and adjacent to route of

pipeline.
14.1.4.5 Quality Control
a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or Material prior to delivery in
accordance with the specification.
b) Products and materials shall be from a manufacturer/supplier who operates a

quality system which is registered to ISO 9000 series or approved equal.
c) To allow the Engineer to inspect the Works the contractor shall give the Engineer
a minimum of a 24 hour notice of carrying out the following activities on site.
(i) Geotechnical investigation.
(ii) Construction of thrust and reception pits / shafts.
(iii) Undertaking each stage of NDM work.
d) Ensure instrumentation is calibrated for each drive. Provide a valid calibration

certificate. Ensure that the certificate is available to the Engineer upon request.
e) The designer shall be an approved qualified Engineer experienced in the design

of this work or similar.
f) The installer shall be an approved company with specialised personnel in

performing the work with minimum 5 years experience in the application of non
disruptive method of pipeline construction of projects of similar size.
(i) All operators in the employment of the Contractor and his sub- contractor
shall be skilled and have a minimum 12 months experience in their
respective trades and in particular in operating a machine similar to the
machine used by the Contractor. Operators shall be subject to a
probationary period of three months.
(ii) Curriculum Vitae of key personnel and operators shall be submitted for
approval by the Engineer and interviews may be taken at the discretion of
the Engineer.
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(iii) The supervising operator who will perform the work for the Contract duration
shall have a minimum of 5 years of experience of similar works.
g) Approval for method statements and to carry out the work shall be obtained from
the Engineer and the concerned authorities including RTA and Works Department
as appropriate prior to excavation.
14.1.4.6 Delivery, Storage and Handling
a) Delivery, storage and handling of products and materials shall be in accordance

with the manufacturer's recommendations and the following provisions.
(i) 1. Delivery storage and handling shall at all times be performed in a manner
to avoid product damage and be in accordance with the manufacturer’s
recommendations.
(ii) 2. Pipes and fittings shall not come in contact with any sharp
projections that may cause damage to the pipes and fittings during
transportation loading and unloading. Ensure that pipes and fittings are well
secured during transit and adequately supported along their length. Cover
pipes and fittings of plastic materials during transportation. Do not allow
pipe to overhang the end of a vehicle during transportation.
(iii) 3. Ensure that pipes and fittings are lifted using nylon or large
diameter rope slings positioned at a quarter of the pipe length from each
end. Do not allow the use of wire rope chains or unpadded forks or clamps
on forklifts to lift pipes.
(iv) 4. Store pipes and fittings on a flat level area and follow
manufacturer’s storing requirements.
(v) 5. Stack non-crated pipes to the approval of the Engineer.
1. Stack pipes of different sizes and thickness separately.
2. Do not allow stacked pipes to exceed 2m in height or as

recommended by the supplier whichever is the lesser.
(vi) Store GRP pipes and fittings under opaque cover and out of direct sunlight
at all times. Maintain a free flow of air around the pipes at all times.
(vii) Coated and cured RC pipes shall be protected from UV exposure during
storage if required by coating manufacturer.
(viii) Store joint materials and gaskets in a well ventilated place free from
exposure to sunlight and in their original packing until they are needed.
(ix) The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.
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1. Any products damaged during delivery, storage and handling shall be

marked by the Contractor and set aside.
2. Proposals for repair of any damaged products shall be submitted in

writing to the Engineer for approval.
3. Any damaged products deemed unsuitable for repair by the Engineer

shall be removed from site and replaced.
b) Store the lubrication material in a manner recommended by the

supplier/manufacturer.
14.1.4.7 Safety
a) Adopt safe working practices for tunnelling in accordance with

provisions of BS 6164 and BS 5228: Parts 1 & 2.
b) Allow only authorised personnel access to the site.
c) Provide a Safety Officer, suitably experienced in tunnelling operations and with

adequate authority to control and implement safe working practices.
d) Provide and maintain suitable arrangements at site for personnel including:
(i) Telephone service.
(ii) Telecommunication equipment between the control room and the working
crew.
(iii) Approved gas detectors.
(iv) First aid kit.
(v) Emergency escape or breathing apparatus sets.
(vi) Transport.
e) Provide a separate cage type ladder for each pit/shaft.
f) Fence the shafts/pits on all sides with close steel panels of a minimum 1.8m in
height equipped with orange safety warning lights. Join the panels, maximum
space between the panels is 100mm, by steel rods supported on concrete blocks.
g) Provide adequate lighting and ventilation to the shafts/pits. Except where

otherwise necessary, electricity shall be 110 volts from a centre tapped to earth
(CTE) supply and up to 220 volts with use of ELCB protection.
h) Provide an air-conditioned control room at the thrust pit/shaft with sufficient space
for a desk and chair for one inspector.
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14.1.4.8 Investigation Requirements
a) Obtain existing utility information, and excavate trial pits to locate and confirm
services at pit/shaft locations and along the proposed tunnelling route as
necessary. Obtain approval of utility authorities and relevant Department prior to
the commencement of work.
b) Carry out all geotechnical site investigation including ground water level
monitoring, as considered necessary and as minimum at the proposed pits/shafts
locations and along the proposed tunnelling route as necessary.
c) Carry out a geophysical survey on a 10 metres wide strip along the proposed
tunnelling route covering a depth range between ground level and up to 5
metres below the invert of the proposed tunnel. The objective of this survey
is to detect any cavities or broken or collapsed subsurface strata, so that any
such cavities or strata can be treated to allow tunnel construction. The general
requirements and specification for the geophysical survey are as follows:
(i) The survey shall be applicable to depths greater than 15m from existing
ground level to invert of pipe.
(ii) The survey shall provide information on both lateral and vertical extent of
subsurface conditions together with the identification and classification of
the geophysical materials in the subsurface sequence within the targeted
depth of investigation. The information provided is to include details on
likely size, depth and character of the features interpreted.
(iii) The geophysical survey and all associated works shall only be carried out
by specialist companies approved by the Dubai Municipality.
(iv) Before commencement of the survey, the Contractor shall submit the
anticipated calibration work required to fully assess and interpret the
geophysical survey, and confirm his acceptance that the objectives of the
survey are achievable.
(v) The geophysical survey technique to be used is that of resistivity imaging,

and shall be generally conducted as follows:
1. Establish benchmarks and topographically survey and inspect routes for

interference.
2. Undertake data acquisition and assess the data quality.
3. Provide the preliminary resistivity section and preliminary interpretation

result and undertake drilling of boreholes required for the calibration of
the resistivity results.
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4. Provide precise interpretation of resistivity anomalies, supplement

interpretation with physical evidences, drilling of boreholes, borehole
logs and core photographs.
5. Provide a survey report with the final interpreted sections, colour scale
of sections should be standardised.
6. The location of anomalies/cavities shall be marked and flagged by the

Contractor at the exact location indicated by co-ordinates Easting and
Northing.
(vi) One borehole in accordance with BS 5930 and BS 1377 for each 50 survey
stations is included in the scope of geophysical survey in order to be used
by the Contractor for calibration/interpretation of the survey results. Each
borehole shall incorporate SPT at 1m intervals, groundwater level, rotary
drilled coring of solid strata and photographs of cores.
(vii) All basic data recording, preliminary and final interpretation and borehole
records shall be included in the NDM design report.
d) Notwithstanding the general requirements of Clause 14.1.4.8 above, soil

conditions and ground conditions shall constitute the Contractors risk and the
Contractor shall undertake such investigation as necessary to establish the sub
surface conditions at no extra cost to Dubai Municipality.
14.1.4.9 Design Requirements
a) The Contractor is responsible for the design of all pipes including all joints, the
thrust and reception pits/shafts including supports and thrust wall, the size of the
pits/shafts to suit his method of construction and for the design of the jacking
system in general.
b) Ensure that the design of the thrust wall and any other associated Temporary
Works is such as to prevent damage to any part of the Permanent Works or any
immediately adjacent service or structure.
c) Design thrust and reception pits/shafts to allow the safe operation of the plant,
equipment and handling of the materials and to withstand all loading imposed by
ground pressure, superimposed loads from surface structures and maximum
proposed thrust force.
d) Design pipes to withstand the maximum axial thrust with a factor of safety of 4
based on the full effective area and the ultimate compressive strength of the pipe
material. For reinforced concrete pipes, use the full effective area at the joint.
e) Where GRP or similar material pipes with concrete surround are proposed, the
concrete surround shall be designed to withstand the maximum jacking force. The
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design shall also ensure that the GRP or similar material pipe is not subjected to
any forces during installation.
f) Design pipe joints in conjunction with resilient packing that avoids projections
which could obstruct the travel of the pipe. Ensure that the joints will be
watertight under axial loading and at the permissible deflection of the pipes.
g) Design joints for concrete pipes such that with an angular deflection of 10 degree.
(i) The areas available for transmitting the maximum permitted thrust force will
be sufficient to ensure that there will be no pressure at any point greater
than the maximum permissible pressure.
(ii) There will be no damage to the pipe or loss of structural strength.
(iii) There will be no ingress or egress of water or lubricant under the maximum
operational or test pressures.
(iv) There will be no ingress of soil/groundwater onto the bearing surfaces.
h) Design shall take account of the behaviour of the pipe joint at the maximum
permitted angular deflection of 1º with the maximum permissible bearing stress in
conjunction with the stress/strain relationship obtained from the packing
compression tests and maximum jacking loads.
i) Where it is proposed to construct certain section within larger diameter pipes and
grout the annular space:
(i) Ensure that the difference between the external face of the inner pipe and
the internal face of the outer pipe is not less than 150mm and no more than
250mm unless otherwise approved by the Engineer.
(ii) The external pipe/sleeve may be of steel with full circumferential weld or
reinforced concrete pipe. In either case, the casing pipe and the grout shall
be regarded as sacrificial and the inner pipe shall be designed as a stand
alone pipe, capable of withstanding installation and grouting forces and soil,
traffic and groundwater loads. Where pipe-brackets, spider clamps, are
used, rubber packers shall be placed between the steel brackets and pipe.
j) Limit the dimensions of drive and reception pits/shafts to the minimum required to
construct the permanent works or to construct the pits/shafts, whichever is larger.
k) Determine the excavated dimensions of the drive and reception pits/shafts as

required to suit the site conditions. Minimum pit/shaft dimensions shall be used at
all locations where utilities, roads or trees exist adjacent to the required pit/shaft
locations.
l) Where it is proposed to use a tail tunnel as the reaction surface the maximum
permitted thrust force is not to exceed the lesser of the following.
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(i) The maximum permissible thrust force.
(ii) 50% of the sum of the maximum forces recorded at the rigs used to
construct the tail tunnel if the overbreak has not been grouted up.
(iii) If the overbreak to the tail tunnel has been grouted up, 100% of the sum of
the maximum forces recorded at the rigs used to construct the tail tunnel.
m) Any tail tunnel which has been used as a reaction surface shall pass the specified
water tightness test at a time not less than 14 days after the load has been
removed.
n) Lubricant fluid holes shall be threaded to enable plugs to be screwed into the
socket and withstand the external pressure. Non-return valves shall be fitted
where opening a hole would permit ground loss.
o) Confirm the tunnelling route is clear from cavities or obstructions or recommend

and design for grouting of cavities and/or dealing with obstructions.
14.1.4.10 Use of Approved Specialist Firms/Sub Contractors
The Contractor shall engage specialist Firms/Sub-Contractors to carry out/execute

work for Micro-tunnelling / Pipe jacking on this project. All specialist Firms/Sub-
Contractors are subject to approval for each aspect of work on this project in the field
of their respective specialisation. Only those companies that can demonstrate
successful experience on projects similar to that required for this work (scope, size,
condition, and programme) shall be proposed by the Contractor for consideration and
approval. Companies proposed for approval shall demonstrate the necessary
registration as a contractor licensed to work in Dubai either directly or through a legal
association with a registered Contractor.
14.2 EQUIPMENT AND PIPE MATERIALS
14.2.1 Equipment
The Contractor shall use only NDM (Non-disruptive Method) equipment that is
appropriate for the intended installation, site and ground conditions, length of drive,
and other relevant factors and can meet the contents of these specifications to the
satisfaction of the Engineer. It is envisaged that the NDM equipment will have the
following capabilities but the final choice of equipment will be the responsibility of the
Contractor to the approval of the Engineer.
14.2.1.1 Tunnel Boring Machines (TBMs)
a) The Contractor shall provide, install, maintain and remove on completion TBMs
suitable for excavation in the ground conditions as described in the Contract
documents.
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b) The proposed TBM manufacturers shall be recognised commercial TBM

manufacturers with no less than 5 years of successful experience in the design
and manufacture of the type of TBMs proposed by the Contractor.
c) All TBMs for internal pipeline diameters greater than 1200mm shall be new or
newly refurbished/rebuilt, with all major components tested and guaranteed by the
TBM manufacturer. TBMs for pipelines between 600mm and 1200mm diameter
shall have a maximum of three thousand working hours, and shall have newly
retooled and refurbished cutterheads, and be supported by documentary
evidence of service history. TBMs/moles/drilling equipment for pipelines less than
600mm diameter shall have a maximum of five thousand working hours, and shall
have newly retooled and refurbished cutterheads, and be supported by
documentary evidence of service history.
d) All TBMs provided must be capable of satisfactory performance in the anticipated

ground conditions presented in the Volume 5.
e) The design of the TBM shield shall include an articulated joint as required to
ensure construction of the pipe jack/ microtunnel to the theoretical alignment as
shown on the Contract drawings.
f) The Contractor shall provide a TBM Guidance and Control System with laser
theodolite. This shall be a commercially manufactured system.
g) The TBM shall have a proven system for monitoring the presence of hazardous or
explosive gases. Systems shall be arranged with adjustable limits and shall have
a first level warning signal and a second level with automatic shut-off of
equipment. Gases to be monitored shall be methane, hydrogen sulphide, oxygen,
carbon dioxide and carbon monoxide.
h) The TBM shall be designed to withstand all the jacking loads as well as the full
overburden pressure and hydrostatic pressure.
i) The TBM shall be capable of fully supporting the face during both excavation and
shutdown periods, and shall have the capability of exerting a continuous,
controllable stabilizing pressure at the face as required to prevent loss of ground
and groundwater inflows.
j) Only TBM synthetic oils HFDU (biodegradable, fire resistant polyesters) shall be
used. All oils must be approved by the TBM manufacturer.
k) In addition to above, TBM should also comply with the following requirements:
(i) Steerable and incorporating hydraulic rams to move the articulated head.
(ii) Designed to ensure no rotation or rolling during installation.
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(iii) Remote controlled and can transmit information such as jacking force, face
pressure, length, roll, pitch, steering attitude, temperature, valves open or
closed, cutter torque, rate of progress, slurry pressure, slurry flow, earth
face pressure to a microprocessor console on the surface from where the
system is operated.
(iv) Incorporates meters and gauges to measure the slurry flow and
pressures.
(v) Capable of operating under groundwater conditions as necessary with a

hydrostatic balance not less than 3m head of water.
(vi) Fitted with a calibrated laser target, robustly constructed and rigidly
secured.
(vii) Guidance system shall be laser or an approved equivalent for the control of
tunnel alignment. The guidance system shall be mounted independently of
the thrust wall or machine jacking rig or anything else that may move during
operations.
14.2.1.2 Thrust System
a) The rig shall distribute the thrust to the pipes via a thrust ring and packing. The
jacks shall apply the thrust to the thrust ring by means of a symmetrical
distribution. Interjack stations shall be used where frictional resistance or other
causes would otherwise result in unacceptable thrust forces.
b) If used, spacer blocks shall be true and free from any distortions.
c) All thrust rings shall be true and free from any distortions and sufficiently stiff so
as to transfer the load from the jacks uniformly to the packing.
d) Other than at the shield, each group of jacks shall be interconnected to ensure
that an evenly distributed load is applied to the thrust ring.
e) Fitted with automatic thrust recording equipment monitoring load cells

incorporated in each jack together with a pressure metering device.
14.2.1.3 Tunnelling Shields for Pipejacking
a) Where considered necessary, the Contractor shall provide and maintain a shield
suitable for excavating in the ground conditions as envisaged by him and in
accordance with his chosen method of excavation.
b) In determining the type of shield and method of excavation to be used, the

Contractor shall take account of the need to ensure that the face of the
excavation is adequately secured at all times such that ground loss is kept to a
minimum and is controlled to prevent excessive ground loss. The shield shall be
removed on completion of the tunnelling operation.
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c) Rotating excavating heads fitted to shields shall be capable of rotating clockwise

and counter-clockwise.
d) The shield shall be equipped with steering jacks and such heads, ploughs and
copy cutters as may be required for adjusting the alignment of the pipes.
e) Multiple lubricant injection points shall be provided within the shield in order to
provide immediate ground support when necessary.
f) In case of manual excavation, the shield should be pushed into the soil. The
excavation should be limited to the soil falling inside the sleeve. No excavation
should protrude outside the shield face.
14.2.2 Pipe Materials
a) Acceptable pipe materials for microtunnelling and pipejacking applications include

the following, subject to approval by the Engineer :
(i) Concrete Encased GRP Jacking Pipe (CEGRP)
(ii) GRP Jacking Pipe (GRPJP)
b) It is a requirement that CEGRP and GRPJP be standard jacking pipes, certified

by European or US accreditation authorities.
c) Only one type of pipe shall be used for the project.
d) The manufacturer of the pipe materials must demonstrate a 10-year recent history
of successful installations in similar corrosive environments.
e) Warranty
(i) The manufacturer and the Contractor shall jointly guarantee the completed
pipe system, including any protective coatings and linings, to be free from
defects in materials and workmanship for a period of 10 years from the date
of completion of the Works.
(ii) The Contractor shall furnish the Employer with the manufacturer’s
guarantee and warranty certificates for all materials and components used.
(iii) If the protective coating and lining system are found to be defective during
the warranty period, the manufacturer and Contractor shall replace and/or
repair the protective coating and lining system to the satisfaction of the
Engineer at no cost to the Employer.
f) The pipe and any fittings must be manufactured within six months of the Contract
commencement date.
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g) Before delivery the manufacturer shall submit a written “Certificate of Compliance”

that the pipe to be supplied meets all applicable BS, European and ASTM
Standards as referred to in the Specification.
14.2.2.2 Concrete Encased GRP Jacking Pipe – minimum requirement
a) General
(i) Contractor shall design the GRP pipe stiffness for reinforced concrete
encased GRP Jacking pipe as per the requirement given below or on the
recommendation of manufacturer depending on pipe diameter and site
conditions (soils, installation, compaction, loads etc.) in compliance to the
performance requirements and warranty conditions specified in this
document:
1. Minimum acceptable pipe stiffness for GRP pipe shall be 10,000N/m²

(SN 10,000).
(ii) Minimum concrete strength shall be grade C50, unless otherwise approved
by the Engineer.
(iii) The manufacturer of the pipe materials and pipes must demonstrate a 10-
year recent history of successful installations in similar corrosive
environments.
(iv) Warranty
1. The manufacturer and the contractor shall jointly guarantee the

completed pipe system, including any protective coatings and linings , to
be free from defects in materials and workmanship for a period of 60
years from the date of completion of the works.
2. The Contractor shall furnish the Employer with the manufacturer’s

guarantee and warranty certificates for all materials and components
used.
3. If the protective coating and lining system are found to be defective

during the warranty period, the manufacturer and Contractor shall
replace and/or repair the protective coating and lining system to the
satisfaction of the Engineer at no cost to the Employer and restart the
guarantee.
4. All pipe jointing systems and seals shall withstand a minimum external
water pressure of 1.5 bar. One joint in 100 shall be tested at the
manufacturer’s works.
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5. All pipe jointing systems and seals shall withstand a minimum internal
water pressure of 2 bar. One joint in 100 shall be tested at the
manufacturer’s works.
(v) The pipe and any fittings must be manufactured within six months of the
Contract commencement date.
(vi) Before delivery, the manufacturer shall ensure that factory acceptance test
(FAT) has been undertaken and a factory acceptance certificate (FAC) shall
be submitted.
(vii) Before delivery, the manufacturer shall submit a written “Certificate of

Compliance” that the pipe to be supplied meets all applicable BS, European
and ASTM Standards as referred to in the Specification.
b) Concrete Encased GRP Jacking Pipe
(i) Concrete Encased GRP Jacking Pipe design and performance requirement
includes:
1. Demonstration of the design and installation procedure ensures that the

reinforced concrete encasement takes the maximum jacking load. The
design shall ensure that the GRP pipe is not subjected to any forces
arising from the jacking installation.
2. Provision of UAE and Middle East case histories regarding the particular
pipe and joint system, ground conditions, drive lengths, water tightness
tests, and as-built tolerances and conditions.
3. Ensure that the manufacturer provides angular tolerances on installation

specific to this pipe system, supported by calculations justifying the
proposed tolerances.
4. A pipe system design demonstrating that the GRP coupling is adequate

to achieve the structural, durability and watertightness requirements up
to the end of the design life of 60 years, when installed at the limit of the
angular tolerance between pipes.
5. A pipe system design demonstrating that the encasement in concrete

results in no adverse chemical or physical effects to the GRP pipe.
(ii) Unless superseded by clauses herein, the requirements of ’Section 4-

Pipes, Pipework ,Manholes and Chambers’ apply.
(iii) Resin Systems: The manufacturer shall use only resin systems with a
proven history of performance in this particular application. The historical
data shall have been acquired from a composite material of similar
construction and composition as the proposed product.
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(iv) Additives: Resin additives, such as curing agents, pigments, dyes, fillers,
thixotropic agents, etc., when used, shall not detrimentally effect the
performance of the product.
(v) The inner liner of the pipes exposed to sea water /sewer flow shall be
manufactured using a vinylester resin with a 50% elongation (minimum)
when tested in accordance with ASTM D638/ ASTM C581. The interior
surface shall provide crack resistance and abrasion resistance. The exterior
surface of the pipes shall be comprised of a layer which provides UV
protection to the exterior.
(vi) Joints: Unless otherwise specified, the pipe shall be field connected with
fibreglass sleeve couplings that utilize elastomeric sealing gaskets as the
sole means to maintain joint water tightness. The joints must meet the
performance requirements of ASTM D4161.
(vii) Concrete encased GRP Jacking pipe shall be protected externally with an
epoxy coating as per Specifications 7.1.15 & 7.2.2.1(e).
c) Other Requirements
(i) Collars
1. Collars for butt-jointed pipes shall be designed for the specified design
life, and shall be manufactured from the following:
 Steel alloys having a minimum Pitting Resistance Equivalent Number

(PREN) >40.
 GRP: Joints utilising GRP sleeve couplings must meet the
performance requirements of ASTM D4161 or BS EN 1636-5:2001.
 Other material having equal or better performance than Steel Alloy or
GRP, subject to approval of the Engineer.
2. Collars shall be cast integrally with and securely anchored to the pipes
but shall not be attached to reinforcement or associated spacers.
(ii) Bentonite and grout holes
1. Bentonite injection holes shall be provided according to the tunnel

boring machine manufacturer’s recommendation. A minimum of three
holes at equal circumferential spacing shall be formed through every
third pipe.
2. Pipes may incorporate lifting holes and fixing holes for securing
temporary apparatus, all holes shall be threaded to enable plugs,
approved by the Engineer, to be screwed into the sockets to withstand
the external water pressure. On completion of the tunnel and following
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grouting of the voids around the pipe all holes shall be filled with a non-
shrink cement mortar to a mix approved by the Engineer.
(iii) Packing
1. Joint packing material when subjected to the maximum permitted

bearing pressure shall have under dry conditions:
 A restoration after 1 hour of at least 65% of the original thickness.

 A compression of at least 50% of the original thickness.
Independently authenticated test results to demonstrate that the
packing complies with the specification shall be submitted and shall
include a graph of the stress/strain relationship over the range of
conditions which will be encountered during the Works.
2. The material used for packing to withstand all imposed loading applied
during the installation of all pipes for each completed length without
showing signs of deterioration or distress.
3. Packers shall be made of Medium Density Fibreboard (MDF) or any

material of similar mechanical properties, subject to Engineer’s
approval. For MDF packers a thickness between 15 and 19mm and
bending strength of at least 20 N/mm2 are required.
(iv) Pipe Joint Sealing System
1. Pipe joints shall be designed to be watertight against both the external

water pressure head and any internal pressure, depending on the depth
and intended use of the pipeline. The integrity of the joint water-
tightness shall be guaranteed in writing by the manufacturer for the
2. Sealing rings shall be manufactured using an EPDM ring(s) complying

with BS EN 681-1:1996 and guaranteed to perform satisfactorily for the
whole design life.
3. All sealing rings shall have physical and chemical properties, including
hardness (measured in International Rubber Hardness Degrees-IRHD),
compatible with the pipe material. Sealing rings shall be stored in a
clean, cool condition out of direct sunlight and without being deformed.
Sealing rings for use with thermoplastic pipes shall contain no
component which can react with the material of the pipes.
(v) Lubrication and Conditioning Agents
1. It is envisaged that lubricating fluid shall be one of the following but the
final choice of fluid will be the responsibility of the Contractor to the
approval of the Engineer. Lubricating fluid shall generally be a polymer
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or bentonite based slurry lubrication material. In suitable ground

conditions water alone may be used. For clay soils, non-aqueous
lubricants shall be used.
2. The material used for lubrication shall be stored and mixed in a manner
recommended by the Supplier.
3. It is the responsibility of the Contractor to assess and allow for the

chemical effects, if any, of gypsum or high salinity ground and
groundwater, and/or any contaminated ground encountered, on his
proposed slurry and lubrication fluids and any additives.
4. Inert fillers such as limestone or sand may be added but no other

materials. Where inert fillers are proposed the sub-Contractor shall
submit the material type to the Engineer, for approval.
5. The term soil conditioning refers to the use of suitable additives

(conditioning agents) in various proportions to alter the soil properties of
the excavated spoil such as foams, polymers, slurries. The Contractor
shall seek compliance with both safety-in-use and disposal regulations.
All conditioners shall be inert and bio-degradable.
(vi) Contact Grouting
1. Overbreak grouting Portland cement and water determined by

geotechnical data and as directed by the Engineer, nominal strength
shall be of at least 20N/mm². Admixtures shall be used only if tests
have shown to the satisfaction of the Engineer that their use improves
the properties of the grout, e.g. by increasing workability or slightly
expanding the grout.
2. As annular space filling a low strength grout or foam concrete shall be

used and placed at low pressures. The density of the mix shall be in the
range of 900 to 1200kg/m³ and the free water/cement not greater than
0.6.
3. Cavities grouting Portland cement, Portland cement/sand or Portland

cement/bentonite mortars shall be determined based on ground
investigation data.
4. Grout shall be cementitious, containing between 2% and 4% bentonite

with a 7-day unconfined compressive strength of at least 3MPa per BS
EN 206-1:2000 and shrinkage less than 5%. Add sand to the mix for
voids larger than 50mm.
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14.2.2.3 GRP Jacking Pipes – Minimum requirement
a) Unless superseded by clauses herein, the requirements of ’Section 4- Pipes,

Pipework, Manholes and Chambers’ shall apply.
b) Acceptable standard jacking pipe product shall be as per vendor list.
c) This sub-clause relates to solid wall jacking pipe, not a composite e.g. concrete
encased GRP.
d) Pipes manufactured by a centrifugal casting process are preferred.
e) Pipes shall have an interior acid resistant liner. The inner liner shall have a
minimum thickness of 1.5 mm, consisting of ‘C’ glass veil backed with chopped
strand glass all impregnated with vinylester resin.
f) Resin Systems: The manufacturer shall use only resin systems with a proven
history of performance in this particular application. The historical data shall have
been acquired from a composite material of similar construction and composition
as the proposed product.
g) Glass Reinforcements: The reinforcing glass fibres used to manufacture the

structural wall shall be of highest quality commercial grade E-glass filaments with
binder and sizing compatible with impregnating resins.
h) Silica Sand: Sand shall be minimum 98% silica with a maximum moisture content
of 0.2%.
i) Additives: Resin additives, such as curing agents, pigments, dyes, fillers,

thixotropic agents, etc., when used, shall not detrimentally effect the performance
of the product.
j) Pipes: Manufacture pipe by the centrifugal casting process to result in a dense,

nonporous, corrosion-resistant, consistent composite structure. The interior
surface of the pipes exposed to sewer flow shall be manufactured using a resin
with a 50% elongation (minimum) when tested in accordance with ASTM D638.
The interior surface shall provide crack resistance and abrasion resistance. The
exterior surface of the pipes shall be comprised of a sand and resin layer which
provides UV protection to the exterior.
k) Joints: Unless otherwise specified, the pipe shall be field connected with
fibreglass sleeve couplings or bell-spigot joints that utilize elastomeric sealing
gaskets as the sole means to maintain joint water tightness. The joints must meet
the performance requirements of ASTM D4161. The joint shall have
approximately the same O.D. as the pipe, so when the pipes are assembled, the
joints are essentially flush with the pipe outside surface. Joints at tie-ins, when
needed, may utilize gasket sealed closure couplings.
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l) Wall Thickness: The minimum wall thickness, measured at the bottom of the
spigot gasket groove where the wall cross-section has been reduced, is
determined from the maximum jacking load. Minimum factor of safety against
jacking force is 2.5 based on straight alignment.
m) End Squareness: Pipe ends shall be square to the pipe axis with a maximum
tolerance of 1.5mm.
n) Pipes: Pipes shall be manufactured and tested in accordance with ASTM D3262.
o) Joints: Joints shall meet the requirements of ASTM D4161.
p) Stiffness: The stiffness of the pipe should be suitable to site conditions & be
approved by the Engineer. Stiffness test should be carried out in accordance with
ASTM D2412 .
q) Strain Corrosion: The extrapolated 50-year strain corrosion value shall not be less
than 0.9% as determined in accordance with ASTM D3681 and ASTM D3262.
14.2.3 Joint Packing
a) Joint packing material when subjected to the maximum permitted bearing

pressure shall have under dry conditions:
(i) A restoration after 1 hour of at least 65% of the original thickness.
(ii) A compression of at least 50% of the original thickness. Independently

authenticated test results to demonstrate that the packing complies with the
specification shall be submitted and shall include a graph of the stress/strain
relationship over the range of conditions which will be encountered during
the Works.
b) The material used for packing shall be suitable to withstand all imposed loading
applied during the installation of all pipes for each completed length without
showing signs of deterioration or distress.
14.2.4 Joint Seal
The joint seal shall comprise one or more elastomeric rings complying with BS EN
681-1.
14.2.5 Dewatering Equipment
a) Dewatering equipment may include the use of or the combination of well pumps,
eductors, deep wells, well-points, monitoring wells, temporary pipelines for water
disposal, temporary hose, manifolds, rock or gravel placement, containment
basins, sediment traps, settling tanks, cut-off or curtain walls, and/or other means.
Standby pumping equipment including self-contained emergency power
generators shall be maintained on Site at all times.
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b) The Contractor shall install Piezometers at locations, intervals or spacing as

recommended by the dewatering system designer; however, if dewatering
beneath shaft invert is used for shafts, the Contractor shall provide a minimum of
two observation wells or piezometers per shaft, equidistant between adjacent
dewatering wells, well points, eductors, or similar equipment. Piezometers shall
be installed to a depth allowing confirmation that water level is 1.5 metres below
the bottom of the shaft excavation.
c) Sump pumps in the shaft invert or any other excavations shall not be an
acceptable means of dewatering. Sump pumps will be allowed in emergency
situations only to remove small quantities of accumulated stormwater run-off.
Discharge of any sump pump shall be subject to all the provisions of dewatering
permits and the Construction Environmental Management Plan (CEMP).
14.3 EXECUTION
14.3.1 General
a) Confine surface operations to pits/shafts and the area immediately adjacent to

pits/shafts. Keep the working area to the minimum practicable for the proper
construction of the works.
b) Contractor shall take any measures necessary to prevent damage or deterioration

of the soil reaction face during the construction of the temporary and permanent
works from whatever possible cause, such as ingress of water, softening,
corrosive soil or loss of fines from a granular soil.
14.3.2 Examination
a) Contractor shall obtain existing utility information, and execute trial pits to locate
and confirm services at pit/shaft locations and elsewhere as required.
b) Pre construction photographs and pre construction grid survey of surface levels
along the length of the proposed tunnel shall be taken by the Contractor.
14.3.3 Cavity Grouting
a) In case cavities have been confirmed to exist along the tunnelling route by
geophysical survey, such cavities shall be grouted.
b) Grouting of existing cavities where required shall be carried out by means of

drilling and pressure grouting of cement, cement/sand or cement/bentonite mortar
to fill in the cavities and open fissures. This work shall be designed, carried out
and tested by a specialised Contractor to a method statement approved by the
Engineer.
c) Boreholes shall be drilled vertically to the required depth below existing ground
levels. Grouting shall be completed from the base of the boreholes up to ground
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levels. Verification boreholes shall be drilled, water pressure tested and grouted
to assess the effectiveness of the treatment.
d) Drilling shall be executed using rotary drilling methods with a casing advancer
system to prevent borehole collapse in unconsolidated materials. Borehole
diameter shall be a minimum of 100mm.
e) Grouting shall be carried out in stages in accordance with the approved method
statement. Inflatable packs shall be used as necessary to isolate areas requiring
grouting and to enable pressure grouting. Grout shall be pumped through flexible
hoses or steel pipes to the grout holes location. Grouting pressure shall be
regulated up to a maximum of 2 bar unless ground conditions dictate otherwise.
Grout shall be introduced to the grout hole via a tremmie pipe placed at the base
of the borehole. The tremmie pipe shall not be removed until 100% grout is
observed and maintained at the grout holes surface.
14.3.4 Shafts, Jacking and receiving Pits
a) The Contractor shall design, construct, maintain and backfill on completion all
temporary work shafts. Where a permanent structure like Manholes, Vortex
Chamber, or other permanent ancillary structure is built wholly or partially within a
temporary work shaft, the Contractor’s rates for the temporary shaft and the
permanent structure(s) shall fully take into account the method of construction of
both temporary and permanent works.
b) Pits/Shafts
(i) It is envisaged that pits/shafts will be constructed as follows but the final
design will be the responsibility of the Contractor to the approval of the
Engineer.
(ii) The Contractor shall select between using inter-locked sheet pile cofferdam,
secant piling or reinforced concrete caisson as the most appropriate for the
site conditions and for the soil profile.
(iii) All the joints between caisson rings shall be sealed with joint sealant and
the caisson grouted from outside in order to make it watertight.
(iv) Interlocked steel sheet piles shall be braced by suitable steel framing
welded to the sheet piles. No struts shall be used for bracing. The first set
of bracing shall be 0.5m from the ground surface.
(v) The pit bottom shall be sealed with a concrete plug, which shall be placed
underwater and designed to resist water uplift as well as forces from the
jacking equipment to be installed in the pit.
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(vi) A reinforced concrete wall shall be provided in the thrust pit to resist the
jacking force. A properly braced concrete wall shall be provided in the thrust
and reception pits in order to install the exit and entry rings.
(vii) If a portion of the pit is to be constructed in rock, then this portion may be
unsupported provided the rock layer is strong enough to safely resist all the
expected forces and stresses. Contractor shall prove this by testing and
calculation. Special precautions shall be taken to seal the interface between
the caisson or sheet piles and the rock so that it is water and soil tight.
Rock faces should also be treated if necessary to make them watertight.
(viii) Maintain the pits/shafts dry prior to commencing and throughout tunnelling
works. Dealing with groundwater shall be carried out carefully and slowly.
Provide standby facilities.
(ix) Thrust wall shall be:
1. Perpendicular to the proposed line of thrust.
2. Sufficient to accept repeatedly the maximum permitted thrust force

without undue movement and without thrusting directly off any part of
the permanent works comprising any shaft, chamber or pumping station
unless this is specifically designed to withstand the thrust reaction.
3. Not joined to the jacking rig base.
4. Any void between the soil face used to provide a reaction to the thrust
force and the thrust wall filled completely with grout or concrete.
5. The design of the thrust wall and any associated temporary works shall
be such as to prevent damage to any part of the Permanent Works.
(x) Provide entry and exit sealing rings to ensure a watertight joint around the
pipe at all times.
c) Shaft Support System
(i) Excavation support systems shall be designed by an experienced engineer

with Equivalent Qualifications. Contractor shall be responsible for all
support systems.
(ii) Excavation support system shall be designed to support ground and

groundwater loads, utility loads, traffic and construction loads, and all other
applicable surcharge to prevent damage to or minimise movement of
existing buildings, structures and services. The Contractor shall ensure that
the groundwater regime surrounding the shaft is not affected by the
construction of the shaft unless the Contractor can adequately demonstrate
that a temporary drawdown of the water table around the shaft will not
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cause any damage and or settlement to nearby buildings, structures and

services.
(iii) Excavation support systems shall be designed to be compatible with the

geological conditions described in the Volume 5, and as updated or
supplemented and approved based on the results of the Contractors
additional Geotechnical Explorations, Testing and Evaluation Programmes.
(iv) Excavation support systems shall be designed for control of water,

maintaining bottom stability and protection of subgrade.
(v) The size, type, and design of the shaft excavation support system are the
Contractor’s responsibility, and are subject to review and approval by the
Engineer. The Contractor shall assume full responsibility for the design,
construction, and safety of the shaft support system.
(vi) The system of support may consist of the following alternatives:
1. Bored pile walls (e.g. secant or tangential);
2. Sheet pile walls
3. Precast ring or segment caissons;
4. Slurry/diaphragm walls;
5. Drilled shafts with temporary casings;
6. Other alternatives;
7. With the exception of ring caissons, walls may be secured in place with
bracing members such as ring beams, struts or tieback anchors.
(vii) Each support member shall be designed to support the maximum loads that
may occur during construction.
(viii) The bottom of the support system shall be carried to an adequate depth
below the main excavation to minimise lateral and vertical ground
movements. Where additional excavation is carried below the main
excavation, a means to control movement of the main excavation supports
shall be provided.
(ix) The shaft shall be sized and the excavation support system designed to
allow the required free space for the safe movement of workers,
Contractor’s Equipment, and materials in and out of the shafts.
(x) If the proposed shaft support system includes tieback anchors, the
Contractor shall provide the geotechnical profile for which each anchor is
intended, the design load for the full depth of the excavation, the maximum
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design and proof loads, and the criteria proposed for deformations under
proof loads. Any such anchors must be indicated on Contractor’s
applications for permits or Notices of Intent.
(xi) If removal is required wholly or in part, such removal shall be performed in a

manner that shall not disturb or damage adjacent structures, construction,
or utilities. Fill voids immediately with lean concrete or approved compacted
backfill.
(xii) The Contractor’s designs and method statements for temporary work shafts
shall include as a minimum the following:
1. Details, arrangement, and method of assembly of the support system.
2. Method of preloading and bracing.
3. Ground reinforcement details.
4. Load test procedures.
5. Grouting materials and methods.
6. Loads for various stages of bracing removal and concrete placement.
7. Anticipated construction equipment loads.
8. Maximum design load to be carried by the various member systems and

preloads.
9. Depths below the ground surface to which the proposed support system
will be installed.
10. Maximum theoretical deflections of the support members and

surrounding ground
11. Special attention shall be applied in design and construction to ensuring

that the resultant settlement caused by the excavation of shafts is within
the limits specified in Section 16.
d) Invert Slab
(i) The invert slab at each excavation shall be designed to protect the
excavation invert in accordance with these minimum design criteria:
1. Capable of resisting maximum hydrostatic uplift recommended in the

GIR, with a minimum safety factor of 1.5, either with or without a
groundwater/pressure relief system. Reliance on pumping alone is not
acceptable. Pump or power failure shall not result in unsafe hydraulic
gradients, exceeding capacity of filters or excessive loads and
deformation of shoring.
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2. Capable of supporting such combined dead and live loads as are

required by the Contractor’s means and methods.
14.3.5 Tunnelling / Pipe Installation
a) Tunnelling:
(i) Before any particular tunnelling commences, provide sufficient pipes, and, if
required, provide intermediate jacking station assemblies to ensure
continuous operation.
(ii) Carry out the tunnel construction using the recommended accepted method
to the satisfaction of the Engineer and to meet the contents of these
specifications.
(iii) Limit the thrust force to the maximum permissible as determined and based
on submitted and approved calculations.
(iv) Excavation rate not to exceed the horizontal drive rate throughout the
operation.
(v) Prevent both subsidence and heave during all stages of the setting up,
tunnelling operation and dismantling.
(vi) Remove slurry/excavated soil mixture properly from the excavation, settle in
a stilling basin and remove from the site to a suitable location. Avoid stock
piling on site.
(vii) Maintain tunnel face support for balancing full earth pressure and
groundwater pressures.
(viii) Tunnelling operation shall be run continuously between drive and

reception pits/shafts.
(ix) Cuttings spoil removal and cutter face operation not permitted when the
pipe thrust is not being carried out.
(x) Fill the annular overbore voids around the outside of the pipe to avoid
collapse and upward migration of the void prior to permanent grouting.
Avoid drilling fluid injection overpressure.
(xi) Casing and carrier pipes: place and join carrier pipe sections individually
within the sleeve or mount on guide rails or trolleys in such a manner as to
transmit the pulling/pushing forces through the carriage and not
through the pipe.
b) Pipe Installation:
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(i) All pipes shall be installed in accordance with the manufacturer’s installation
instructions.
(ii) If the Contractor’s design requires that pipe jacking operations be driven in
a downhill direction then the Contractor shall submit to the Engineer his
proposals for ensuring the security of his operations against flooding of the
tunnel.
(iii) TBM operation shall be capable of maintaining ground control at the face to
complete the work without exceeding the ground movement limits specified
in Section 16 ‘Protection of Existing Structures and Services’.
(iv) Earth Pressure Balance Machines shall be operated in closed mode.
(v) Each pipe must be inspected for damage before installation and approved
for use by the Engineer. Pipe ends must be undamaged without any signs
of dirt or chipping. Defective packings and sealing rings must be discarded
before installation and joint sleeves must not show any dents, damage or
distortion.
(vi) The angular deviations between pipe faces can cause severe localisation of
stress and should be avoided. The angular deviation at each face shall not
exceed 0.15 degrees with a maximum total of 0.30 degrees.
(vii) Pipes should be straight and uniformly dimensioned, have squared ends
and have joints that are designed to allow for efficient load transfer from
pipe to pipe.
(viii) The jacking frame, jacks and steering head should be aligned along the
planned line and grade and shall be square and true to the thrust wall to
minimise eccentric loading. Steering corrections should be made gradually
to minimise abrupt misalignment angles between two pipes resulting in
eccentric loads.
(ix) Overcut around the circumference of the tunnel shield should be designed
to allow steering corrections to be made and lubricant to be injected to
completely coat the pipe exterior but the overcut should not be greater than
20mm on the radius of the skin of the shield.
(x) The jacking frame and the capacity of the jacks shall be designed by the
contractor to ensure uninterrupted operation of the works. Calculations shall
be submitted to the Engineer for his information.
(xi) The TBM and associated equipment must be capable of monitoring slurry
pressures. Regular inspection of the ground surface and existing
stormwater and sewer pipelines near underground slurry injection locations
is required to ensure that hydrofracture and loss of slurry is prevented and
managed.
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(xii) Intermediate Jacking Stations: If the jacking force, after applying a safety
factor of 1.5, exceeds 75% of the maximum working load for the pipe, the
use of intermediate jacking stations is required. The Contractor shall notify
the Engineer in writing of his intent to install an intermediate jacking station.
(xiii) The Contractor shall take a sample from either the separation plant (slurry)
or muck skip (EPB) once per day for each drive. Each sample shall be
minimum 1 litre in volume. The sample shall be bagged, sealed and
labelled with: Contract #, Drive/Line #, Date, Chainage. Samples shall be
stored in a secure building out of direct sunlight, and available for inspection
by the Engineer from the day following the sampling.
14.3.6 Constructions Shift Records
Construction shift records shall be submitted to the Engineer and shall include :
a) Extent and causes of any delays.
b) Face logs of the as-dug strata.
c) Machine performance (advance rates, slurry flow rates, jacking thrust loads,
machine torque measurements).
d) Computer output: grade and roll of MTBM, Torque and RPM of the cutterhead ,
instantaneous jacking rate and total distance jacking rate, indication of steering
direction, volume of the slurry in both the supply and the return side of the slurry
loop, and indication of the pressure of the slurry in the slurry chamber. All
parameters should be logged in real time and over distances.
e) Line and level of the lead pipe on completion of the installation of each pipe
during the shift.
f) Records of mucking out and muck deliveries to disposal site, ticketed and
stamped at the disposal site.
g) Copies of the shift records shall be submitted daily to the Engineer.
14.3.7 TBM Real Time Monitoring
a) Continuous data monitoring and logging of TBM performance shall be submitted

to the Engineer in real (instantaneous) time for the duration of TBM excavation.
Data collection shall be accomplished by automatic electronic continuous
recording systems. Data to be collected shall include the following:
(i) For every jacking shove or stroke, the date, time and station at start of
shove; duration of shove; type of soil; cutter head revs; drive speed;
average drive motor current or hydraulic pressure; power consumption;
thrust/propel cylinder pressure; number of operating motors; mode of
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operation and cutterhead chamber pressure; jacking pressure; interjack

pressures; lubrication and grout volumes and pressures.
(ii) Slurry line pressure, flow, density, viscosity.
(iii) Gas monitoring and alarm.
(iv) Excavated volume against theoretical volume for the actual advance. The
system shall incorporate an audio visual alarm with preset alert limits in the
TBM operator cabin to warn of potential over-excavation.
(v) TBM orientation and deflection from line, level and grade, roll, and other
information provided by automatic data acquisition systems.
b) The data acquisition system supplied to the Engineer’s office shall allow the
Engineer to study and print out real time and historical data for each TBM and
guidance system via a dedicated computer and backup computer. There shall be
one dedicated data acquisition system per TBM to be installed in the Engineer’s
office.
c) Should the TBM guidance system not be part of the TBM data acquisition
program, an additional dedicated guidance system computer is required to
duplicate the data acquisition system’s scope. Alternatives which require the
closure of the data acquisition program to view the guidance system are not
acceptable although separate windows running the data/guidance programs
simultaneously maybe acceptable, subject to the Engineers approval.
d) The data and guidance systems in each office are to be linked to the network
printers at the corresponding Engineers office.
14.3.8 Guidance and Control System
a) The setting of the laser and target and the alignment of the tunnel relative to the
laser beam shall be accurate and checked constantly.
b) Where pipeline diameter allows, manual checking of line and level shall be carried
out by conventional theodolite and level techniques.
c) If the deviation exceeds the specified tolerance, work shall cease immediately
and the Engineer informed forthwith. The Contractor shall submit proposals to
rectify the deviation and work shall only recommence on the written instruction of
the Engineer.
d) The alignment shall be determined by a surface survey. Care should be taken in

the transfer of the survey to the shaft bases. The guidance is achieved by using a
self-levelling Laser transit unit.
e) The Laser shall be mounted independently of the thrust wall so that minor
deflections of the wall would not result in inaccurate readings.
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14.3.9 Drilling Fluid Tests
Contractor shall carry out control tests on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be measured
daily as a check on the quality of the suspension being formed. The measuring
device shall be calibrated to read to within 0.005 g/ml. Tests to determine density,
viscosity, shear strength and pH value shall be applied to bentonite supplied to the
pipe bore. For average soil conditions the results shall generally be within the
ranges in Table 14.1 below.
Table 14.1 – Bentonite Suspension Properties
Property Test Method Range of Results
Density Mud density balance Less than 1.10g/ml
Viscosity Marsh cone method 30 to 90s

Fann viscometer less than 0.020Pa-s
Shear strength Shearometer 1.4 to 10Pa
10 minute gel strength Fann viscometer 4 to 40Pa
pH pH indicator paper strips or 9.5 to 12

electrical pH meter
Notes to Table 14.1
1) Where the Fann viscometer is specified, the fluid sample should be screened by
a 300 µm sieve before testing.
2) The Contractor shall propose the frequency of testing bentonite slurry and the
method and procedure of sampling for approval before the commencement of work.
The frequency may subsequently be varied as required, depending on the
consistency of the results obtained, subject to approval.
3) Carry out tests until a consistent working pattern has been established, account
being taken of the mixing process, any blending of freshly mixed bentonite
suspension and previously used bentonite suspension, and any process which may
be used to remove impurities from previously used bentonite suspension. When the
results show consistent behaviour, the tests for shear strength and pH value may be
discontinued, and tests to determine density and viscosity shall be carried out as
agreed with the Engineer. In the event of a change in the established working
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pattern, tests for shear strength and pH value shall be reintroduced for a period if
required.
14.3.10 Grouting
a) Upon completion of a section the grout should be pumped through all lubrication
holes. The pressure and quantity of grout injected shall be calculated by the
Contractor and approved by the Engineer.
b) Commence grouting at the lower holes systematically working from one end of
the pipejack to the other. Where injection holes can be opened without loss of
ground, pump grout through the lower injection holes until it emerges from the
upper holes.
c) Monitor grouting progress continuously to ensure no heave.
d) Protect the carrier pipe and joints from the possible adverse physical or chemical
effect of grout. Wrap compressible material around the carrier pipe if required.
e) Install a free venting standpipe of not less than 100mm diameter on the grout
injection feed to restrict grouting pressures to a maximum of 1 bar.
f) Plug lubrication holes watertight on completion and make good pipe lining or
coating. Maintain the pressure of the lubricant when it is to be replaced by grout.
g) Grouting (external to pipe):
(i) Immediately following the jacking operation the Contractor shall pressure
grout the jacked section to fill all voids existing outside of the pipe. Grouting
shall be from the interior of the pipe through grouting holes as specified.
(ii) System of standard pipe, fittings, hose, and special grouting outlets
embedded in the pipe walls shall be provided by the Contractor. Care shall
be taken to ensure that all parts of the system are maintained free from dirt.
Grout composed of cement, sand, other Engineer approved compound and
water shall be forced under pressure into the grouting connections at the
invert and shall proceed until grout begins to flow from upper connections.
Connections shall then be made to those holes and the operation continued
to completion.
(iii) Apparatus for mixing and placing grout shall be of a type approved by the
Engineer and shall be capable of mixing effectively and stirring the grout
and then forcing it into the grout connections in a continuous uninterrupted
flow.
(iv) After grouting is completed, pressure shall be maintained by means of stop

cocks, or other suitable devices until the grout has set sufficiently. After the
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grout is set, grout holes shall be completely filled with dense concrete and
finished neatly without evidence of voids or projections.
(v) For pipes with concrete protection liners, grouting shall be carried out and
the Contractor shall ensure that the pipeline is watertight before proceeding
with the jointing of the linings of the pipes and the patching of the lining over
the filled grout holes. Grout holes patching shall be carried out using same
lining material.
14.3.11 Tolerances
a) Lateral deviation of any part of the pipeline shall be not more than ±50mm.
b) Level deviation of any part of the pipeline shall be not more than ±20mm for pipe
diameter up to 1800mm and ±50mm for pipe diameter above 1800mm.
c) Maximum lipping between the edges of adjacent pipes shall be not more than
±5mm.
d) Ground movement shall be limited to the following:
(i) Ground or roadway surface above the pipe centreline 5mm (unless the
Roads Authorities requirement is more stringent).
(ii) Adjacent structures 3mm.
e) There shall be no pipeline backfall at any point.
f) Any pipe which is not laid in its correct position must be adjusted to obtain its
correct position
14.3.12 Dewatering
a) The Contractor shall carry out work specified in this Section including design,
installation, operation, maintenance, and removal of ground dewatering systems
for shafts and trenches, and establishment of a groundwater level monitoring
programme.
b) Dewatering shall only be employed as a form of ground treatment/ground

improvement after obtaining the Engineer’s approval in writing. To obtain the
Engineer’s approval, the Contractor shall demonstrate to the satisfaction of the
Engineer that dewatering operations at each proposed location shall not cause
any damage to existing building, structures and services and/or shall not cause
unacceptable surface settlement either in the short term or long term. The
Contractor shall be also required to demonstrate that the ground water regime
after decommissioning of the dewatering system shall not be permanently
affected by the dewatering, e.g. a permanent drawdown of the water table in the
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area surrounding the dewatering well(s), migration of contaminants into the area,
etc.
c) The Contractor shall be solely responsible for the design, installation, operation
and maintenance of the sumps and dewatering systems under this Contract, and
shall provide all labour, materials, and equipment so as to lower and maintain the
groundwater table to the level necessary to allow safe excavation, construction of
structures, installation of pipes, structures and appurtenances, and backfilling of
excavations to be carried out under dry conditions. Care shall be taken to prevent
migration of natural soils and softening of the bottom of excavations due to
formation of “quick” conditions and/or “boils.”
d) The Contractor shall dispose of water from dewatering operations so as not to

cause injury or damage to adjacent property and shall at all times remain in
compliance with Construction Environmental Management Plan (CEMP)
requirements .
e) The Contractor shall provide, install, operate, and maintain dewatering systems of
sufficient size and capacity to permit excavation and subsequent construction in
dry conditions. Unless otherwise approved by the Engineer, the dewatering
system shall lower and maintain groundwater at a level that will allow safe
excavation while complying with specified settlement limits. Excavations shall be
maintained continuously free of water, regardless of source, and until excavation
is backfilled to final grade.
f) System redundancy shall be provided as required to keep excavations free of

water in event of failure of well point, pump, eductor, or other component.
g) The Contractor shall provide 100 percent emergency pump and power backup
with automatic start-up and switchover in event of electrical power failure.
h) The Contractor shall provide supplemental ditches and sumps only as necessary
to collect water from local seeps.
i) The Contractor shall provide competent workmen and supervision for the
operation of the pumping equipment. Workmen shall be available 24 hours a day
during dewatering to perform emergency maintenance on system components.
j) The Contractor shall grade the site such that at all times, site grading shall
promote drainage and surface runoff shall be diverted from excavations. Water
entering the excavation from surface runoff shall be collected in shallow ditches
around the perimeter of the excavation, drained to sumps, and be pumped or
drained by gravity from the excavation to maintain a bottom free from standing
water. The Contractor shall provide berms, ditches, temporary piping that spans
the excavation, or other means to protect excavations from erosion due to surface
water runoff or stream flooding.
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k) The Contractor shall conduct the dewatering in such a manner as to preserve the
undisturbed bearing capacity of the subgrade soils at proposed bottom of
excavation.
l) If foundation soils are disturbed or loosened by the upward seepage of water or

an uncontrolled flow of water, the contractor shall excavate the affected areas and
replace the materials with geotextile and drain rock in accordance with the
provisions of Section 2, Site Clearance and Earthwork, at no additional cost to the
Employer.
m) The Contractor shall maintain the water level a minimum of 1.5m below the
bottom of shaft excavation, where groundwater occurs during excavation,
construction, backfilling, and up to acceptance of work in such a manner to
guarantee the stability of the excavation invert against boiling or quick conditions.
n) The Contractor shall prevent flotation of pipe or other work by maintaining a

positive and continuous removal of water. The Contractor shall be fully and solely
responsible and liable for all damages which may result from failure to adequately
keep excavations dewatered.
o) Wells used to dewater excavations shall be adequately spaced to provide the

necessary dewatering and shall be sand packed and/or filtered by other means
used to prevent pumping of fine sands or silt-size soil particles from the
subsurface. The Contractor shall maintain a continual check to ensure that the
subsurface soil is not being removed by the dewatering operation.
p) Settlement: The Contractor shall repair without additional cost to DM any damage
caused by dewatering.
q) Disposal of water: Water from ground dewatering operations is subject to the

following:
(i) The Contractor shall dispose of water from the Work in a suitable manner
without damage to adjacent property. Contractor shall be responsible for
obtaining any and all permit that may be necessary to dispose of water. No
water shall be drained into work built or under construction without prior
written authorization of the Engineer. Water shall be filtered using a method
to remove sand and fine-sized soil particles before disposal into any
drainage system.
(ii) All dewatering water shall be desilted through adequately sized desilting
tanks, plate clarifier systems or other systems as may be necessary, prior to
discharge.
(iii) The release of groundwater to its static level shall be performed in such a
manner as to maintain the undisturbed state of the natural foundation soils,
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prevent disturbance of compacted backfill and prevent flotation or

movement of structures, pipelines, and sewers
14.3.13 Slurry Separation Plant
The excavated material from the face cut, crushed and mixed with the slurry shall be
separated and the water recycled or disposed of at a location agreed by the
Engineer. Cleaning of the slurry shall be achieved by using either:
a) Settling tanks, where the tank is cleaned by an excavator or grab, the water is
recycled and the solid material is disposed off the site; or
b) Separation plant, where a separate unit of screens and cyclones continuously

removes the solids and recirculates the slurry for further use or disposal.
14.3.14 Protection of existing Structures and Services
Protection of existing structures and services shall be carried out as per Section 16.
14.3.15 Monitoring Ground Surface Movement
Monitoring ground Surface movement shall be carried as outlined in Section 15.
a) The Contractor shall continuously monitor the ground surface adjacent to

structures and buried utilities and shall control activities such as excavation,
tunnelling and dewatering to prevent movement and or damage to existing
structures.
b) Install movement points and monitor prior to any excavation associated with the
pipeline.
c) Determine the optimum location for points to monitor existing structures to the
d) Provide monitoring points within the existing structures and on the road surface to
the approval of the Engineer. Generally, monitoring points along the road surface
shall be located along the pipe centreline on each side. The distance for the
location of the monitoring points along the same line shall be calculated to fall
within the HS 20 wheel loads in each lane. Points on existing structures shall
be located approximately 500mm above the ground surface. Location of
settlement points in the vicinity of the pits/shafts will be agreed with the Engineer.
e) Monitor all points with reference to benchmarks located outside the area of
influence of the Works. Monitoring shall demonstrate repeatability to 3mm.
f) Obtain the elevations of monitoring points as described below.
(i) For monitoring points within 20m of the heading, after each advance
of 5m.
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(ii) For monitoring points greater than 20m but less than 100m away from the
heading, daily.
The monitoring point elevations shall be reported to the Engineer within 24 hours
during the course of construction of the pipeline and related pits/shafts.
g) Should surface movement occur greater than the specified limits, at any location
affected by the Works, the Engineer may require modification of the method or
sequence of the work or a shutdown of the work to make appropriate changes in
the construction operation. Changes required to keep surface movement within
the specified acceptable limits shall be made solely at the Contractor’s expense.
h) Upon completion of the pipeline, continue to monitor point elevations during the
maintenance period as required by the relevant authority, record findings and
report to the Engineer on a monthly basis. If the specified limits are exceeded,
report immediately and submit a proposal to rectify the road surface and prevent
further settlement.
14.3.16 Pipe Testing
Unless superseded by clauses herein, the requirements of ‘Section 4- Pipes,

Pipework, Manholes and Chambers’ apply.
a) Conduct infiltration test upon completion of the permanent construction of the

tunnel to verify the joints are water tight. The infiltration test shall be carried out
after dewatering is stopped and the groundwater has attained normal levels. In
the case of lined concrete pipes the leakage tests shall be carried out after
installation and before the liners of the successive pipes are joined and sealed.
After joining and sealing of the liners, there shall be no evidence of a build-up of
groundwater pressure at the joints of the concrete pipe.
b) Man entry pipelines shall be visually inspected only. Any leaks to be

repaired/stopped.
c) Infiltration or pipe deflection is not permitted in sections of pipelines underneath

roads, paved areas and services.
d) In the event of the works failing the test, for whatever reason, the Contractor shall
take such remedial action as is necessary to correct the deficiencies, subject to
the Engineer’s approval of any methods proposed. The works shall be re-tested
until such time as the works pass the test.
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DEPARTMENT
SECTION 15
GEOTECHNICAL INSTRUMENTATION & MONITORING
DM/SRPD Section 15 Geotechnical Instrumentation & Monitoring Rev 00 June
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DM/SRPD Section 15 Geotechnical Instrumentation & Monitoring Rev 00 June Page i of ii
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SECTION 15
GEOTECHNICAL INSTRUMENTATION & MONITORING
CONTENTS
15 GEOTECHNICAL INSTRUMENTATION & MONITORING ............................................... 1
15.1 GENERAL...................................................................................................................... 1
15.1.1 Scope.................................................................................................................... 1
15.1.2 Submittals ............................................................................................................. 1
15.1.3 Quality Control ...................................................................................................... 1
15.2 MATERIAL..................................................................................................................... 2
15.2.1 Grout Mix .............................................................................................................. 2
15.3 EXECUTION .................................................................................................................. 2

15.3.1 General ................................................................................................................. 2
15.3.2 Installation ............................................................................................................. 5
15.3.3 Monitoring Frequency ......................................................................................... 10
15.3.4 Protection, Maintenance and Repair .................................................................. 11
15.3.5 Removal .............................................................................................................. 11
15.3.6 Drawings ............................................................................................................. 12
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15 GEOTECHNICAL INSTRUMENTATION & MONITORING
15.1 GENERAL
15.1.1 Scope
The work specified in this Section includes furnishing, installing, and monitoring
geotechnical instrumentation for the following:
a) All buildings, structures and services likely to be affected by the Works.
b) Performance of pipejack/microtunnelling equipment.
c) Pipeline ovality sections at selected locations for pipelines of 900mm diameter or

greater.
d) All shafts and excavations deeper than 5 m unless stated otherwise.
15.1.2 Submittals
The following documents shall be prepared by the Contractor and submitted to the
Engineer:
a) Method Statements: Submit a detailed instrumentation monitoring programme in

a written method statement to the Engineer for approval within 10 weeks from the
Commencement Date. It should include installation procedures, instrument types,
locations, monitoring procedures, monitoring frequency, and all requirements
imposed by the parties responsible for monitoring the affected structures.
b) Drawings: Submit planned depths, planned locations, and detail drawings for all
required and proposed instrumentation.
a) Qualifications: Engage a professional and independent geotechnical

instrumentation and monitoring firm, acceptable to the Engineer to carry out the
instrumentation and monitoring programme. The responsible person shall be a
Civil Engineer with a minimum of 5 years’ experience in geotechnical
instrumentation and monitoring.
b) Survey Methods and Survey Control:
(i) Establish deep cased bench marks from the approved datum for use in
instrumentation monitoring.
(ii) Establish the elevations of deep cased bench marks by running level
circuits started and closed at the specified bench mark and as follows:
1. Establish turning points so that foresights and backsights are

approximately equal. Foresights and backsights shall be less than 60 m.
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2. Turning points shall consist of well defined surface points of solid

objects or masonry nails driven into pavement.
3. Each error of closure shall be less than 3 mm. If any error of closure is
greater than 3 mm, re-survey the circuit.
4. Prove the established elevations of deep cased bench marks by running

at least three separate and complete level circuits which yield consistent
results. Re-survey all level circuits until correct and repeatable
elevations are obtained.
(iii) Determine initial locations and elevations of all monitoring points,

instruments, and bench marks by optical surveying techniques.
(iv) Provide initial readings of building settlement points by conducting at least

three separate and complete sets of optical survey readings on each
instrument which yield consistent results.
15.2 MATERIAL
15.2.1 Grout Mix
Bentonite grout shall comply with requirements of Table 15.1 below unless otherwise
Details of cement grout mixes and placement methods shall be submitted to the
Engineer approval prior to incorporation into the Works.
Table 15.1: Bentonite Grout Mix

Materials Weight Ratio by Weight
Portland cement 50 kg 1
Bentonite 13.2 kg 0.3
Water 125 litres 2.5
15.3 EXECUTION
15.3.1 General
a) Commence the monitoring programme as soon as possible after the Date of

Commencement and at least 4 weeks before construction work is scheduled to
start. Determine the present on-going rate of intrinsic settlement or subsurface
ground movement, background vibration levels, etc., at the site during this period
for the purpose of differentiation while the Works are in progress.
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b) The monitoring programme shall include the installation of settlement observation

points, inclinometers, vibration monitoring equipment, extensometers,
piezometers, and water level observation wells as specified below. Provide
additional monitoring stations, devices, and procedures if deemed necessary or if
directed by the Engineer during the progress of the Works. The Contractor may
propose additional or alternative instrumentation not listed herein.
c) Performance Monitoring of pipejacked/microtunnelled pipelines:
(i) Monitor TBM performance at selected locations within a minimum of four

monitoring zones, at least two of which shall be located on the conveyance
pipe line. The entire length of a monitoring zone shall be 16 m or less.
Install from the ground surface within each monitoring zone a series of
settlement observation points above the pipeline crown and transverse to
the centreline to determine the shape and depth of the longitudinal and
transverse settlement troughs. Install within each monitoring zone, a
minimum of 21 settlement points, including seven points at each of three
perpendicular pipeline cross-sections.
(ii) Install within each of the monitoring zones described above at least one
piezometer, four inclinometers, and three multiple point borehole
extensometers. Install the deepest extensometer a maximum of 0.5 m
vertically above the pipeline crown.
(iii) Install surface settlement points every 100 m along the pipeline centreline
and deep extensometers about every 500 m along the pipeline centreline.
(iv) Install in any building within the zone of influence of bored tunnel one
levelling settlement point every 25m along the building perimeter or at least
one point at each corner, at least one tilt meter and crack meters as
required based on actual condition. On other structures within the zone of
influence, above mentioned instruments to be installed, so as to adequately
monitor their behaviour during tunnelling works, at locations approved by
the Engineer.
d) Performance Monitoring of Shafts and Open-Cut Excavations:
(i) For shafts with excavated diameters of 4m or greater or deeper than 5m,
internal convergence points, strain gauges on lateral support elements,
surface settlement points, one inclinometer, one piezometer and building
settlement monitoring points shall constitute a minimum monitoring plan.
(ii) For shafts with excavated diameters greater than 6m diameter, include in
the monitoring plan, the same instrumentation as described in d) 1. above in
this section plus two additional inclinometers.
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(iii) The monitoring points for any given shaft shall be of sufficient spacing and
density to determine the displacements around the shaft and at affected
structures.
(iv) Install piezometers in order to properly define the extent, if any, of

groundwater drawdown.
(v) Install borehole extensometers between any structure with shallow

foundations or sensitive pipelines at higher elevations at the following
locations.
1. Within the zone of influence of any dewatering
2. In areas of mixed face conditions
(vi) Install convergence points at pipeline/shaft junctions immediately after

installation of the initial ground support systems at the approved locations.
(vii) Install in any building within the zone of influence of a shaft one levelling
settlement point every 25m along the building perimeter or at least one point
at each corner, at least one tilt meter and crack meters as required based
on actual condition. On other structures within the zone of influence, above
mentioned instruments to be installed, so as to adequately monitor their
behaviour during shaft construction works, at locations approved by the
Engineer
e) Notify the Engineer in the event that any of the approved instrumentation
locations are inaccessible and propose alternative monitoring locations, subject to
the Engineer’s approval and the parties responsible for the affected structures.
Where settlement observation points are inaccessible, propose an indirect
measurement or alternative form of measurement.
f) At a minimum, monitor displacements and vibration levels of any structure or any

ground surface that is adjacent to a shaft, open excavation, or pipeline where
predicted displacements exceed 5 mm, predicted induced settlement slopes
exceed 1/500, or where subjected to greater than 50 mm/sec peak particle
velocity (PPV) construction vibration levels.
g) Design all deformation monitoring instrumentation for ground settlements, heaves

or deformations which may occur. Replace or reset any instrumentation that
exceeds 85 percent of its design value.
h) Rates shall allow for carrying out the monitoring programme as specified,
including any additional stations, devices and procedures as directed by the
Engineer.
i) Use survey methods for instrument reading as specified for survey control.
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j) Keep a continuous boring log of drilling observations including soil types, water
levels, and drilling difficulties encountered during drilling. Submit a boring log
template for the Engineer’s approval. Submit a completed boring log to the
Engineer at the completion of installation work for each water level observation
well and piezometer.
15.3.2 Installation
a) Deep Cased Bench Marks:
(i) Drive outer casing vertically to refusal. Drill ahead of outer casing as
required for penetration into dense soil or weathered/fractured rock.
(ii) Seat the outer casing within firm ground. Drill below the outer casing to the
depth shown. Blow out soil and/or rock fragments from the drilled hole with
compressed air of sufficient pressure introduced at the bottom of the drill
hole.
(iii) Place cement grout in the drilled hole. Seat the inner bench mark pipe
within the cement grout.
(iv) Install centring devices between the inner bench mark pipe and outer
casing.
(v) Weld the stainless steel ball reading point to the top end of the bench mark
pipe.
(vi) Install lockable protective boxes over the top end of outer casing.
b) Near Surface Settlement Points:
(i) Flexible Pavement: Use survey masonry nails, with nail head flush with
pavement surface, suitable for use with levelling rod.
(ii) Rigid Pavement/Sidewalk: Install as shown on the drawing in Clause 15.3.6

of this Specification. Drive steel pipe to the depth shown using a coupling
and nipple as a striking surface. Remove coupling and install pipe cap with
read point.
(iii) Unimproved Areas: Install as shown on the drawing in Clause 15.3.6 of this
Specification. Install monument enclosure and cover as shown.
c) Building Settlement Monitoring Points: Install as shown on the drawing in Clause

15.3.7 of this Specification or in accordance with the manufacturer's
recommended procedures. Remove drilling debris from the drilled hole by air or
d) Ground Inclinometers:
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(i) Install inclinometer casing as shown on the drawing in Clause 15.3.6of this
Specification and in accordance with the manufacturer's recommended
procedures. Advance and clean the boring by rotary wash boring methods.
Stabilise the borehole with temporary casing or drilling mud. Remove
temporary casing after installing inclinometer casing.
(ii) Place protective cap on bottom of inclinometer casing and seal with solvent
cement to provide a waterproof seal.
(iii) Assemble additional sections of inclinometer casing using appropriate

couplings and lower the sections into the hole. Fully extend telescoping
coupling and ensure that seals are watertight.
(iv) Add clean water to inside of inclinometer casing to facilitate lowering

inclinometer casing through water or drilling mud in the borehole.
(v) Position inclinometer casing so that the orthogonal grooves are parallel and
perpendicular to the shaft wall or pipeline.
(vi) Grout the annulus between the inclinometer casing and the borehole. Place
grout with a detachable flexible tremie pipe or grout pipe attached to the
bottom of the inclinometer casing. Ensure an intimate soil/grout contact.
(vii) Immediately after grouting, jet and flush inclinometer casing with clean
water.
(viii) Lower a dummy probe into inclinometer casing in two directions to ensure
that all four grooves are free of obstructions over their entire length.
(ix) Install lockable monument cover and enclosure over the top end of the
inclinometer casing as shown on the drawing in Clause 15.3.6 of this
Specification.
e) Vibrating-Wire Strain Gauges:
(i) Install strain gauges on steel struts or ring beams in accordance with the
manufacturer's recommended procedures.
(ii) Waterproof the strain gauges, cables, and cable connections using
recommended procedures.
(iii) Tack-weld bolts to strut web and secure protective channel covers to strut.
Wrench-tighten nuts. Attach steel and plates to channel by welding across
long dimensions of channel. Provide hole in end plate of cover to allow
passage of flexible conduit.
(iv) Protect cables from damage and lead them to an accessible platform within
the excavation where readings can be made. Terminate cables in
enclosures with panel boards.
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f) Extensometers:
(i) Install extensometers as shown on the drawing in Clause 15.3.6 of this

Specification or in accordance with the manufacturer's recommended
procedures.
(ii) Drill holes to adequate depths. Avoid over drilling. Do not use drilling mud,
oil, or other materials in the hole which will adversely affect the bond
between soil, rock, grout, and extensometer anchors.
(iii) Grout extensometer anchors, attached extensometer rods, and protective

tubing within the borehole. Grout from the buried end of the borehole until
the borehole is filled. Do not interrupt grouting until the installation is
complete. Ensure an intimate ground/grout contact.
(iv) Terminate the top of extensometer rods and the top of the protective tubing
within the extensometer reference head guide sleeves.
(v) Clearly and permanently identify on extensometer reference head the

instrument identification number for each extensometer anchor and
connecting extensometer rod.
g) Crackmeters:
(i) Install crackmeters in accordance with the manufacturer's recommended

procedures, and as approved by the Engineer.
(ii) Wherever crack displacement after installation exceeds the crackmeter

displacement measuring range in one or more directions, dismount, reset,
and reinstall the crackmeter in the same location or approved alternate
location. No crackmeter shall be reset without prior approval by the
Engineer.
h) Tilt Meter
(i) Install tilt plates in accordance with the manufacturer's recommended

procedures and as approved by the engineer. Install tilt plates on buildings
and structures indicated in the approved plans. Monitor change in tilt of
building and structures using portable tiltmeter and readout unit cum
datalogger.
i) Water Level Observation Wells:
(i) Prior to construction operations, install observation wells. Install observation

wells at the locations and depths shown on the approved plans.
(ii) For each installation, drill hole using water as the drilling fluid. Support the
hole by using a hollow stem auger or by installing temporary casing. The
minimum diameter of the hole shall be 125 mm.
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(iii) At the completion of drilling, flush the drilled hole with clean water to remove
drilling fluid.
(iv) Place a minimum of 100 cm filter sand in the bottom of the hole. Then insert
the well screen and riser pipe assembly into the hole. Fill the annulus
between the well assembly and the wall of the hole with filter sand to within
1 m of the top of the hole, withdrawing the hollow stem auger or temporary
casing as the sand is placed, to prevent caving of the hole around the filter
sand or riser pipe.
(v) Fill the top 1 m of the hole with lean concrete or similar.
(vi) Develop well by flushing out the installed riser pipe with clean water.
(vii) Survey the piezometer to document its exact location and collar elevation.
Fit the top of the riser pipe with a vented screw plug. Install the monument
enclosure and cover as shown.
(viii) Prepare a well installation log in a format approved by the Engineer.
(ix) Replace at no additional cost and within 48 hours any piezometer that is
damaged or destroyed.
j) Standard Piezometers:
(i) Prior to construction operations, install standpipe piezometers. Install

standpipe piezometers at the locations and depths shown on the approved
plans.
(ii) For each installation, drill a 125 mm (minimum) diameter hole using water
as the drilling fluid. Support the hole by using a hollow stem auger or by
installing temporary casing.
(iii) At the completion of drilling, flush the drilled hole with clean water to remove
drilling fluid.
(iv) Place a minimum of 30 cm of filter sand below the planned piezometer tip
depth. Insert the piezometer tip and riser pipe assembly into the hole. Fill
the annulus between the piezometer assembly and the wall of the hole with
filter sand to a minimum of 120 cm above the piezometer tip of the porous
piezometer top.
(v) Check that the required level of filter sand was placed in the hole by using a
measuring device, subject to the Engineer’s approval.
(vi) Place bentonite pellets in the annulus and tamp in place to produce a
bentonite seal a minimum of 50 cm thick above the top of the filter sand.
Provide a reliable apparatus, subject to the Engineer’s approval, for tamping
the pellets. Check the depth of the bentonite using the approved measuring
2016

Dubai Municipality
device specified above to ensure that the required seal thickness has been
achieved.
(vii) Fill the remaining annulus with bentonite grout.
(viii) Develop the piezometer by flushing out the installed riser pipe with clean
water.
(ix) Survey the piezometer to document its exact location and collar elevation.
Fit the top of the riser pipe with a vented screw plug. Install the monument
enclosure and cover as shown.
(x) Prepare a well installation log in a format approved by the Engineer.
(xi) Replace at no additional cost and within 48 hours any standpipe piezometer
that is damaged or destroyed.
k) Electric Vibrating-Wire Piezometers:
(i) Install electric vibrating-wire piezometers as shown on the drawing in

Clause 15.3.7 of this Specification or in accordance with the manufacturer's
recommended procedures. The location and depth of installation shall be as
per approved plan.
(ii) For each installation, drill hole using water as the drilling fluid. Support the
hole by using a hollow stem auger or by installing temporary casing.
(iii) After drilling is completed, flush hole with clean water to remove drilling
fluid.
(iv) Place a minimum of 300 mm of filter sand in the bottom of the hole.
Encapsulate a piezometer sensor in a canvas bag filled with filter sand.
Lower the encapsulated piezometer sensor and signal cable into the hole.
Fill the borehole annulus around and above the piezometer sensor with filter
sand to a minimum of 150 mm above the top of the piezometer sensor.
(v) Check that the required level of filter sand was placed in the hole by using a
measuring device, subject to the Engineer’s approval.
(vi) Place bentonite pellets in the borehole annulus and tamp in place to
produce a bentonite seal a minimum of 1 m thick above the top of the filter
sand. Provide a reliable apparatus, subject to the Engineer’s approval, for
tamping the pellets. Check the depth of the bentonite using the approved
measuring device specified above to ensure that the required seal thickness
has been achieved.
(vii) Simultaneously withdraw casing and fill the borehole annulus with bentonite
grout to the bottom of the next sensor's filter sand zone or, if no more
sensors are to be installed, to within 1 m of the top of hole.
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Dubai Municipality
(viii) After the grout above the final sensor has taken an initial set, fill the top 1 m
of the hole with bentonite grout and set the monument enclosure and
lockable cover in place at a level flush with the surrounding ground surface.
Provide approved signal cable insulation protection in monument enclosure.
Provide terminal caps and plugs for each sensor cable. Clearly and
permanently tag cable ends to indicate the sensor to which each is
connected.
(ix) Demonstrate at key intervals throughout installation that each installed

sensor is properly functioning by connecting sensors to the approved
readout unit. Prior to demobilizing installation equipment and crews,
demonstrate in the Engineer's presence that each piezometer sensor is
functioning properly by connecting sensors to the approved readout unit.
Immediately replace, at no additional cost, any non-functioning sensor with
an instrument installed in an adjacent borehole.
(x) Survey the piezometer to establish its installed location and monument
cover elevation.
(xi) Replace at no additional cost and within 48 hours any electric vibrating-wire
piezometer that is damaged or destroyed
15.3.2.2 Vibrating Monitoring
a) Monitor all structures that are subjected to continuous or transient construction-

induced ground vibrations greater than 15mm/sec and 50 mm/sec PPV for un-
reinforced/light framed structure and reinforced/framed structure respectively.
b) Select a seismic monitoring readout unit, subject to the Engineer’s approval, to

monitor vibrations at structures. At a minimum, the readout unit shall have three
seismic channels with a triaxial transducer. The triaxial transducer shall utilize
three high output/low distortion geophones, a permanent photographic record of
the particle velocity in each of the three axes, a flat frequency response from 4 to
200 Hz, input range of 2 to 500 mm/sec, and a vibration resolution equal to 0.025
mm/sec.
c) Structures having background PPVs greater than 50 mm/sec due to external

disturbances such as adjacent manufacturing facilities, shall be brought to the
Engineer’s attention. Modify the monitoring plan for these structures and submit to
the Engineer for approval.
15.3.3 Monitoring Frequency
a) Measure and record daily, displacements from appropriate instruments located

within a 30 m horizontal distance in any direction from a microtunnel/pipejack
drive face. Thereafter, measure and record weekly until three consecutive
readings show no detectable movements. Thereafter, measure and record
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Dubai Municipality
monthly until 6 weeks after the pipeline installation is completed within 300 m of a
given monitoring point. Measure and record groundwater levels within the same
distance and frequency as displacement monitoring.
b) Measure and record displacements from appropriate instruments required by

section 15.3.1 d) of this specification every 2 m of shaft excavation depth or four
times a week, whichever frequency is greater, until final grade is reached.
Thereafter, read weekly until three consecutive readings show no detectable
movements. Thereafter, read monthly until 6 weeks after all final lining and
permanent support walls have been installed and all planned recoverable
temporary support elements have been removed. Measure and record
groundwater levels at the same frequency as displacement monitoring.
c) Take readings more frequently than that specified above at no additional cost, if
the Engineer determines that such additional monitoring is warranted by actual
construction conditions.
15.3.4 Protection, Maintenance and Repair
a) Protect and maintain in good working condition all monitoring instruments and
devices throughout the Contract period. If in the opinion of the Engineer, any
instrument or device is not functioning properly or accurately, replace immediately
and at no additional cost.
b) All monument enclosures shall be lockable and keyed alike.
c) Protect and maintain all instrument systems. Maintenance shall include draining
or flushing monument enclosures and repairing damaged or missing components
of systems. Repair or replace damaged or missing instrumentation within five
days and at no additional cost
15.3.5 Removal
a) Instrumentation shall not be demolished, abandoned, removed, disposed of, or

rendered inaccessible without prior approval from the Engineer.
b) Remove instrumentation prior to final acceptance of the work or when directed by

the Engineer.
c) Remove and dispose of terminal boxes and covers.
d) Grout all remaining open portions of the boreholes and inclinometer casings,
backfill the area, patch pavement or surface, and restore to the Engineer's
satisfaction.
e) Remove reference points and paint marks on buildings and patch any holes or
spills on walls resulting from reference point removal
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Dubai Municipality
15.3.6 Drawings
a) Deep Cased Benchmark
Lockable protective cover

Survey pin
G.L.
75
Concrete
(500x500) mm
1
2" GI pipe socket
1
2" GI pipe, od-~22 mm.
15 m
PVC socket
PVC pipe, od-50 mm.
Cement-bentonite grout
Coupler
Anchor, Ø25x1000 mm.
Concrete
Ø100 mm
b) New Surface Settlement Point for Flexible /Rigid Pavement/Sidewalk
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Dubai Municipality
Ø100
2
80 1
Epoxy fill
Pavement
or Tarmac
Base soil
Ø10
Item Description
1 Plastic Tapered Disc
2 Retaining nail
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Dubai Municipality
c) New Surface Settlement Points for Unimproved Areas

500x500
Lockable protective cover

Angle Survey pin, Matl. : AISI-304
G.L. frame
75
35
Soil
Sand
1000
Extension rod,
Matl. : M. S., Ø16
PVC pipe
(OD-48, ID-37)
Surrounding soil
Concrete, Cement :
sand : gravel (1:2:4)
Grouting plate
(M S - 100x100x5)
d) Building Settlement Monitoring Point
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Dubai Municipality
e) Ground Inclinometer
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Dubai Municipality
500x500
Lockable
Angle protective cover
frame Top cap
G.L.
200
125
500
Niche
Concrete
Fixed coupling
Grout
Casing
Bottom cap
Bore hole Ø125
f) Vibrating-Wire Strain Gauges

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Dubai Municipality
g) Crack Meter
HILTI : HPS 1 55x2.5

Acrylic plate
Red cursor
Crack
Screws
30.0
0
1 2 3 4 5
Ø5.0
30.0
Scale
30.0
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Dubai Municipality
h) Tilt Plate
(to be monitored using portable tiltmeter)
Item Description
1 Tilt plate
2 Impact Anchor
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Dubai Municipality
i) Extensometer
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Dubai Municipality
Ø100
Wrapped in 14
a plastic bag
19 2
15,16
17,18 V 3
13
24 & G
25 8.b 1
B
7 9
15 17
8.a
6
PLAN (without cover)
16
Ø160
5
18
A
22
10
11 1 23
12
Ø82
Displacement A B 20
50 mm 248 200
100 mm 378 240
Item Description
1 Anchor
3
2 Connecting rod
3 Vent tube 4
4 Grout tube
5 Flanged housing Cable tie
6 Adaptor
7 Guide plate
8.a Grub screw, M4x5 2
8.b Grub screw, M4x8
9 Allen head screw, M5x12
10 Rubber bush Grout
11 Washer
1
12 Hollow bolt
13 Spacer
14 Reference plate
15 Reference button
Link plate Ø76
16
17 Sensor tightening nut
18 Sensor lock nut
19 Cover
20 Displacement sensor
21 Expandable anchor
22 Nipple with chuck nut
23 Junction box assembly
j) Electric Vibrating Piezometer
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Dubai Municipality
Lockable protective cover (250x250)

G.L.
Cavity
(250x250
x150 depth)
Concrete
Terminal box
for observing data
Sand cement grout

5000
500
Bentonite seal
Sensor cable
1000
10000
V W piezometer
Saturated clean sand
Sand cement grout

500
Bentonite seal
Sensor cable
1000
V W piezometer
Saturated clean sand

300
Borehole Ø100
Note : All dimensions in mm.
2016

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 16
PROTECTION OF EXISTING STRUCTURES AND SERVICES
DM/SRPD Section 16 Protection of Existing Structures & Services Rev 00 June 2016

Dubai Municipality
DM/SRPD Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page i of ii

Dubai Municipality
SECTION 16
PROTECTION OF EXISTING STRUCTURES
AND SERVICES
CONTENTS
16.............PROTECTION OF EXISTING STRUCTURES AND SERVICES 1

16.1 GENERAL .............................................................................................................. 1
16.1.1 Scope .................................................................................................................. 1
16.1.2 Submittals............................................................................................................ 1
16.1.3 Quality Control..................................................................................................... 1
16.2 EXECUTION ........................................................................................................... 2
16.2.1 General................................................................................................................ 2
16.2.2 Performance Requirements ................................................................................ 2
16.2.3 Preliminary Assessment and Preliminary Assessment Report ........................... 2
16.2.4 Detailed Assessment and Final Assessment Report .......................................... 3
DM/SRPD Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page ii of ii

Dubai Municipality
16 PROTECTION OF EXISTING STRUCTURES AND SERVICES

16.1 GENERAL
16.1.1 Scope
a) This section of the Specification contains the performance requirements of

the Works as they relate to impacts on existing structures and services and
contains the requirements for:
1. Assessing the effect of the deep excavation/ micro tunnelling Works on
existing structures and utilities.
2. Identifying which structures and utilities to monitor and instrument during
construction.
3. Evaluating the appropriate protection measures needed to prevent
damage or to reduce damage risk to structures and utilities.
b) All structures within the zone of influence of the pipeline construction are to
be considered.
16.1.2 Submittals
The following documents shall be prepared by the Contractor and submitted to the
Engineer:
 A preliminary report entitled, “Preliminary Report: Assessment of

Construction Impacts on Structures,” duly endorsed by a Registered
Professional Engineer or Chartered Engineer or Engineer with equivalent
qualifications shall be submitted to the Engineer by the Contractor within 8
weeks of the Commencement Date.
 A draft report entitled, “Draft Final Report: Assessment of Construction
Impacts on Structures,” shall be submitted to the Engineer 30 days prior to
the commencement of any excavation and shall be approved by the Engineer
before issuance as the final report.
 A final report entitled, “Final Report: Assessment of Construction Impacts on
Structures,” duly endorsed by a Registered Professional Engineer or
Chartered Engineer or Engineer with equivalent qualifications shall be
submitted to the Engineer and shall be unchanged from the approved draft
report, except for minor editorial changes.
The Contractor shall engage an independent specialist firm with not less than 10
years of professional experience in similar work to carry out the construction impact
assessment work.
DM/SRPD Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page 1 of 5

Dubai Municipality
16.2 EXECUTION
16.2.1 General
Should changes to the pipeline alignment result in more than a 5 metre horizontal
shift, the Contractor shall re-assess the construction effects for all structures and
services within the zone of influence of the re-aligned section.
16.2.2 Performance Requirements
a) Contractor shall design both temporary and permanent works to ensure that
ground movements are kept to an absolute minimum. Proven techniques
and good workmanship are required to restrict ground loss that would lead to
ground movement.
b) Contractor shall select and operate construction equipment in a manner such
that damage to structures from vibrations is negligible.
c) Construct all pipelines and shafts using equipment and materials that are
able to quickly and adequately support the ground and that are able to
minimise and positively control the inflow of water. Exercise care to ensure
that a minimum of over excavation takes place.
d) Contractor shall meet the local regulatory requirement of maximum permitted
surface settlement during microtunnelling operation.
e) Initiate remedial measures when settlement reaches 60 percent of the
maximum permitted settlements. The Engineer may require remedial
measures when settlement reaches less than 60 percent of the maximum
permitted settlement if the rate of settlement is higher than predicted in the
assessment report.
f) The Contractor shall first discuss with the Engineer and then consult with and
advise the owner of any structure identified in the report, “Final Report:
Assessment of Construction Impacts on Structures,” of the risk and level of
damage expected. If required by the owner, the Contractor shall reach
agreement with the owner of the respective structures about the level of
protection and monitoring required and submit all the details to the Engineer.
Employer/ Engineer will assist Contractor in reaching such agreement with
the owner.
16.2.3 Preliminary Assessment and Preliminary Assessment Report
a) The Contractor shall carry out a preliminary assessment of the anticipated

displacements induced by the Works, the effects of those displacements, and
the effects of construction vibrations shall be carried out for all structures in
the vicinity of the Works.
b) A Preliminary Report shall be prepared presenting ground displacements
may be estimated by empirical methods. Empirical calculations for TBM
excavations shall assume a minimum face loss percentage equal to 0.25
percent and 0.5 percent considering average settlement and worst case
settlement scenario.
c) The report entitled, “Preliminary Report: Assessment of Construction Impacts
on Structures,” shall identify all structures and services within the zone of
influence of the pipeline construction. Each structure identified shall be

Dubai Municipality
categorized according to Table 16.1.

d) The Contractor shall show that structures outside of the zone of influence of
the pipeline construction are not affected by short term or long term ground
deformations arising from the Works.
Table 16.1 Slope, Settlement, and Risk Categories for Structures

Maximum
Maximum Slope Description of Probable
Settlement
(mm/mm) Damage
(mm)
Negligible: Superficial damage
< 1/500 <10
unlikely
Possible superficial damage
1/500 to 1/200 10 to 50 which is unlikely to have structural
significance
Expected superficial damage to
structures; Possible damage to
1/200 to 1/50 50 to 75
structures; Possible damage to
rigid utilities
Expected structural damage to
>1/50 > 75 structures; Expected damage to
utilities
e) For each tunnel drive, the Contractor shall measure the actual settlement
occurring and compare this with the predicted values. The operation of the
TBM shall be adjusted to limit the rate of spoil removal to bring the settlement
back into line with the allowable values.
16.2.4 Detailed Assessment and Final Assessment Report
a) The installation, operation and removal of geotechnical instrumentation and

monitoring equipment shall be in accordance with the requirements of
Section 15 “Geotechnical Instrumentation and Monitoring”.
b) The contractor shall carryout:
1. A detailed assessment of the anticipated displacements induced by the

Works and the damage potential caused by those displacements shall
be carried out for all structures influenced by the works and for those
structures and services in Risk Category II or higher as determined from
the preliminary assessment.
2. The potential for groundwater drawdown and vibration effects shall be

further investigated for all structures and services influenced by the
works and for those structures and services in Risk Category II or higher
as determined from the preliminary assessment.
3. For structures in the proximity of excavations where the use of large

plant creates ground vibrations, the peak particle velocity shall be
measured at the face of the building or any other location where it is

Dubai Municipality
necessary to limit vibration.
4. The measurements of peak particle velocity (PPV) shall be obtained

from instruments capable of measuring along three orthogonal axes, one
of which shall be aligned parallel to the centre line of the excavation, and
another shall be vertical.
5. The Contractor is to provide supports for the measuring instrument if so

required by the manufacturer’s instructions.
6. The measurement of particle velocities shall be the responsibility of the

Contractor. Copies of the readings in an agreed form shall be supplied to
the Engineer.
7. Equipment for the measurement of vibration shall be in accordance with

BS ISO 4866:2010. Following the commencement of works, the
Contractor shall demonstrate that the peak particle velocities given in BS
7385 Part 2:1990 are not being exceeded.
8. Ground displacements shall be estimated by numerical methods

acceptable to the Engineer.
9. The report entitled, “ Draft Final Report: Assessment of Construction

Impacts on Structures,” shall identify all buildings, structures and
services influenced by the works and those buildings, structures and
services in Risk Category II or higher as determined from the preliminary
assessment. As a minimum, include for each identified structure and
service, the following:
i. Subsurface conditions
ii. Estimated peak particle velocity (PPV) and corresponding
frequencies
iii. Potential for damage due to construction vibrations
iv. The potential for damage due to construction impacts, e.g.
surface settlement, heave, etc.
v. Summary and the results of detailed numerical analyses
vi. Proposed preventative and remedial measures for protection
vii. Instrumentation and monitoring requirements
10. The report entitled, “Draft Final Report: Assessment of Construction

Impacts on Structures,” shall contain, at a minimum, the following:
i. Summary of findings from the preliminary assessment report

ii. Proposed construction equipment, methods, and sequencing
iii. The results of the assessments for additional structures,
should the pipeline or shaft locations change positions since
the preliminary assessment was performed
iv. Description of all analyses performed
11. The above report shall be submitted to the Engineer 30 days prior to the
Commencement of any excavation and shall be approved by the

Dubai Municipality
Engineer before issuance as the final report.
12. Following the approval by the Engineer, a final report entitled, “Final
Report: Assessment of Construction Impacts on Structures,” duly
endorsed by a Registered Professional Engineer or Chartered Engineer
or Engineer with equivalent qualifications shall be submitted to the
Engineer and shall be unchanged from the approved draft report, except
for minor editorial changes.

Dubai Municipality
DUBAI MUNCIPALITY
DRAINAGE AND IRRIGATION DEPARTMENT

General Specifications
PART 2
Table of Contents
Section 17 General Electrical and Mechanical Specification
Section 18 Electrical & Instrumentation Works
Section 19 Mechanical Works
Section 20 Fire Fighting Works
Section 21 Geotechnical Investigation Works
Appendices
Appendix 1 Standard Details for Road Construction, Road Diversions,

Road Signs and backfilling to GRP pipes
Appendix 2 Testing and Workmanship of Insitu Lining Material
Appendix 3 Manhole entry (Including Elevated Manholes and Access to

Elevated Sewers)
Appendix 4 Additional Specifications relating to Road Works
Appendix 5 Laboratory Testing

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 17
GENERAL MECHANICAL & ELECTRICAL WORKS
DM/SRPD Section 17 General Mechanical & Electrical Works Rev 00 June

2016

Dubai Municipality
DM/SRPD Section 17 General Mechanical & Electrical Works Rev 00 June Page i of iii
2016

Dubai Municipality
SECTION 17
GENERAL MECHANICAL AND ELECTRICAL WORKS
CONTENTS
17 GENERAL MECHANICAL AND ELECTRICAL WORKS .............................................. 1
17.1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED ............................................ 1
17.2 TROPICALISATION ................................................................................................................ 1
17.2.1 General ......................................................................................................................... 1
17.3 PLANT AND EQUIPMENT ...................................................................................................... 3
17.3.1 Resistance to Corrosion ............................................................................................... 3
17.3.2 Robustness................................................................................................................... 4
17.3.3 Adaptation of Equipment .............................................................................................. 4
17.3.4 Co-ordination ................................................................................................................ 5
17.3.5 Special Tools ................................................................................................................ 5
17.3.6 Spares .......................................................................................................................... 5
17.3.7 Lubrication of Plant ....................................................................................................... 6
17.3.8 Noise and Vibration ...................................................................................................... 6
17.4 ELECTRICAL EQUIPMENT .................................................................................................... 7
17.4.1 Compliance................................................................................................................... 7
17.4.2 Operating Voltages ....................................................................................................... 8
17.4.3 Protection and Co-ordination........................................................................................ 8
17.4.4 Power Factor Correction .............................................................................................. 8
17.4.5 Harmonics .................................................................................................................... 9
17.4.6 Electromagnetic Compatibility ...................................................................................... 9
17.4.7 Motor Starting ............................................................................................................... 9
17.4.8 Electrical Control Panels ............................................................................................ 10
17.4.9 Standard Designs/Circuit Requirements .................................................................... 11
17.4.10 Segregation of Services ............................................................................................. 11
17.5 ELECTRICAL APPARATUS FOR HAZARDOUS AREAS .................................................. 12
17.5.1 Scope ......................................................................................................................... 12
17.5.2 Standards ................................................................................................................... 12
17.5.3 Apparatus Group and Temperature Class ................................................................. 12
17.5.4 Certification................................................................................................................. 13
17.5.5 Index of Protection ..................................................................................................... 13
17.6 SAFETY ................................................................................................................................. 13
17.6.1 General ....................................................................................................................... 13
17.6.2 Authorized Persons .................................................................................................... 14
17.6.3 Permit to Work Arrangements .................................................................................... 14
17.7 PLANT SUPPLIERS FOR THIS CONTRACT ....................................................................... 14
17.8 WORK IN DANGEROUS AREAS ......................................................................................... 14
17.9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE .............................................. 15
17.10 HEALTH AND SAFETY AT WORK, ETC. ACT 1974....................................................... 15
17.11 DRAWINGS & INFORMATION FOR ELECTROMECHANICAL PLANT ......................... 16
17.11.1 At the Start of the Contract ......................................................................................... 16
17.11.2 Drawing Maintenance ................................................................................................. 16
17.11.3 Prior to Delivery of the Plant....................................................................................... 17
DM/SRPD Section 17 General Mechanical & Electrical Works Rev 00 June Page ii of iii
2016

Dubai Municipality
17.11.4 Prior to the Issue of the Taking-Over Certificate ........................................................ 17

17.12 FACTORY ACCEPTANCE TESTS ................................................................................... 18
17.12.1 General ....................................................................................................................... 18
17.12.2 Pumps ........................................................................................................................ 20
17.12.3 Motors......................................................................................................................... 20
17.13 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL PLANT21
17.13.1 General requirements ................................................................................................. 21
17.13.2 Testing and Commissioning Procedures and Documents ......................................... 24
17.13.3 Primary Tests and Checks ......................................................................................... 25
17.13.4 Unit Testing ................................................................................................................ 25
17.13.5 System validation tests............................................................................................... 25
17.13.6 COMMISSIONING AND SETTING TO WORK .......................................................... 26
17.14 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF ......................................... 26
17.15 OPERATING AND MAINTENANCE MANUALS .............................................................. 27
17.15.1 General ....................................................................................................................... 27
17.15.2 Requirements and Contents....................................................................................... 27
17.16 GUARANTEE..................................................................................................................... 30
17.17 IDENTIFICATION............................................................................................................... 31
17.17.1 General ....................................................................................................................... 31
17.17.2 Nameplates ................................................................................................................ 31
17.17.3 Tags............................................................................................................................ 32
17.17.4 Stencils ....................................................................................................................... 32
17.17.5 Pipe Markers .............................................................................................................. 32
17.17.6 Instruction Notices ...................................................................................................... 32
17.17.7 Safety Warning Signs and Notices ............................................................................. 33
17.17.8 Identification Colours .................................................................................................. 33
17.17.9 Colour Schedule for Plant and Equipment ................................................................. 33
17.17.10 Identification Colours for Plant and Equipment .......................................................... 33
17.17.11 Identification Colours for Pipelines ............................................................................. 33
17.17.12 Preparation ................................................................................................................. 33
17.17.13 Installation .................................................................................................................. 33
17.17.14 Schedules ................................................................................................................... 34
17.18 STANDARDS AND REGULATIONS................................................................................. 34
17.18.1 General Requirements ............................................................................................... 34
17.18.2 Purpose of Standards ................................................................................................. 35
17.18.3 International Standards .............................................................................................. 36
17.18.4 Local Regulations ....................................................................................................... 36
DM/SRPD Section 17 General Mechanical & Electrical Works Rev 00 June Page iii of iii
2016

Dubai Municipality
17 GENERAL MECHANICAL AND ELECTRICAL WORKS

17.1 Electrical and Mechanical Plant to be supplied
a) Electrical and Mechanical plant shall be supplied and installed as detailed and in
accordance with sections 17 through 19 of the specification.
b) Particular care shall be taken to ensure that all components are suitable for the
corrosive climatic and environmental conditions specified elsewhere in this
document.
c) This document sets out the general standards and information requirements for
Mechanical, Electrical, Instrumentation and Control (ICA) Works, and mention of
any specific material or plant does not necessarily imply that such is included in the
Works.
d) All component parts of the Works, including procedures, practices and services
shall, unless otherwise stated in the contract, should comply with the provisions of
this section. All work undertaken and equipment supplied should comply with all
standards, codes of practice, local regulations and specifications referred to
throughout the contract documents.
e) Where equipment is to be installed into existing Works, the Contractor shall ensure
at the pre-tender visit that the provisional location is adequate for the installation of
the proposed plant and equipment, or indicate otherwise in their tender return.
17.2 Tropicalisation
17.2.1 General
a) All plant and equipment shall be designed for the Dubai, UAE climate having salt
laden dusty atmosphere.
b) Only tropical grade materials shall be used throughout the installation, with the
exception of hermetically sealed equipment.
c) Small iron and steel parts, other than stainless steel of all instruments and electrical
equipment, the cores of electromagnets and the metal parts of relays and
mechanisms are to be treated in an approved manner to prevent corrosion. Cores
etc., which are built up of laminations or cannot for any other reasons be anti-rust
treated, shall have all exposed parts thoroughly cleaned and heavily enamelled,
lacquered or compounded.
d) Unless suitably protected from the elements, the use of iron and steel shall be
avoided in instruments and electrical relays. Screws shall be either of stainless steel
or cadmium or chromium plated.
e) Instrument screws (except those forming part of a magnetic circuit) shall be of brass
or bronze. Springs shall be of stainless steel, brass, bronze or other non-rusting
material. Pivots and other parts for which non-ferrous material is unsuitable are to
be of an approved stainless steel.
f) Fabrics, cork, paper and similar materials that are not subsequently to be treated by
impregnation are to be adequately treated with an approved fungicide. Fabrics
treated with linseed oil or linseed oil varnishes, are not to be used.
DM/SRPD Section 17 General Mechanical & Electrical Works Rev 00 June Page 1 of 48
2016

Dubai Municipality
g) The use of wood in equipment is to be avoided as far as possible. When used,

woodwork is to be thoroughly seasoned teak or other approved wood that is
resistant to fungal decay and is to be free from shakes and warp, sap and wane,
knots, faults, and other blemishes. All woodwork is to be suitably treated to protect it
against the ingress of moisture and from the growth of fungus and termite attack. All
joints in woodwork are to be dovetailed or tongued and pinned as far as possible.
Metal fittings, where used, are to be of a non-ferrous material or stainless steel.
h) The use of hygroscopic insulating materials shall not be permitted except where
immersed in oil or suitably sealed to prevent ingress of moisture.
i) All electronic and ICA equipments shall be suitable for installation in G3

environment where harsh level of corrosion severity and high probability of corrosive
condition prevails.
j) Sun shading shall be provided for all outdoor installations to ensure that plant and
equipment operates satisfactorily in the specified ambient conditions.
k) The minimum de-rating for all electrical equipment including cables shall be in
accordance with the relevant Electrical Standards appertaining to the specified
climatic conditions.
l) Switchboards, motor control centres, and electrical equipment shall be suitable for
continuous operation in an ambient temperature of 55°C. The fact that switch gear,
control rooms, pump rooms may be air conditioned shall not be taken into account.
m) When it is necessary to use dissimilar metals in contact these shall be selected

such that the electro-chemical potential difference is not greater than 250 mV.
n) The below climatic and ground condition should be taken into account. The plant,
equipment and materials shall be suitable for continuous operation under these
conditions.
Table 17–1: Climatic and Ground Conditions
Element Value
Maximum ambient air temperature 55ºC
Minimum ambient air temperature 1ºC
Design Ambient Temperature 55ºC
Maximum Surface Temperature recorded under

85ºC
direct sunlight)
Minimum Barometric Pressure 998 mb
Average Barometric Pressure 1015 mb
Maximum Ambient Humidity 100%
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Element Value
Minimum Ambient Humidity 20%
Design Ambient Humidity 100%
Design Wind Speed 160 km/hr
Average Yearly Rainfall 80 mm - 150 mm
Thermal Resistivity of soil in summer 2°C m/W
Temperature of soil in Summer at 0.7m depth 30ºC
Class G3 of ISA-
Maximum pollution level
S71.04-1985
o) The climate in Dubai is relatively mild from November to April, and hot from May to
October with high relative humidity.
p) Under certain combinations of the above climatic conditions, considerable

condensation may take place.
q) Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with the
extremely high ambient humidity can produce severe corrosion.
r) Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance. However, sudden heavy rainfall can occur in a very short period of
time.
s) The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr and sand storms occur in
the summer months.
17.3 PLANT AND EQUIPMENT
17.3.1 Resistance to Corrosion
a) All materials utilised in the plant shall be the most suitable for the duty concerned,
shall be new and of first class commercial quality and be selected to eradicate or
reduce corrosion to a minimum.
b) Particular attention shall be paid to material selection to minimise corrosion due to

atmospheric conditions, electrolytic action of dissimilar metals, presence of high
concentration of H2S gas or any other causes that may reasonably be associated
with the overall performance of the Works.
c) The use of organic materials shall be avoided whenever possible but where they
have to be used; they shall be treated to make them fire-resistant and non-flame
propagating.
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d) Use of wood is to be avoided wherever possible but where this has to be used, all
woodwork shall be treated to protect it against damage by fire, moisture, fungus,
bacteria or chemical effect.
e) Where, in the opinion of Dubai Municipality/Engineer, during the maintenance

period any moving parts show signs of undue wear, chemical attack or unsuitability
for the purpose for which they are installed, they shall be replaced, at no cost to
Dubai Municipality, notwithstanding that they may otherwise be working in a
satisfactory manner.
17.3.2 Robustness
a) All equipment furnished shall be new, of best commercial quality and guaranteed
free from defects in materials, design and workmanship. It shall be the
manufacturers’ responsibility to ascertain the conditions and service under which
the equipment will operate and to warrant such operation trouble-free in service and
meeting the specification.
b) All equipment shall be designed, fabricated, and assembled in accordance with the
best modern engineering and shop practice. Individual parts shall be manufactured
to standard sizes and gauges so that repair parts, furnished at any time, can be
installed in the field. Like parts of duplicate units shall be interchangeable.
c) Unless otherwise specified, stainless steel that will be submerged all or in part
during normal operation shall have a minimum nominal thickness of 6mm and be of
at least Grade 316L stainless steel.
17.3.3 Adaptation of Equipment
a) No responsibility for alteration of a planned structure to accommodate substitute

equipment shall be taken by the Engineer. Equipment which requires alteration of
the structures will be considered only if the Contractor assumes all responsibility for
making and co-ordinating all necessary alterations, at no additional cost to the
Dubai Municipality. All modifications to structures, mechanical, electrical, or other
work made necessary by such substitution shall require the approval of the
Engineer. The cost of this work shall be made at the Contractor's expense.
b) After approval of the mechanical and electrical drawings the Contractor shall
prepare and submit to the Engineer revised drawings showing any necessary
revisions to the proposed building and civil structures. The location, size and details
of box-outs and fixings for mechanical and electrical and other equipment shall be
shown on the revised drawings and the Contractor shall be responsible for providing
in the civil structures the correct location and size of the box-outs and fixings shown
on the approved mechanical and electrical drawings. The Contractor shall prepare
at his own cost the necessary revised civil drawings and detailed structural and
other design calculations and submit them to the Engineer for approval. The
Contractor shall not be entitled to an extension of time for completion for any delays
from the preparation of such revised drawings. The Contract price shall not be
increased as a result of any changes in the civil structure from that designated
unless such changes are the result of variation properly ordered by the Engineer.
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17.3.4 Co-ordination
a) The Contract Drawings show in a general arrangement form the layout desired for
the principal equipment, piping, and similar appurtenances, and shall be followed as
closely as possible. Proper judgment shall be exercised in carrying out the work to
secure the best possible headroom and space conditions throughout, to secure neat
arrangement of all equipment and accessories, to overcome local difficulties and
interference with structural conditions wherever encountered.
b) The Contractor shall take all measurements for his work at the installation site,
verify all dimensions and conditions at the place of installation verify the sub-
Contractor's drawings and be responsible for the proposed installation, of the
equipment within the available space specified and shown on the Drawings.
Proposed deviations from the Drawings and Specification shall be submitted to the
Engineer in writing giving full details and reasons for the requests. The Engineer’s
approval must be obtained for any modification of the original works.
c) The Contractor shall employ an experienced electro-mechanical Engineer to

cooperate with the manufacturers/supplies of electrical and mechanical equipment.
This Electro-mechanical Engineer shall have at least 15 year experience and shall
be approved by the Consultant for this project and Dubai Municipality.
17.3.5 Special Tools
a) The Contractor shall provide one set of new and unused special tools (i.e. Torque
wrench, breakers test kit (tool used for assessing the whole mechanism and control
electronics of relays), High Voltage Tester complete with Digital reading instruments
for voltage measurements, earth lead and battery charger (if applicable), PLC,
controller, instrument & relay programming / configuration tools complete with
licensed software and various machine related special tools) for maintenance and
testing/operation of each supplied equipment / plant. These special tools shall be
supplied as part of the plant and deemed included in the contract.
b) Any special tools (i.e. breakers draw out trolleys, operation lever, handles and
ramps, machine dismantling tools, and grease gun etc.) needed for the operation
and maintenance of the electrical and mechanical works shall be supplied and
handed over to Dubai Municipality as part of the plant. Prior to handover, Dubai
Municipality and Contractor shall examine the tools that have been used during
plant erection to ensure that they are not damaged and are in good condition.
c) The Contractor shall provide a lockable metal tool box to contain two sets of special
tools as required by (A & B) above together with two sets of steel combination
spanners to fit every nut/bolt size on the plant including the holding down bolts and
unions, plus other tools of a special nature necessary for general maintenance.
d) Recommended tools required for maintenance of the electrical and mechanical

works shall be set out in the appropriate technical schedule and be clearly
referenced in the O&M Manual.
17.3.6 Spares
a) The Contractor shall produce a schedule for all spares recommended by the
manufacturers to cover a minimum period of 2 years operation of the Plant. The
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cost of these spares shall be deemed included within the respective equipment
price in the BOQ.
b) Spares shall be packed and protected for storage to the appropriate standard.
Electrical equipment shall be sealed in polythene or similar bags with a liberal
supply of desiccant. Other items shall be protected so as to avoid corrosion and
spoilage for a minimum of twelve months after handover to the Client. Machined
surfaces of all mechanical components shall be further protected by the application
of a protective coating which may be easily removed at the time of installation. Each
package shall have attached to it a un-tarnish able metal plate giving information for
identification. This shall include the maker’s name and reference description as
shown on the marked-up drawings supplied.
c) The packages of items of spares shall be collected together by the Contractor into
consignments of reasonable size and then packed in secure cases each of which
shall contain a contents list. Where electrical items are involved the cases shall be
of tongue and groove boarding. Each case shall be durably marked with the
contract number and site address, and shall be sent to site after detailed
instructions have been received. Each package shall be clearly identified as to its
contents in both English and Arabic.
d) The Contractor shall provide the detailed agreed schedule in duplicate of the spares
supplied one copy to be retained by the Engineer after checking the goods.
17.3.7 Lubrication of Plant
a) Adequate and, as far as is practicable, automatic means of lubrication shall be

provided for all moving parts.
b) The positions of all greasing and oiling points shall be arranged so as to be readily
accessible for routine servicing. Where necessary, to achieve this, suitable
extension pipes shall be fitted.
c) Lubrication grease points shall comprise hexagon headed nipples except where the
lubrication required is of a special nature. In such event they shall be fitted with
metal labels to indicate the special lubricant required.
d) Where continual grease or oil feeding is required the capacity of the reservoir shall
be sufficient for not less than seven days continuous services.
e) The Contractor shall supply the initial charges of oil, grease electrolyte and similar
materials necessary for the correct setting to work and operation of the Plant.
f) A supply of the recommended lubricants sufficient for a period of two year's running
shall be supplied for the plant. This does not relieve the Contractor of the
responsibility of ensuring that all grease lubricants have been filled and the grease-
gun applied to all nipples before starting up the plant.
g) Lubricants or their equivalents shall be those obtainable in the Dubai markets.
17.3.8 Noise and Vibration
a) The sound levels generated from plant, equipment and the whole of the installation
with the envisaged maximum number of items of plant running 'on load', shall be
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measured outside an envelope of one metre radius from any items of plant, and
shall not exceed the following limit of noise levels at one metre.
i) Internal Noise levels (with all plant running) shall not exceed:
Process and Plant Areas 85 dB (A)
MCC Rooms 55 dB (A)
ii) External noise levels to comply with planning requirements for noise level
at site boundary.
b) The Contractor shall include for suitable sound attenuation, if needed, to better this
level. This will apply in the audible frequency range 20 Hz to 20 kHz. Above 20 kHz,
the Contractor must state whether any fundamental frequencies are generated in
the ultrasonic region.
c) Before leaving the manufacturer's works, all major items of rotating machinery shall
be subjected to noise tests and test certificates shall be provided to Dubai
Municipality/Engineer for approval.
d) Machinery vibration shall not exceed the limits defined in BS 7854-1.
17.4 ELECTRICAL EQUIPMENT
17.4.1 Compliance
a) Electrical equipment shall comply with Dubai Electricity and Water Authority
(DEWA) Regulations; relevant IEC standard and all other applicable statutory
requirement prevails in Dubai.
b) The Contractor shall be responsible for establishing the exact characteristics of all
installed electrical equipment, including fault levels and then ensuring this complies
with the specific regulatory requirements. The prevailing supply characteristics are
as follows:
i) High Voltage (HV): 11,000 V, 3-phase, 3-wire, 50Hz.

ii) Low Voltage (LV): 400V, 3-phase, 4-wire, 50Hz.
iii) Voltage: ±10% at LV (from DEWA)
iv) Frequency: ±3% Transient Disturbed Conditions (from DEWA).
c) Typical system characteristics are as follows:
Table 17–2: Typical System Characteristics
Description 33kV 11kV 400V

Rated Service Voltage 33 11 400/230
Highest System Voltage 36 12.5 1000
Impulse Test Voltage 170 95 ----
Number of Phase 3 3 3
31.5kA for 3 25kA for 3 65/50kA for
Design Fault level
seconds seconds 1 second
Solidly Solidly Solidly
Neutral
Earthed Earthed Earthed
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17.4.2 Operating Voltages
a) The following nominal operating voltages shall be used for the applications listed
below:
i) 400Vac TP and N for all main three phase and three phase and neutral
circuits, including motors and drives.
ii) 230Vac for building services equipment, for single-phase
distribution/power circuits, for power supplies to instrumentation
transmitters and supplies to ICA panels.
iii) 230Vac for all control circuits internal to motor starter equipment through
isolating transformer.
iv) 24Vac control supply for control circuits.
v) 24Vdc regulated power supplies for signalling circuits and for loop
powered instrumentation.
vi) 60Vdc Main circuit breaker supervision trip supplies.
17.4.3 Protection and Co-ordination
a) The protection for the electrical distribution system shall be designed to ensure
correct co-ordination of protective devices, in particular in relation to the co-
ordination of the main LV distribution switchboards and the MV protection devices
and co-ordination with the DEWA distribution system protective devices supplying
the site.
b) A protection design shall be submitted for the stations, which shall be incorporated
into the manuals and shall provide details of the distribution system and its
protection. This documentation shall include a schedule of all devices and settings
and a set of system curves showing the co-ordination of devices as set up.
17.4.4 Power Factor Correction
a) The complete installation shall achieve a minimum power factor of 0.95 lagging and
a maximum of unity under all conditions of plant loads. The power factor of the
stations shall never become leading under any circumstances.
b) Power factor correction shall be achieved by the provision of stand-alone power

factor correction facilities installed at each Low Voltage Distribution Board.
c) This capacitor shall be self-healing type with a pressure monitoring device which
should open the contactor in case of an internal failure or over pressure may occur
and avoid the capacitor from bursting.
d) The power factor correction panel shall be provided with forced air cooling. The air
must be able to flow from bottom to top through cubicle.
e) The reactor / capacitor combination shall be designed to have a tuning frequency

below the lowest critical order of harmonic (usually the 5th) where the non-linear
load exceeds 15% of total connected load as to allow the capacitors to operate in a
harmonic environment.
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f) The capacitor must have a minimum dielectric voltage rating of 565V. In accordance
to IEC 600831, the capacitor temperature classifications should be “D”.
g) The reactor shall be supplied with a temperature sensor which should open the
contactor on its stage if that stage should overheat.
h) Detune capacitor bank is in addition to active harmonic filter, which is obligatory to

be supplied by the contractor while VFDs, soft starters, battery chargers, AC to DC
power supplies and UPS etc. are installed in the station/plant.
17.4.5 Harmonics
a) Total Harmonic Distortion (THD) at the point of common coupling shall comply with
the requirements of IEC 61000 / IEEE519, or otherwise agreed with DEWA. All
equipment generating harmonic currents shall be designed such that the specified
limits of THD are met at all times and under all operating conditions.
b) The Contractor shall submit calculations of the harmonic currents expected before
any equipment manufacture commences and obtain approval from DEWA/Engineer
for the connection of this equipment.
c) When all equipment has been installed and commissioned, the Contractor shall
carry out tests to measure the harmonics generated on the Station. The tests shall
be carried out with all main equipment, including the main water pumps, running at
full load. The harmonic currents shall be established at each frequency to determine
that individual and total values are within the limits stipulated in IEC 61000 / IEEE
519.
d) Additional approved equipment/devices shall be installed by the Contractor without

any additional costs to the Dubai Municipality if the installation is not approved by
DEWA for connection onto the supply.
17.4.6 Electromagnetic Compatibility
All electrical and ICA equipment and systems shall comply with the European
electromagnetic compatibility directive 89/336/EEC and all relevant associated British
Standards. As such all electrical and ICA equipment supplied under this Contract shall
conform to European directives and shall carry the required CE marking.
17.4.7 Motor Starting
a) The Contractor shall provide a motor starting study for all large electric motors and
drives over 110KW in size to determine voltage dip or power inrush limitations at
selected locations due to starting of motors.
b) The Contractor shall obtain from the motor supplier the necessary information to
perform the study. Certified curves for “Safe Time vs. Current at 100% Voltage” and
“Accelerating Time vs. Current at 100% Voltage” and shall become part of the final
report.
c) Motor starters should be provided with full type 2 coordination in accordance with
IEC 60947.
d) For motors greater than 5 KW where assisted starting is required, Soft starter with
bypass contactors shall be the preferred starting method unless the process
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requirements necessitate the use of a variable speed drive. Soft Starters shall have
soft start / soft stop facility.
17.4.8 Electrical Control Panels
a) All electrical control panels shall be designed for standalone operation conforming
to the requirements contract documents and local authority’s regulations.
b) The LV switchboards and MCC’s shall be constructed to IEC 61439 Form 4 Type 6
constructions and shall be fully type tested. The enclosure system shall be
extendable for future additions, modular in all 3 axes.
c) MCCs shall be fully factory equipped, tested and tagged ready to interface with
communication devices such as telemetry, remote terminal units, instrumentation
and other microprocessor-based controllers etc.
d) All circuit breakers rated 800A and above shall be of the withdrawable type.
e) Rated short time current and times shall be determined by assessment of the
protective short circuit currents of the distribution system. The main LV switchboard
however shall have a minimum short time rating in accordance with the following
guide;
Table 17–3: Guide to Short Time Rating
Transformer
Impedance and Fault Level Switchboard specification
Rating
3200kVA 9% 52kVA 65kA for 1 second
2500kVA 8% 44kA 65kA for 1 second
800kVA 4% 26.8kA 50kA for 1 second
f) All electrical panels shall be finished to the same standard and colour.
g) The Contractor shall carryout functional safety study in accordance with IEC 61508
of the plant and related area and should implement a complete system of interlocks
and safety devices shall be provided, as necessary, for the safe and continuous
operation of all installed plant and equipment in order to provide for the following:
i) Safety of personnel engaged in operation and maintenance of the plant.

ii) Correct sequence of operation of the plant during start up and shut down.
iii) Safety of the plant when operating under normal or emergency conditions.
iv) Interlocks and interlocking schemes that is preventative and not corrective
in operation. The design of the interlocks is subject to Dubai Municipality
/Engineer approval.
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v) Locks for interlocking purposes that are of the figure lock type (Castell or
equivalent approved). No spare or master key shall be provided.
h) Rubber matting shall be supplied and fitted along the front and rear lengths of all
switchboards and MCCs. The insulating matting shall be manufactured and marked
in accordance with BS 921 or IEC 61111. The contractor shall allow for longitudinal
cutting and fitting of matting to obtain suitable fitting around obstructions.
17.4.9 Standard Designs/Circuit Requirements
a) A standard approach to MCC internal circuit design shall be developed and

enforced on the MCC and control panel suppliers, to ensure that all similar circuit
types are used across the Project. This shall include panels provided by package
plant suppliers. In particular, the standard requirements for panel construction,
wiring and components shall be noted.
b) This approach shall also be applied to external circuit design, e.g. for instrument
loops etc.
c) All safety interlocks of the plant shall be hardwired.
d) All drives and starters shall be provided with the facility for automatic control from
the MCC control section or ICA panel, whether used for automatic control or not.
e) Conventional drives and starters shall be provided with a separate interlock relay for
the operation of protective circuits operated from the equipment. Drives and starters
utilising intelligent relay/protection unit shall provide interlocks via intelligent
relay/protection unit inputs and outputs.
f) For conventional drives and starter auto-control and interlock circuits shall be
provided by interposing relays. These shall operate in a failsafe manner at 24Vdc
sourced from the control section. The interposing relays shall be installed in the
starter/drive compartments. Drives and starters utilising intelligent overload
relay/protection unit shall provide control interlocks, in a fail safe manner, via the
intelligent relay/protection unit inputs and outputs.
g) Wherever a machine is provided with a protective device such as pump protection

unit, thermistor, bimetal, anti-condensation heater, RTD, enclosure fan, vibration
monitoring system etc. the Contractor should cable/wire it in to provide that
protective function.
h) The MCC compartments shall be spacious for easy maintenance.
17.4.10 Segregation of Services
a) Electrical services shall be segregated as specified throughout the installation to

obviate the following:
i) Electrical interference from one circuit to another.

ii) A fault on one circuit affecting another.
iii) Unnecessary fire damage.
iv) Difficulties in circuit identification.
v) Voltage limits for general safety.
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b) All raceways shall be kept clear of other services except where intentionally earthed
or bonded. Generally, raceways shall be kept 150 mm away from and above hot
water and 75 mm away from other services.
c) Fire alarm cables shall be segregated from other services throughout.
d) Unless specifically indicated otherwise, normal, emergency, low voltage cables and
wiring shall be segregated throughout the installation.
17.5 Electrical apparatus for Hazardous areas
17.5.1 Scope
a) The Contractor shall carryout Hazardous Area Zoning Study to determine the
hazardous area of the plant and should select/provide fitting equipment in line with
the following applicable standards.
17.5.2 Standards
a) Electrical apparatus and systems for use in hazardous areas shall be manufactured
and tested in accordance with IEC 60079 Electrical apparatus for explosive gas
atmosphere – ALL PARTS
17.5.3 Apparatus Group and Temperature Class
a) For areas which have been classified as Zone 1 or Zone 2 hazardous areas as
defined in IEC 60079-10 and where the potentially explosive atmospheres contain
hydrogen sulphide, methane and air, the types of protection used shall not be less
than the following:
i) For flameproof apparatus, EExdIIBT3.

ii) For intrinsically safe apparatus and systems, EExiaIIBT4.
iii) For apparatus with special protection, ExsIIBT4.
iv) For increased safety apparatus, EExeIIBT3.
b) Where types of protection, other than those described in above, are used, they shall
be with the project manager.
c) For areas which have been classified as Zone 0 hazardous areas as defined in IEC
60079-10 and where the potentially explosive atmospheres contain hydrogen
sulphide, methane and air, the types of protection shall not be less than the
following:
i) For intrinsically safe apparatus and systems, EExiaIIBT4

ii) For apparatus with special protection (specifically certified for use in
Zone 0), ExsIIBT4
d) For hazardous areas in which the potentially explosive atmospheres are other than
described in (a) above, the apparatus group and temperature class shall be as
specified or otherwise determined by assessment by the Contractor.
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17.5.4 Certification
a) All electrical apparatus and systems for use in hazardous areas shall be certified for
use in these areas. Each component shall be marked with the certifying agencies
reference for the component and certificates of conformity, certificates of assurance
and certificates of component approval shall be provided.
b) Copies of all such certificates shall be submitted to the Engineer.
c) Certificates shall be by BASEEFA or other recognised national certifying authority.
d) Where certificates are in a foreign language, for example German for PTB
Certification, copies shall be submitted in the original language version plus copies
of a legally authenticated translation in English.
e) Apparatus shall not be despatched to site until such certificates have been
submitted to and accepted by the Engineer.
17.5.5 Index of Protection
a) Equipment shall have enclosure index of protection not less than IP66.
b) Where equipment may be submerged, for example submersible pumps, the

enclosure index of protection shall be not less than IP68 to the specified depth of
submersion for the equipment/plant installed.
17.6 SAFETY
17.6.1 General
a) The Contractor shall operate a safe system of working in relation to electrical and
ICA works. This shall encompass control of all sites working, in particular in the
energising of electrical equipment at MV and LV supply voltages and at ELV
voltages when associated with the automatic control of plant.
b) The contractor shall implement the requirements of EU’s machinery directive

98/37/EC that no person should be put at risk if a relay sticks or if a transistor or two
electrical conductors short-circuit.
c) A fault in the control circuit logic or failure of or damage to the control circuit must
not lead to dangerous situation. This requirement shall be achieved by introducing
safety relay. The safety relay should comply with standards 98/37/EC or EN 60204-
1 and IEC 60204-11.
d) Unit control panel of machines were supplied shall be provided with 400/230-volt
industrial control circuit transformer, being able to handle the inrush current of
control circuit in accordance with IEC 60204-1 (Safety of machinery – Electrical
equipment of machines – Part 1: General requirements). The control transformer
shall comply with IEC 61558-2-2. Provide fuses on both the primary and secondary
sides of the control transformer. Secondary side of the control transformer shall be
centre-tapped and earthed, via a removable bolted earth link.
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e) The requirements and recommendations of IEC 60204 relating to the electrical

equipment of machines shall be implemented to achieve the followings.
i) Safety of persons and property

ii) Consistency of control response
iii) Ease of maintenance
f) Each type of machine has unique requirements to be accommodated to provide by
the contractor for adequate safety related to guarding, interlocking, or control and
the documentation that are needed or required in order to protect persons from
hazards other than electrical hazards.
g) The contractor shall implement a system of permits to work to access energised

plant to ensure that personal injury is avoided. This permit system shall be
presented to the Engineer for approval prior to commencement of any (including
temporary) electrical works on site.
h) The Contractor shall appoint an authorized person or persons at site who shall take
responsibility for ensuring safe working of the Contactor and his subcontractor’s
personnel during construction and commissioning.
17.6.2 Authorized Persons
a) The Contractor should provide a Senior Authorised Person on site, to plan and carry
out necessary switching operations during construction and commissioning,
particularly where MV plant is installed.
b) All Senior Authorised Persons and Authorised Persons carry a current recognized
training certificate for carrying out such operations.
17.6.3 Permit to Work Arrangements
a) The permit to work system shall involve the issue of a permit by an authorized
person to the person carrying out the work.
b) The permit shall have a sign-on and sign-off arrangement and a copy shall always
be held by the authorized person to ensure that no more than one permit is ever
issued against the same item of equipment at the same time.
17.7 Plant Suppliers for this Contract
a) In order to limit the number of manufacturers of electrical and mechanical

equipment used by Dubai Municipality and to simplify related maintenance, the
vendor list is selected and provided in Section 18 &19 for this Contract specification.
b) The Contractor shall be responsible for liaising with the suppliers, obtaining,
checking for accuracy and issuing all drawings and other documents and for co-
ordination of supply and installation.
17.8 Work in Dangerous Areas
a) The Contractor shall comply with any safety precautions called for by the Engineer
such as a "Permit to Work" system for access to designated high risk areas
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including wet wells, sumps, valve chambers sewers and buildings in addition to
Electrical Danger Areas.
b) A minimum of 21 days notice in writing shall be given when requesting Permits to

Work. No unauthorised interruptions to the plant operations will be tolerated. The
applications for permits to work/plant shutdowns shall be accompanied by approved
method statements addressing all working practices, operational implications, safety
procedures, hazards and risks.
c) The "Permit to work" system will be administered by the Engineer.
17.9 Protection and Packing for Shipment/Storage
a) All Plant shall be adequately protected and packed in accordance with the approved
standard. In addition the Plant shall be so protected as to be safe from spoilage
and corrosion until installation or in the case of spare parts for a period not less than
24 months from its date of handover to the Client.
b) Items of plant which are finished painted at the manufacturer’s works such as
switchboards shall be suitably encased in wood (such as hardboard secured by
screws to a wood framework) for their protection before dispatch.
c) Particular care shall be taken in the packing of electrical apparatus. It shall be

packed separately in sealed polythene or similar approved bags (including a liberal
supply of desiccant) taking all precautions to exclude moisture.
d) Packing cases shall be strongly constructed using tongued and grooved boards with
internal and external battens. Each packing case shall be durably marked with the
Contract number and site address and such other marking as may be directed.
e) The Contractor shall make good to the satisfaction of the Engineer any deterioration
of the protective coatings, paintwork, etc., which may occur during transportation.
The Contractor shall be responsible for making all the arrangements necessary for
the transportation of equipment and plant to site including investigation of the route
for bridge clearances, loading etc and for the provision of a police escort, if required.
All transportation details shall be submitted to Dubai Municipality / Engineer for
approval.
f) Unless otherwise specified, temperatures up to 75ºC and Relative Humidity up to

95% shall apply during transport, storage and installation. Equipment subjected to
these extreme service conditions without being operated shall not suffer irreversible
damage when operated under normal specified conditions.
17.10 Health and Safety at Work, Etc. Act 1974
a) The entire installation and apparatus shall comply with the Health and Safety at
Work, etc. Act 1974 (incorporating provisions of the UK Factories Act) which lays
down standards of safety and shall also be in accordance with the current Institution
of Electrical Engineers (UK) Regulations for the Electrical Equipment of Buildings.
b) Copies may be obtained from the Government Bookshop, P.O. Box 569, London
SE1 9NH, UK and local authority requirement such as DEWA/DM.
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17.11 Drawings & INFORMATION for ELECTROMECHANICAL PLANT
As well as complying with the specified procedures for approval the following
documentation shall be supplied and procedures followed for all items of electrical and
mechanical plant in the Contract.
17.11.1 At the Start of the Contract
a) Within 30 days of the Engineer’s order to Commence the Works the Contractor shall
submit the specified request for approval which shall include :-
i) Detailed drawings (6 No.) of the general arrangements and specifications

of all electrical and mechanical plant showing all apertures, holes, chases,
trenches and ducts required in associated structures.
ii) Drawings (6 No.) of electrical and electronic equipment and specifications
giving details, dimensions, circuitry, component details and schematic
diagrams with a legend of symbols used and a written description of the
operation of the circuits marked thereon.
iii) Any additional drawings of particular items, called for by the Engineer.
b) The manufacture of items of Plant shall not be commenced until written approval of
all relevant drawings and specifications have been obtained.
c) If the drawings are not approved one copy will be returned to the Contractor marked
to indicate the alterations required.
d) Upon final approval one copy will be marked ‘Approved’ and returned.
e) After approval of drawings a further six copies shall be provided to the Engineer.
17.11.2 Drawing Maintenance
a) During the course of the Works the Contractor shall maintain a detailed record of
the progress of the works including changes to ensure that these drawings are in all
respects a true record of the installation.
b) The drawings shall be maintained by the Contractor and shall show the complete
works including the sizes and routes of all ducts, pipework and cables. The scales
used shall be such that all details are legible when reduced for inclusion in the
Operation and Maintenance manuals. All drawings shall show scale bars as
appropriate.
c) The drawings shall clearly show the names of the plant manufacturers, giving
model, type numbers and all details of plant and machinery duty ratings, sizes,
current settings, fuse ratings, etc. of all items of plant including electrical distribution
cabling and wiring installations.
d) The Contractor shall provide three prints of all drawings and schedules correctly
modified as final drawings. These shall be submitted to the Engineer for approval
before the issue of a Taking over Certificate and shall be a complete record of the
Mechanical and Electrical installation.
e) If the drawings are not approved, one copy shall be returned to the Contractor with
marked indications of the alterations required.
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f) Upon final approval, one copy of the drawings or document shall be stamped
“Approved” and returned to the Contractor.
g) One set of the approved drawings on paper shall be included in each of the
Operation and Maintenance manuals. These may be full size drawings folded and
inserted into clear plastic sleeves bound directly into the document. Reduced size
drawings shall be legible in all respects, and the actual reduced scale clearly
marked on the drawings.
h) The Engineer will not issue a Taking over Certificate for the Works until approved all
record drawings.
17.11.3 Prior to Delivery of the Plant
a) Before plant is delivered the Contractor shall provide for the use of the Dubai
Municipality and the Engineer:
i) Copies of all Test Certificates demonstrating compliance with the

specifications.
ii) Two copies of Draft Instructions for the Operation of the Plant which shall
describe the installation as a whole and shall give step by step procedures
for every operation in the running of the Plant. All necessary drawings and
sketches shall be included.
iii) Two copies of Draft Instructions for the Maintenance of the Plant. These
instructions shall include charts showing lubrication, checking, testing and
replacement procedures to ensure trouble free operation.
b) A separate section of these Instructions shall be devoted to a complete parts list
based on sectional arrangement drawings of the Plant. The maker’s name, address
and catalogue/serial numbers shall be given for each component of the Plant
supplied.
c) Recommendations for consumable supplies, e.g. lubricants, packing, etc. shall be

included.
d) The Contractor shall obtain the Draft Instructions from the suppliers, check them for
accuracy and shall bind each Instruction Book in Uniform bindings, the cover of
which shall be finished with a black and greaseproof material and the title printed on
the front and the spine including the word ‘Draft’. Draft manuals shall be forwarded
within 2 months of issue of Taking over Certificate. Binding shall be A4 sized, loose
leaf four ring binders with rigid covers. Covers for instructions related to sewerage
works shall be red in colour, those for drainage works in blue and those for irrigation
works in green or as directed by the Engineer.
e) The Instructions shall be specific to this Contract; a collection of manufacturer’s

descriptive leaflets will not be acceptable.
f) The Plant shall not be considered to be completed for purposes of delivery until the
above information has been provided.
17.11.4 Prior to the Issue of the Taking-Over Certificate
a) Within 3 months of the issue of the Taking-Over Certificate, the Contractor shall
provide for the use of the Dubai Municipality and the Engineer:
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i) Three copies of Approved Instructions for the Operation of the Plant which
shall describe installation as a whole and shall give step by step
procedures for every operation in the running of the Plant. Copies of the
as-built record drawings and sketches shall be bound in the document.
ii) Three copies of Approved Instructions for the Maintenance of the Plant.
These instructions shall include charts showing lubrication, checking,
testing and replacement procedures to ensure trouble free operation.
iii) 1 No. copy on CD or memory disk with digital drawings in latest version of
Microstation as appropriate and two hard copies of the following as-built
record drawings:
iv) Drawings showing the internal construction of the major items, with parts
list and reference numbers for ordering spares.
v) Complete assembly drawings of machinery and ancillary plant showing all
pipe connections and fittings.
vi) General arrangement drawings showing all equipment, cabling, and tray
work, etc.
vii) Detailed arrangement of any conduit work buried in floors, walls or
ceilings, in any structure.
viii) Detailed wiring diagrams of the main circuits.
ix) Diagrams of connections between all items of equipment (e.g. main and
auxiliary switchboards, generators, control boards, motors, starters,
batteries, meters, instruments, relays, and allied equipment, etc. with
component values
x) Three copies of detailed revised Specifications and Schedules of the Plant
as actually installed.
b) Upon the approval of the above drawing/document by the Engineer, the Contractor
shall provide two prints of each drawing or detail on thick paper for the use of the
Purchases, and one 35 mm photographic negative of each drawing or detail
mounted in a card frame 187 mm x 83 mm for the use of the Engineer.
c) A separate section of these Instructions shall be devoted to a complete parts list

based on sectional arrangement drawing of the Plant. The maker’s name, address
and catalogue/serial numbers shall be given for each component of the Plant
supplied.
d) Recommendations for consumable supplies, e.g. lubricants, packing, etc. shall be

included.
17.12 Factory acceptance tests
17.12.1 General
a) All MEICA equipment shall be tested both on the manufacturer’s premises (at
factory acceptance tests) and on site (at site acceptance tests) and Test Certificates
shall be submitted to Engineer for approval.
b) Unless otherwise stated, Dubai Municipality / Engineer shall witness the inspection
and testing of fabricated equipment and/or Factory Built Assemblies at the factory.
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c) All products shall be subjected to inspection, examination and witness testing by the
Dubai Municipality / Engineer or its representative.
d) The Contractor shall notify Dubai Municipality / Engineer 4 weeks prior to such
tests, so that preparation for travelling to the factory inspection and testing can be
arranged.
e) The Contractor shall provide prepaid air travel, hotel accommodation, surface travel
and other advanced arrangements for designated personnel from Dubai Municipality
/ Engineer to witness the manufacture or testing of plant and associated systems.
Airline transportation shall be, as a minimum, full fare economy class. Hotels shall
be single rooms, minimum of 4 stars following a recognised grading criterion.
Surface transportation shall be by rental car or similar private means. The
Contractor shall also provide a per diem amount for subsistence equal to Euro 200
per person per day. The full cost of the programme shall be borne by the Contractor
and shall be included in the unit price of the equipment, or system indicated in the
Contract schedule of prices.
f) Prior to the witness test, the Contractor shall assure Dubai Municipality / Engineer
that the equipment requested for inspection and testing has already been
thoroughly tested by the manufacturer. Provisional Test Reports of such tests,
showing that the plant has past such tests shall be submitted to Dubai Municipality /
Engineer prior to the works witness test.
g) Where tests and inspections have been completed to the satisfaction of Dubai
Municipality / Engineer and when test certificates, tabulated and graphical results,
etc. have been checked, Dubai Municipality / Engineer shall confirm acceptance.
The plant shall not be incorporated in the Works and made ready for delivery until
this acceptance has been received.
h) Successful works witness testing shall allow the manufacturer to deliver the
equipment to the site, but it does not constitute final acceptance or approval of the
equipment. Such approval will only be granted on successful completion of final
testing during commissioning tests of the installed equipment.
i) No inspection or passing by the Dubai Municipality / Engineer, of plant or materials

covered by this Contract, whether carried out or supplied by the Contractor, shall
release him from any of his obligations under the Contract.
j) If works tests are beyond the resources of the manufacturer, the Contractor shall
state another location for these tests to be conducted in the appropriate tender
technical schedules.
k) During the course of the contract, additional testing, or retesting may be requested
by Dubai Municipality / Engineer to prove that the plant, equipment, product,
material or workmanship meets the specification. Such tests will be at no extra cost
to Dubai Municipality.
l) Test results shall be submitted to Dubai Municipality / Engineer for approval in

accordance with the submittals section of this specification.
m) The Contractor shall carry out tests as stated in the current appropriate ISO, British
Standard, IEC and/or Harmonised European standards or other approved
equivalent standard.
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n) All test certificates, curves, supporting engineering calculations, drawings and

documentation, etc. shall be submitted to Dubai Municipality / Engineer within two
working weeks from the date of completion of any witnessed tests.
o) Equipment that fails witness testing shall be subjected to retest. All costs involve
rearranging the test, including the Dubai Municipality / Engineer costs, shall be
borne by the Contractor. An extension of time for the preparation and retesting will
not be allowed unless approved by Dubai Municipality / Engineer.
p) Testing equipment and instruments used during witness testing shall have been
recently calibrated and comply with the appropriate testing standard and safety
regulations and/or requirements for the safety of the Plant and the men working
thereon. The test equipment furnished by each Contractor shall have a calibration
tag of an acceptable calibration service.
17.12.2 Pumps
a) Pump sets shall be subjected to a works test to ensure that they function correctly,
perform to the guaranteed duty, and are manufactured and supplied to the
specification.
b) For all pump sets regardless of size, type test certificates shall be submitted as
indicative of the pump set performance. Where such certified evidence is not
available, a letter of intent from the testing authority shall be submitted.
c) Each pump shall be statically and hydraulically tested at the works to a pressure at
least 50% greater than the maximum working pressure it will incur on site. During
the test, the pump shall show no signs of leakage or failure of any components.
d) Each pump shall be tested with its own motor supplied from its soft starter or
variable speed controller at the manufacturer's premises to show the plant is
capable of achieving the guaranteed duty point values as detailed in the Contract.
Site conditions shall be simulated as near as possible, particularly the suction
conditions.
e) Pump characteristic curves shall be produced for the following:

i. Head/Quantity.
ii. Power Absorbed/Quantity.
iii. Overall Efficiency/Quantity.
iv. NPSH Required/Quantity.
f) Contrary to ISO 9906: 2000, the overall efficiency of each combined motor-pump
derived in accordance with the tests shall not be less than that guaranteed.
g) Cavitation tests, as detailed in ISO 9906: 2000, shall form part of the tests.
17.12.3 Motors
a) Witness testing may be waived on standard types of small motors from recognised
manufacturers and on small components used in the manufacture of units of plant.
b) Motors of 15 kW and above shall be witness tested for performance to the approved
standard.
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c) Type test certificates shall be provided and shall include the following information for
all motors:
i) Approved standard of manufacture

ii) Class of insulation
iii) Size and type of cable fittings
iv) Type of bearings, sizes and lubricant
v) Type and rating of heaters
vi) Brush sizes and maker (if fitted)
vii) Line current all phases
viii) Phase current balance
ix) Efficiency and P.F. at 100%, 75% and 50% of Full load
x) Temperature rise test
d) After initial witness testing each motor shall be combined with its driven units and
witness tested to demonstrate satisfactory performance, correctness of assembly
and ease of re-assembly at site. The assembled units shall be adequately marked
and dowelled.
17.13 Site Testing and Commissioning of Electrical and Mechanical Plant
17.13.1 General requirements
a) Works tests shall be carried out in order to determine whether the components
and/or pump station items comply with the Specification and to provide the
necessary functional data. Where appropriate, all tests shall be arranged to
represent the working conditions as closely as possible.
b) Unless an alternative place of testing is agreed or specified the tests shall be carried
out at the Manufacturer's Works.
c) Not less than three weeks notice of all tests shall be given to the Employer, in order
that he may be present if he so desires. This duration shall be extendable if the
Employer/Engineer is unable to obtain the necessary approvals for travel. As many
tests as possible shall be arranged together, in accordance with a programme to be
agreed with the Employer. Six copies of the Contractor's records of all tests shall be
submitted to the Employer for approval immediately after the conclusion of each
test. These records shall be clearly marked so that the Contract equipment items or
components to which they refer can be readily identified.
d) Type tests will not be required in those cases where the Contractor can produce
certified evidence to the satisfaction of the Employer that the required type tests
have been performed successfully on identical equipment or equipment which is for
practical test purposes similar and produced in the factory where the equipment
offered is to be manufactured. Evidence to this effect shall be submitted at the time
of tendering, or as soon as practicable thereafter.
e) After the Contract has been awarded, a Manufacturers Inspection and Testing
Programme shall be established by the Contractor, in the form of detailed Quality
Control Plans for each item of plant and equipment. The Contractors Quality Control
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Plans will be subject to the Employer's approval. The Employer reserves the right to
call for additional tests as may be necessary to prove compliance with the
Specification. The Contractor shall pay the cost of all such tests.
f) Cables laid underground shall be tested in accordance with the appropriate

standard specification and to Dubai Electricity & Water Authority (DEWA).
g) The connections of all electrical circuits shall be proved to be correct and the whole
installation shall be tested for insulation resistance and earth loop resistance in the
presence of the Engineer or DEWA - Electricity Division Representative with
instruments provided by the Contractor. Any faults or defects shall be remedied at
the Contractor’s expense.
h) On completion of erection, all pipelines shall be tested to ensure tightness of joints

and connections.
i) Penstock shall be tested to maximum working pressure for on-seating and off-
seating permissible leakage.
j) Lubrication and fuel lines, sumps, tanks, etc., shall be adequately flushed to remove
any foreign matter before being put to use.
k) On completion of erection of each item of Plant the Contractor shall test and check it
and as far as is possible proving it under working conditions.
l) The Contractor will check that the installation is in safe working order and fulfils the
function for which it is intended.
m) Operational demonstrations and system validation tests are required for all
mechanical and electrical equipment, instrument, control and automation system.
n) Cost of consumable i.e. diesel, lubricant, coolant, materials, water, chemicals and
electrical power required to carry out testing, commissioning and validation of
equipment / systems shall be borne by the Contractor.
o) Temporary facilities, storage, and similar facilities necessary for these testing,
commissioning and validation of equipment / systems shall also be supplied by the
Contractor.
p) Testing and commissioning shall be performed under continuous presence of

Engineer’s representative.
q) All defects and malfunctions found during testing and commissioning shall be
corrected immediately, using approved method and new materials for repairs as
required. Interruption time necessary for corrective work may, at the Engineer's
discretion, be added to the specified testing and commissioning period.
r) Satisfactory completion and approval of required commissioning and testing is one

of the conditions for precedent to the Engineer's acceptance of the work, but does
not constitute final acceptance.
s) The contractor to provide all necessary measuring instruments, indicators,

temporary pipe work, temporary pumping plant and all other apparatus necessary to
carry out tests. The Contractor shall provide all necessary skilled personnel required
for the testing and commissioning.
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t) The Contractor should liaise with his sub-Contractors associated with the
completion of any part of the Works to ensure that all parties concerned are present
during any tests to carry out their responsibilities within the defined limits of their
individual sub-contracts.
u) Testing and commissioning shall be in accordance with the project specification,

relevant International Standards, DEWA regulation and requirements, Dubai
Municipality requirements, industrial norms and to the Engineer's approval.
v) A record of bearing, coupling clearances, protective device settings and alignments

shall be tabulated to show the "as-built" condition of each pump set.
w) A record of all limit switches, relays and protective settings etc. shall be tabulated to
show the "as-built" condition of each applicable part of FBA’s and other electrical
switchgear.
x) All cables shall have an insulation test to confirm the integrity of the insulation. A
tabulated record of results shall be made.
y) All earthing systems shall be tested to demonstrate the resistance of the electrodes
to earth and the earth conductor continuity is in accordance with the Specification.
The tests shall be made on completion of the installation.
z) Earth loop impedance shall be tested for each circuit.
aa)The control centre, control panel and instrumentation shall be tested together to
confirm the correct sequence and functional operation.
bb)Each pump shall be operated individually over the entire operating range with a
temporary arrangement using fresh water recirculation.
cc) All equipment subject to water pressure shall be hydraulically tested at 1.5 times the
maximum working pressure or 1.5 times the surge pressure whichever is greater.
dd)The hydraulic tests shall also be applied to the above ground pipework. The
Contractor shall provide the necessary equipment including any temporary blank
flanges which may be required to isolate equipment.
ee)All cranes shall be tested at works with a load 25% in excess of the rated load and
shall be tested and certified by relevant local authority.
ff) Any instruction of the Employer's personnel may be performed simultaneously but
requires written agreement of the Engineer if this constitutes a variance to the
contract specification.
gg)Testing shall be carried out in stages as follows:
i) Primary tests and checks

ii) Unit testing
iii) System validation tests
iv) Commissioning and setting to work
hh)The Contractor shall not proceed from one stage to the next without the Engineer's
approval.
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17.13.2 Testing and Commissioning Procedures and Documents
a) At least 45 days before testing and commissioning is to be performed, a detailed

and comprehensive method statement shall be submitted for the performance of
each separate test.
b) Method statement shall describe and itemise the involved system including
associated electrical equipment, instrumentation and control system.
c) Evidence of an organised step-by-step procedure, properly co-ordinating the efforts

of the various trades and manufacturers representative involved, and of the
operations of the facilities should be provided.
d) Method Statements shall include an estimated duration and commencement date

for each procedure and a schedule of personnel and equipment required.
e) Method statement shall include the following information, as applicable:
i) Description of temporary facilities, including drawings and sketches as

necessary to fully illustrate the requirements
ii) List of material and estimated quantities
iii) List of instruments either these are part of the final system or furnished
separately for temporary use.
iv) Calibration certificates of testing equipment.
v) Names of supervisor and participating personnel
vi) Recording intervals
f) Instruments, gauges, and other sensors and display devices forming a part of the
various systems shall be employed for data acquisition where applicable.
g) The Contractor shall furnish all required instrument, gauge, recorder and testing
devices etc. conforming to approved method statement.
h) All applicable data such as, but not limited to, level, flow, pressure, head
differentials, duration of run, various instrument reading, voltage setting, drive
speeds, motor running current, torque, voltage etc. in accordance with approved
testing procedure shall be recorded at the start and finish of each operational
demonstration and at 30 minute intervals during system validation tests, unless
other intervals are specified.
i) Contractor shall take prior approval of forms required to record various tests.
j) Test records shall be maintained by the Contractor. Forms shall be designed to

record the following aspect and parameters:
i) Result anticipated
ii) Result obtained
iii) If incorrect, corrective action taken
iv) Re-test/check result
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k) Test and commissioning reports including results, final settings and adjustments
made shall be provided in a separately bound volume of the Operations and
Maintenance Instruction Manuals.
17.13.3 Primary Tests and Checks
a) All component unit and complete systems shall conform to the Specification,
Drawing and the approved working drawings, samples, construction manuals,
materials lists, and other approved submittals.
b) All specified components and complete systems shall have been installed
satisfactorily and are operable.
c) All installation shall be safe to use. Temporary access, covers etc., will only be
permitted if approved by the Engineer.
d) All cleaning work shall be completed.
e) Equipment shall be free from physical damage due to mechanical force, exposure to
the elements, incorrect connection etc.
17.13.4 Unit Testing
a) Unit testing is defined as tests on individual equipment items such as pumps,

compressors, deodorisers, blowers, fans, conveyors and all similar equipment
items. Tests may be performed simultaneously on groups of identical equipment,
items, and groups of items supplied by one manufacturer, if practicable.
b) Clean water shall be used to fill tanks, wells piping and systems that contain water,
sewage or sludge in normal operation. Where necessary specified chemical shall
be used for chemical systems but shall not exceed in-service concentrations.
c) Tests shall show that all component units operate with the quantities, efficiency,
repeatability, and accuracy specified.
d) Tests shall be carried out continuously for a minimum period of 24 hours.
17.13.5 System validation tests
a) System validation tests shall not commence until primary test & check and unit
testing have been satisfactorily completed and accepted.
b) This is defined as testing of complete systems that perform a discrete process

function such as auto operation of pumping systems, odour control system,
emergency power system, control system, SCADA and similar systems. Each
system shall include associated structures, tanks, piping, utilities, instrumentation
and controls, and like related items.
c) Clean water shall be used for system validation tests if it is possible to carry them
out satisfactorily with this medium. If the tests require use of the medium used in
service, then this shall be used.
d) System validation tests shall be carried out for minimum of 24 hours, unless longer
is needed to prove the performance of the system.
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17.13.6 COMMISSIONING AND SETTING TO WORK
a) The commissioning shall be carried out as follows under the control of the
Contractor's staff and the supervision of the Engineer. The purpose of these trials
shall be as follows:
i) To confirm the performance guarantee

ii) To provide a comprehensive record of machinery performance
b) Commissioning is defined as the testing of all the equipment and system together
under actual operating conditions using all the mediums used in actual operating
conditions. Once the equipment and systems are operating satisfactorily they are
left to work.
c) Each system shall be tested including standby equipment by continuous operation

under the "in-service" condition for not less than 14 consecutive days, with no
interruptions except for normal maintenance or corrective work. Where the in-
service condition is an automatically controlled cycle with on/off intervals it shall be
so operated.
d) Systems shall be operated continuously under constant inspection of trained

operators. System operation shall be cycled from lean load to peak load, as
practicable. Variable speed equipment shall cycle through the applicable speed
range at a steady rate of change. Simulated alarm and failure operating conditions
shall be induced as and when directed by Engineer during commissioning and
testing period. Controls and protective devices shall be tested for correct operation
in adjusting system functions or causing system shutdown.
e) Subject to Contractor's request and Engineer's approval in each case, the

Contractor may simulate certain operating conditions relating to flow rates, water
levels and malfunctions. Permission for simulations will be granted only where it is
unwise or impossible to obtain the conditions covered by the capability of ranges or
equipment. The simulation method shall reflect reasonable anticipated operating
conditions.
17.14 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF
a) The Contractor shall provide qualified personal to instruct and train the Employer
nominated staff for plant operation and maintenance.
b) After the equipment has been installed, tested, adjusted and placed in the
satisfactory operation the Contractor shall provide the service of the manufacturer’s
representative at site for the training of nominated operation and maintenance staff.
c) An instruction and training programme shall be conducted for up to 6 operators or

as nominated by the Employer.
d) The Contractor shall give the Employer at least two month written notice of the
proposed instruction and training programme. Instruction and training shall cover
the basic system operation theory, routine maintenance, repair, and "hands on”
operation of equipment.
e) The duration of the instruction and training period shall be based on the complexity
of equipment involved and the equipment manufacturer’s recommendations. The
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Engineer/ Employer acceptance of the satisfactoriness of training received must be

obtained before terminating the programme.
17.15 Operating and Maintenance Manuals
17.15.1 General
a) The Operating instructions shall be prepared in English in such a way as to provide

a step by step description of the preparation and setting to work of the plant and its
shutting down.
b) A copy of the appropriate schedules and instructions shall be mounted on neatly

finished plywood boards suitably protected by clear varnish or other approved
material and fixed on the wall adjacent to the item of plant to which they refer.
c) The Maintenance Instructions shall be in English and include the following:-
i) Schedules of routine maintenance for each item of the plant.

ii) Schedule of equipment supplied giving manufacturer's name and
appropriate Make/Model No. /Cat. No.
iii) Schedule of spares supplied.
iv) Schedule of tools supplied.
v) Sectional arrangement drawings of major items of plant i.e. pumps, valves
etc. with dismantling instructions.
vi) Plant layout drawings showing the "as erected" installation.
vii) General arrangement and schematic diagrams of the "as installed" control
panel.
viii) "As wired" diagrams of all electrical connections between the control panel
and installed loads.
ix) Full and comprehensive instructions for the maintenance of all items of
equipment installed.
x) Test certificates for motors, pumps, compressors, pressure vessels, lifting
equipment, transformers, electrical installation and other items where
appropriate.
xi) Pump performance curves as tested.
xii) System curves.
xiii) Schedule of recommended lubricants and their equivalents.
17.15.2 Requirements and Contents
a) Two copies of the draft manuals shall be submitted to the Engineer for review and
approval before delivery of the equipment.
b) The final copies of the manuals shall be provided in CD and also 6 sets in hard copy
to the Engineer within 60 days of the commencement of the maintenance period.
They shall include all revisions and comments made by the Engineer and any
revisions or corrections necessitated by changes made during installation and
testing.
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c) Manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment.
d) Where several sub-Contractors and manufacturers have supplied equipment the

Contractor shall provide a complete integrated manual which clearly demonstrates
the inter-relation of the equipment.
e) Manuals shall be provided in durable hard backed A4 sized loose-leaf four ring
binders according to DIND standard O&M manual format. Lever arch binders are
not acceptable.
f) The manuals shall enable the client to safely operate, maintain, dismantle,
reassemble and adjust all part of the works.
g) Original copies of leaflets and instructions provided by the specialist manufacturers

shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text.
h) All instructions and manuals shall be written in accordance with appropriate National
Standards and other recognised guidelines on technical manual writing.
i) These shall comprise a number of volumes, dependent on the amount and technical
content of the equipment installed. The operating instructions shall always form a
separate volume. Manuals shall include sections containing information as
described in the following paragraphs.
j) Introduction:
i) The name, address, telephone and fax numbers of the Site, the Engineer,
the Consultant, the Contractor, Sub-Contractors, Manufacturers and their
Agents.
ii) The date the Contract commenced, and the date of the Taking Over
certificate.
iii) A brief description of the plant provided and the contractual scope of the
work, with descriptions of any work subcontracted.
k) General description of equipment:
i) General description of the mechanical equipment. This shall provide a

brief description of all mechanical plant provided.
ii) General description of the electrical equipment and control system. This
shall provide a brief description of the equipment provided, listing
individual control panel compartments and the remote controls.
l) Detailed description of the mechanical equipment.
i) This shall provide details of all the mechanical equipment including

manufacturer type, rating, duties, characteristic performance curves
ii) Schedules for all components stating serial numbers.
m) Detailed description of the electrical and control system.
i) This shall provide details of all electrical equipment and cables including
information on the control panel(s), listing the display and controls
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available for each compartment and stating the rating, manufacturer and
supplier of main components,
ii) Component schedules with serial numbers, calibration procedures
iii) Schedule of input and output signals, signal type, polarity, digital open or
closed state and analogue range.
n) Operating instructions.
i) These shall provide details of how each piece of plant is controlled and
operated in both automatic and hand modes, including the control
philosophy and its interrelationship with other interdependent plant.
ii) Details of plant operation under non-routine conditions
iii) Details of start-up and shut-down procedures with any associated safety
checks shall be provided.
o) Inspection and maintenance instructions.
i) These shall provide schedules recording the time interval for routine
inspection, maintenance and lubrication tasks, with reference to individual
manufacturer's instruction manuals for full details. They shall describe
briefly the more complex tasks that must be under taken at irregular
intervals. In addition to the routine operating and maintenance task this
section should identify the following:
ii) More complex tasks, involved with plant shut-downs, fault rectification to
components level, fault diagnostics, overhauls, etc.
iii) Specific hazards associated with operating and maintaining the plant, e.g.
auto starting, high voltage, noise levels.
iv) Highlight any particular complex or critical tasks over the above normal
requirements.
v) Measurements and guidance on limits of acceptable wear for all items
subject to wear.
p) Fault finding and correction. This shall provide a guide to first line checks that can
be undertaken in the event of plant failure without the need for reference to the
detailed instructions.
q) Inventory of installed plant. A schedule of this shall be provided.
r) Drawings list. A list of the ‘As-Built’ drawings shall be provided.
s) ‘As Built drawings’. Approved copies of all "As-Built" drawings shall be included for
the following:
i) Process and instrumentation diagram

ii) Site layout showing main works operational features
iii) Equipment and machinery layout
iv) Mechanical and electrical details
v) Electrical power circuit diagrams
vi) Control schematic diagrams
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vii) HV and LV distribution single line diagrams

viii) HV and LV cable routes
ix) Hard / soft copy of PLC and RTU programmes or computer programmes
x) One master copy of the proprietary software package shall be provided to
the Engineer within one week of Contract completion. All software licenses
and/or registration requirement must be forwarded promptly to the
Engineer for subsequent registration with the manufacturer. Sole rights to
all software developed and written on all schemes financed by the
Engineer shall be retained by the Engineer.
xi) Assembly drawings shall clearly show the construction details and be in
sufficient detail to facilitate re-assembly.
xii) Cable schedules shall include cable reference numbers and core
reference numbers relating to power circuit diagrams.
xiii) The above are to be supplied to the satisfaction of the Engineer. The
Contractor shall provide the Engineer black and white prints of each on
thick paper and one ISO size A2 (594 x 420) negative of each. All
drawings shall be prepared on a MICROSOFT system and printed on DM
standard sized paper (650 x 1250) unless specifically requested
otherwise. Each drawing shall be marked with the Engineers Consultant's,
Contractor's and manufacturers names and references, drawing number,
title, scales, date of completion and a full description and date of all
amendments, and shall be certified 'As-built'. The project title shall be
included in a box at the bottom right had corner of each drawing.
17.16 Guarantee
a) The Contractor shall provide a guarantee for the maintenance period for all
equipment in accordance with the General Conditions of Contract. In addition to the
general guarantee requirements, equipment warranty shall cover:
i) Faulty or inadequate design

ii) Improper assembly or erection
iii) Defective workmanship or materials
b) During the guarantee period, a warranty check of each system required to be
validation tested shall be performed twice by qualified technical representatives of
the various system manufacturers, including manufacturers of equipment
components within systems. Checks shall be detailed and complete, requiring not
less than 8 hours at the site, and shall be performed under the observation and to
the satisfaction of Dubai Municipality / Engineer. All costs for in-service checks
shall be included in the Contract Price.
c) The Contractor shall notify Dubai Municipality / Engineer in writing at least ten days
prior to the start of each warranty check and obtain his approval of the proposed
dates.
d) At the time of each warranty check, each qualified technical representative shall
review the O&M Manual and the pertinent operational and maintenance problems
encountered, and furnish technical advice and recommendations to Dubai
Municipality / Engineer.
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e) The initial warranty check shall be performed approximately six months after final
acceptance of the plant. The second warranty check shall be performed within thirty
days of the end of the contractual guarantee period.
f) The Contractor shall submit a written report of each warranty check, signed by the
appropriate manufacturer or his representative, to Dubai Municipality / Engineer
within ten days following the check. The report shall describe the checking
procedure in detail, and shall restate all advice and recommendations given to
Dubai Municipality / Engineer.
17.17 IDENTIFICATION
17.17.1 General
a) Pipes, valves, pumps, compressors etc shall be colour coded. The coding shall
indicate the contents of the pipelines, purposes of the valves etc. and show whether
or not the fluids being handled are dangerous.
b) Tape banding of pipes of the appropriate colour shall be spaced at 3m intervals and
at every valve or junction. Direction of flow arrows shall be provided together with
process stream contents.
c) Lagged pipe work shall be colour coded prior to lagging. Lagging surface shall be
continuously colour coded.
d) Stainless steel shall not have any paint system applied to its surface but
imperfections and heat-affected zones shall receive a suitable treatment to give a
high quality, uniform surface appearance.
e) CE/UL labels shall be fixed on all electrical equipment, components and

accessories.
f) The Contractor shall provide and fix necessary diagrams and/or instructions, notices
for all systems. They shall be located adjacent to the appropriate items of Plant.
Such notices shall be protected from the environment by glass or clear plastic
covers as approved by Dubai Municipality / Engineer.
17.17.2 Nameplates
a) The Contractor shall supply and fix name and rating plate(s) to each item of plant.
b) The plates shall be engraved or stamped with, but not limited to:
i) Manufacturer's name.
ii) Type and serial number of the Plant.
iii) Details of the loading and duty at which the item has been designed to
operate.
iv) Sufficient detail to allow the assembly to be readily identified in
correspondence and when ordering spare parts.
c) Additional information shall be engraved on the plate as specified in specific
sections of this specification.
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d) A schedule of plant nameplates shall be provided at the detailed design stage to

enable these numbers to be allocated.
e) The plates shall be robust, weatherproof and resistant to cracking and fracture.
f) Colourfast numbering and lettering, in block capitals and/or symbols, shall not be
less than 5mm high, engraved in both Arabic and English.
g) The plates shall include a maintenance reference number obtainable from Dubai
Municipality / Engineer, for the item of plant to which they are fixed.
h) All plates shall, where practicable, be mechanically fixed to plant. The use of other
fixings shall be subject to specific written approval of Dubai Municipality / Engineer.
17.17.3 Tags
Metal Tags shall be of Stainless Steel with stamped letters; tag size shall be minimum
40mm square with smooth edges.
17.17.4 Stencils
a) Stencils shall be produced with clean cut symbols and letters of the following sizes:
i) 20-30mm Outside Diameter of Insulation or Pipe: 200mm long colour field,

15mm high letters.
ii) 40-50mm Outside Diameter of Insulation or Pipe: 200mm long colour field,
20mm high letters.
iii) 65-150mm Outside Diameter of Insulation or Pipe: 300mm long colour
field, 30mm high letters.
iv) 200-250mm Outside Diameter of Insulation or Pipe: 600mm long colour
v) Over 250mm Outside Diameter of Insulation or Pipe: 800mm long colour
vi) Ductwork and Equipment: 65mm high letters.
b) Stencil Paint shall be semi-gloss enamel, colours conforming to BS4800.
17.17.5 Pipe Markers
a) Pipe marking colours shall conform to BS4800.
b) Plastic pipe markers shall be factory-fabricated, flexible, semi-rigid plastic,

preformed to fit around pipe or pipe covering; minimum information indicating flow
direction arrow and identification of fluid being conveyed.
c) Plastic tape pipe markers shall be flexible, vinyl film tape with pressure sensitive
adhesive backing and printed markings.
d) Underground plastic pipe parkers shall be bright coloured continuously printed

plastic ribbon tape, minimum 150mm wide by 4mm thick, manufactured for direct
burial service.
17.17.6 Instruction Notices
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a) The Contractor shall supply all necessary diagrams and instructions and notices for
special systems.
b) All diagrams, instructions and notices shall be located and fixed adjacent to the
appropriate items of plant.
17.17.7 Safety Warning Signs and Notices
a) Signs and Notices specifically required for Safety and Warning purposes shall
comply with the requirements of Dubai Municipality / Engineer.
b) Any items of equipment that start automatically shall have permanent warning signs
affixed to them with the legend in English and Arabic stating “Warning Equipment
Automatic Starting, Isolate Elsewhere”.
17.17.8 Identification Colours
BS 4800 shall be used for mechanical and electrical equipment.
17.17.9 Colour Schedule for Plant and Equipment
The contractor shall prepare colour coding schedule based on BS/RAL and submit it
for Dubai Municipality / Engineer approval.
17.17.10 Identification Colours for Plant and Equipment
The contractor shall prepare colour coding schedule based on BS/RAL and submit it
for Dubai Municipality / Engineer approval.
17.17.11 Identification Colours for Pipelines
The contractor shall prepare colour coding schedule based on BS standard and
submit it for Dubai Municipality / Engineer approval.
17.17.12 Preparation
a) Surfaces shall be degreased and cleaned to receive adhesive for identification

materials.
b) Surface preparation shall be in accordance with Section 09900 for stencil painting.
17.17.13 Installation
a) Nameplates shall be installed with corrosive-resistant mechanical fasteners, or

adhesive. Sufficient adhesive shall be applied to ensure permanent adhesion and
shall be sealed with a clear lacquer.
b) Tags shall be installed with corrosion resistant chain.
c) Plastic pipe markers shall be installed in accordance with manufacturer's

instructions.
d) Plastic tape pipe markers shall be installed completely around the pipe in
accordance with the manufacturer's instructions.
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e) Underground plastic pipe markers, shall be installed 150 to 200mm below finished
grade, directly above buried pipe.
f) Air handling units, pumps, heat transfer equipment, tanks, and water treatment
devices shall be identified with plastic nameplates or stencil painting. Small
devices, such as in-line pumps, may be identified with tags.
g) Control panels and major control components outside panels shall be identified with
plastic nameplates.
h) Thermostats relating to terminal boxes or valves shall be identified with nameplates.
i) Valves in main and branch piping shall be identified with tags.
j) Air terminal units and radiator valves shall be identified with numbered tags.
k) Automatic controls, instruments, and relays shall be tagged and referenced to

control schematics.
l) Concealed or exposed piping shall be identified with plastic pipe markers, plastic
tape pipe markers or stencilled painting. Tags shall be used on piping of 20mm
diameter and smaller. Service, flow direction and pressure shall be identified in clear
view and aligned with axis of piping. Identification points shall not exceed 6m
intervals on straight runs including risers and drops. They shall be adjacent to each
valve and tee and be at each side of penetrations of structures or enclosures, and at
each obstruction.
m) Ductwork shall be identified with plastic nameplates or stencilled painting. Air

handling units shall have an identification number and area served. Identification
shall be provided at air handling units, at each side of penetrations of structures or
enclosures, and at each obstruction.
n) Ceiling tags shall be provided to locate hidden valves or dampers above T-bar type
panel ceilings. They shall be located in the corner of a panel closest to the
equipment.
17.17.14 Schedules
a) When identifying specific equipment, the Contractor will provide an appropriate

schedule.
b) The following may assist in developing such a schedule:
i) Equipment type.
ii) Identification size/colour.
iii) Background size/colour.
iv) Lettering.
17.18 STANDARDS AND REGULATIONS
17.18.1 General Requirements
a) All products and services shall comply with any International ISO, IEC, BS EN, BS
and ASME covering such items, as a minimum, unless otherwise specified. Unless
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otherwise stated, ISO shall take precedent over IEC, which shall take precedence
over BS EN, which will take precedence over BS, which will take precedence over
all remaining standards.
b) Supportive technical literature shall be provided at the material submittal stage from
Contractor to show that products comply with the specification. Where requested by
Dubai Municipality / Engineer, or specified, the Contractor shall submit supporting
test data to substantiate compliance in conformity with specified standards,
complete with a statement from the manufacturer that original non-conformities
have been observed, and subsequently addressed to meet this specification.
c) The laws and regulations of UAE include regulations for electrical Installations and
associated regulations managed by the DEWA-ED. The Contractor shall make
himself aware of all the relevant requirements and shall implement the Works in
strict compliance with them.
d) All component parts shall be manufactured to a strict system of ‘Limits and Fits’ and
complete inter-changeability of similar parts are required, where international
standardisation of such parts is in place.
e) All references to codes, regulations, specifications and standards referred to in the

contract documents shall, unless otherwise stated, mean the latest edition,
amendment or revision of such reference standard in effect as of the date of
submission of these bid documents by the bidders.
f) Quoted reference standards referred to in the contract documents shall deem

mandatory under this contract. Products or workmanship specified by association,
trade, or other consensus standards, are also deemed mandatory, except when
more rigid requirements are specified or are required by applicable codes.
g) Should specified reference standards conflict with contract documents, then

clarification shall be sought from Dubai Municipality / Engineer before proceeding
with the supply or manufacture of plant and equipment.
h) References to published standards shall be construed as reference to a recognised

equivalent standard.
i) Obtain an original copy of the latest edition of all codes, regulations, standards and
technical literature referred to in the Contract documents and the same shall be kept
on the project site, properly indexed and maintained in good order and readily
available to Dubai Municipality / Engineer at all times. Upon completion of the works
the said codes, standards, etc., shall be handed over to Dubai Municipality.
j) Manufacturer’s manufacturing premises, sub-Contractors and suppliers shall

operate on an internationally recognised and approved quality system, or an
equivalent in-house quality system approved by the Engineer. The Contractor shall,
if required supply full details of the quality system to the Engineer for his review and
approval.
17.18.2 Purpose of Standards
a) Standards shall be treated as a documented agreement with respect to the

technical specifications and shall be followed throughout as rules and guidelines to
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ensure that the equipment, plant, materials, installation and systems, etc. are in
accordance with the requirements of the specification.
b) To ensure that the proposed equipment, plant, materials, installation and systems,
etc. have been carefully examined by the Contractor that ensure product full
compliance with the those requirements specified in the basic standards, product
manufacturing standard, functional standards and quality standards.
17.18.3 International Standards
a) The following International Standards shall be used:
i) ISO International Organization for Standardization

ii) IEC International Electrotechnical Commission
iii) BS EN British Standards European Norm
iv) BS British Standards
v) PD Published Documents
vi) CEN European Committee for Standardization
vii) UL Underwriters Laboratories
viii) NFPA National Fire Protection Association
ix) ATEX Explosive Atmospheres Directive
17.18.4 Local Regulations
a) The following Local Regulations shall be followed:
i) DEWA Dubai Electricity & Water Authority

ii) FEA Federal Environmental Agency
iii) ETISALAT Emirats Telecommunication Corporation Ltd.
iv) DU Telecommunications Service provider
v) DCD General Directorate of Civil Defence
vi) JAFZA Jebel Ali Free Zone
vii) RTA Road Transport Authority
viii) DM Dubai Municipality
ix) DUSUP Dubai Supply Authority
x) MOD United Arab Emirates - Ministry of Defence
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Table 17–4: STANDARDS
Sr. STANDARDS DESCRIPTION

Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-
1 BS EN ISO 5167-1
section conduits running full. General principles
and requirements
2 BS EN ISO 5167-2 differential devices inserted in circular cross-
section conduits running full. Orifice plates
Rotodynamic pumps. Hydraulic performance
3 BS EN ISO 9906
acceptance tests. Grades 1 and 2
Reciprocating internal combustion engines.
4 BS ISO 3046-1 Performance. Declarations of power, fuel and
lubricating oil consumptions, and test methods.
5 BS ISO 3046-3
Performance. Test measurements
6 BS ISO 3046-4
Performance. Speed governing
7 BS ISO 3046-5
Performance. Torsional vibrations
8 BS EN 3 Specification for Portable Fire Extinguishers
Specification for Control and Indicating Equipment
9 BS EN 54-2 and -4
(Supersedes BS 5839 : Part 4)
Fire Detection and Fire alarm System. Heat
10 BS EN 54-5
Detectors. Point Detectors
Smoke Detectors. Point Detectors using Scattered
11 BS EN 54-7
Light, Transmitted Light or Ionisation.
12 BS EN 54-11 Specification for Manual Call Points
Fire detection and fire alarm systems. Smoke
13 BS EN 54-12 detectors. Line detectors using an optical light
beam
Ductile iron pipes, fittings, accessories and their
14 BS EN 545 joints for water pipelines. Requirements and test
methods
Industrial valves. Face-to-face and centre-to-face
15 BS EN 558 dimensions of metal valves for use in flanged pipe
systems. PN and Class designated valves
16 BS EN 593 Industrial valves. Metallic butterfly valves
Specification for Hose Reels with Semi Rigid Hose
17 BS EN 671-1
Overall dimensions of rotodynamic pumps.
18 BS EN 735 Tolerances
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Dubai Municipality

Valves for water supply. Fitness for purpose
requirements and appropriate verification tests.
19 BS EN 1074-1 General requirements

20 BS EN 1074-2 requirements and appropriate verification tests.
Isolating valves
21 BS EN 1074-4 requirements and appropriate verification tests. Air
valves
22 BS EN 1074-5 requirements and appropriate verification tests.
Control valves
Flanges and their joints. Circular flanges for pipes,
23 BS EN 1092-2 valves, fittings and accessories, PN designated.
Cast iron flanges
Valves. Materials for bodies, bonnets and covers.
24 BS EN 1503-1
Steels specified in European Standards
25 BS EN 1563 Founding. Spheroidal graphite cast iron
26 BS EN 1711 Industrial valves. Cast iron gate valves
27 BS EN 1982 Copper and copper alloys. Ingots and castings
Continuously hot-dip coated steel sheet and strip.
28 BS EN 10143
Tolerances on dimensions and shape
Seamless steel tubes for pressure purposes.
29 BS EN 10216-1
Technical delivery conditions
Welded steel tubes for pressure purposes.
30 BS EN 10217-1 Technical delivery conditions. Non-alloy steel tubes
with specified room temperature properties
Non-alloy steel tubes suitable for welding and
31 BS EN 10255
threading. Technical delivery conditions
Industrial valves. Testing of valves. Pressure tests,
32 BS EN 12266 test procedures and acceptance criteria.
Mandatory requirements
33 BS EN 12334 Industrial valves. Cast iron check valves
34 BS EN 13157 Cranes. Safety. Hand powered lifting equipment
35 BS EN 13789 Industrial valves. Cast iron globe valves
Measurement of fluid flow in closed conduits.
36 BS EN 24006
Vocabulary and symbols
Electromagnetic compatibility. Requirements for
37 BS EN 55014-1: household appliances, electric tools and similar
apparatus. Emission. Product family standard
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Specification for pipe threads for tubes and fittings
38 BS 21 where pressure-tight joints are made on the
threads (metric dimensions)
Threaded pipe fittings in malleable cast iron and
39 BS 143
cast copper alloy
Specification for power driven overhead travelling
40 BS 466 cranes, semi-goliath and goliath cranes for general
use
Fire tests on building materials and structures.
41 BS 476-20 Method for determination of the fire resistance of
elements of construction (general principles)
42 BS 5158 Specification for cast iron plug valves
Valves for waterworks purposes. Predominantly
43 BS 5163 key-operated cast iron gate valves. Code of
practice
Rules for the design of cranes. Specification for
44 BS 2573-1 classification, stress calculations and design
criteria for structures
Rules for the design of cranes. Specification for
45 BS 2573-2 classification, stress calculations and design of
mechanisms
Standards. Specification for high tensile steel
46 BS 2903 hooks for chains, slings, blocks and general
engineering purposes
Specification for class II arc welding of carbon steel
47 BS 2971
pipework for carrying fluids
Fire hydrant systems equipment. Specification for
48 BS 5041-1
landing valves for wet risers
Code of practice for fire extinguishing installations
49 BS 5306-1 and equipment on premises. Hose reels and foam
inlets
Fire extinguishing installations and equipment on
50 BS 5306-2
premises. Specification for sprinkler systems
Fire extinguishing installations and equipment on
51 BS 5306-3 premises. Commissioning and maintenance of
portable fire extinguishers. Code of practice
52 BS 5306-4 Specification for Carbon Dioxide Systems
Fire Detection and Alarm Systems for Buildings;
53 BS 5839-1 Code of Practice for System Design, Installation,
Commissioning & Maintenance
Fire detection and alarm systems for buildings.
54 BS 5839-3 Specification for automatic release mechanisms for
certain fire protection equipment
55 BS 5839-6 Fire detection and fire alarm systems for buildings
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Code of practice for fire protection for electronic
56 BS 6266
equipment installations
57 BS 7121) Code of practice for safe use of cranes
Specification for steel and copper alloy wafer check
58 BS 7438
valves, single-disk, spring-loaded type
Recommendations for colour coding to indicate the
59 BS 7863 extinguishing media contained in portable fire
extinguishers
Non-magnetic coatings on magnetic substrates –
60 ISO 2178 Measurement of coating thickness – Magnetic
method
Specification for Metallic flanges and bolts for Cast
61 ISO 7005-2
Iron, Part 2.
Quality Management and Quality System Elements
62 ISO 9004
Guidelines
63 ISO 10474 Steel and steel products -- Inspection documents
Mechanical vibration -- Evaluation of machine
64 ISO 10816-3 vibration by measurements on non-rotating parts --
Part 3: Industrial machines
Welding -- General tolerances for welded
65 ISO 13920 constructions -- Dimensions for lengths and angles
-- Shape and position
66 DIN 8563 Welding classes standards
67 DIN 15018 Crane classification
68 DIN 15020/FEM Hoist classification
69 DIN 15401 Manufacturing of single hooks
70 DIN 15402 Manufacturing of double hooks
71 DIN 15404 Certification of hooks
72 DIN 18800 Construction for quality of welding
73 DIN 30677 Epoxy coating standard
74 NFPA-10 Standard for Portable Fire Extinguishers
Standard on Carbon Dioxide Extinguishing
75 NFPA-12
Systems
76 NFPA-13 Standard for Installation of Sprinkler System
77 NFPA-20 Standard for Installation of Centrifugal Fire Pumps
Standard for the Installation of Private Fire Service
78 NFPA-24
Mains and their Appurtenances
79 NFPA-70 National Electrical Code
80 NFPA-72 Standard for Protective Signalling Systems
81 NFPA-72E Standard for Automatic Fire Detectors
Standard for the Installation of Air Conditioning and
82 NFPA 90A
Ventilating Systems
83 NFPA 220 Standard on Types of Building Construction
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Method of Test of Surface Burning Characteristic of
84 NFPA 255
Building Material
Recommended Practice for Fire Flow Testing and
85 NFPA-291
Marking of Hydrants
86 IEC 60423
87 ARI 210 Unitary Air Conditioning Equipment
Standard for Sound Rating of Outdoor Unitary
88 ARI 270
Equipment
Commercial and Industrial Unitary Air-Conditioning
89 ARI 340/360
Equipment
Forced Circulation Air-Cooling and Air-Heating
90 ARI 410
Coils
91 ARI 430 Central Station Air-Handling Unit
92 ASHRAE 15 Safety Code for Mechanical Refrigeration
Methods of Testing for Rating Remote Mechanical
93 ASHRAE 20
Draft Air Cooled Refrigeration Condensing Units
Methods of Testing for Rating Positive
94 ASHRAE 23
Displacement Condensing Units
Method of Testing Air Cleaning Devices Used in
95 ASHRAE 52 General Ventilation for Removing Particulate
Matter
96 ASHRAE Hand Books
97
Power Piping Code 11. ISO 10474 Steel and Steel
98 ASME B31.1
Products
Standard Specification for Pipe, Steel, Black and
99 ASTM A 53/A 53M
Hot Dipped coated Welded and Seamless.
Standard Specification for Composition Bronze or
100 ASTM B 62
Ounce Metal Castings
Standard Test Method for Weight of Coating on
101 ASTM A 90/A 90M
Zinc-Coated (Galvanized) Iron or Steel Articles
Standard Specification for Seamless Copper Tube
102 ASTM B 280
for Air Conditioning and Refrigeration Field Service
Specification for Sintered Nickel Steel Structural
103 ASTM B 484
Parts
Standard Specification for Cellular Glass Thermal
104 ASTM C 552
Insulation
Standard Specification for Steel Sheet, Zinc-
ASTM A 653/ A
105 Coated by the Hot-Dip Process, Lock-Forming
653M
Quality
106 PD 5304 Safe use of machinery
Specification for Drives Using Classical Multiple V-
107 RMA IP-20
Belts, And Sheaves – Cross Section A, B, C and D.
108 UL 181 Factory-Made Air Ducts and Connectors
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Refrigerant – Containing Components and
109 UL 207
Accessories, Nonelectrical
110 UL 900 Standard for Safety Air Filter Units
UL Standard for Safety Heating and Cooling
111 UL 1995
Equipment.
VDE 0113, VDE Electrical equipment of crane and applicable CEE
112
0100 standards
113 WIS 4-52-01 Specification for Polymeric Anti-corrosion Coatings
114 IEC-60034 Rotating electrical machines
115 IEC 60034-1 Rating and performance
Methods for determining losses and efficiency of
116 IEC 60034-2
rotating electrical machinery from tests
Degrees of protection by enclosure for rotating
117 IEC 60034-5
machinery
118 IEC 60034-6 Methods of cooling rotating machinery
Classifications of types of construction and
119 IEC 60034-7 mounting arrangements of rotating electrical
machinery
Terminal marking and direction of rotation of
120 IEC 60034-8
rotating electrical machines
121 IEC 60034-9 Noise limits
122 IEC 60034-11 Built-in thermal protection
Mechanical vibration of certain machines with shaft
123 IEC 60034-14 heights 56 mm and higher measurement,
evaluation and limits of the vibration severity
Impulse voltage withstand levels of rotating a.c.
124 IEC 60034-15
machines with form-wound stator coils
Efficiency classes of single speed, 3 phase, cage
125 IEC 60034-30
induction motors
Selection of energy efficient motors including
126 IEC 60034-31
variable speed applications- application guide
127 IEC 60038 Standard voltages
128 IEC 60044 Instrument transformers
129 IEC 60050 International Electrotechnical Vocabulary
Direct acting indicating analogue electrical
130 IEC 60051
measuring instruments and their accessories
131 IEC 60059 Standard current ratings
132 IEC 60060 High-voltage test techniques - ALL PARTS
133
Dimensions and output series for electrical
134 IEC 60072
machines
135 IEC-60076 Power transformers
136 IEC 60076-6 Power transformers - Part 6: Reactors
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137 IEC 60076-7 Loading guide for oil-immersed power transformers
Determination of transformers and reactors sound
138 IEC 60076-10
levels
139 IEC 60076-11 Dry type power transformers
140 IEC 60079 Electrical apparatus for explosive gas atmosphere
Explosive atmospheres - Part 0: Equipment -
141 IEC 60079-0
General requirements
Explosive atmospheres - Part 1: Equipment
142 IEC 60079-1
protection by flameproof enclosures ‘d’
143 IEC 60079-2
protection by pressurized enclosures ‘p’
144 IEC 60079-5
protection by powder filling ‘q’
145 IEC 60079-6
protection by oil immersion 'o'
146 IEC 60079-7
protection by increased safety 'e'
Electrical apparatus for explosive gas atmospheres
147 IEC 60079-10
- Part 10: Classification of hazardous areas
148 IEC 60079-11
protection by intrinsic safety 'i'
149 IEC 60079-14 - Part 14: Electrical installations in hazardous areas
(other than mines)
150 IEC 60079-15 - Part 15: Equipment protection by type of
protection 'n' electrical apparatus
151 IEC 60079-18 - Part 18: Equipment protection by type of
protection encapsulation 'm' electrical apparatus
152 IEC 60079-25
- Part 25: Intrinsically safe systems
Explosive atmospheres - Part 26: Equipment with
153 IEC 60079-26
equipment protection level (EPL) Ga
Electrical Insulation - Thermal evaluation and
154 IEC 60085
designation
Surge arresters - Part 1: Non-linear resistor type
155 IEC 60099-1
gapped surge arresters for a.c. systems
156 IEC 60127 Miniature fuses
Insulated bushings for alternating voltages above
157 IEC 60137
1,000V
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Semiconductor converters - General requirements
158 IEC 60146-1-1 and line commutated converters - Part 1-1:
Specification of basic requirements
Semiconductor converters - General requirements
159 IEC 60146-1-2 and line commutated converters - Part 1-2:
Application guide
Semiconductor convertors - General requirements
160 IEC 60146-1-3 and line commutated convertors - Part 1-3:
Transformers and reactors
Semiconductor converters - Part 2: Self-
161 IEC 60146-2 commutated semiconductor converters including
direct d.c. converters
Semiconductor convertors - Part 6: Application
162 IEC 60146-6 guide for the protection of semiconductor
convertors against over current by fuses
Insulating liquids - determination of the break down
163 IEC 60156
voltage at power frequency
Safety of machinery - Electrical equipment of
164 IEC 60204
machines -ALL PARTS
Polyvinyl chloride insulated cables of rated
165 IEC 60227
voltages up to and including 450/750 V
166 IEC 60228 Conductors of insulated cables
167 IEC 60230 Impulse tests on cables and their accessories
Rubber insulated cables - Rated voltages up to and
168 IEC 60245
including 450/750 V
169 IEC 60255 Electrical relays
IEC 60265 / IEC High-voltage switches - Part 1: Switches for rated
170
62271-103 voltages above 1 kV and less than 52 kV
171 IEC 60269 LV fuses (Part 1 to 4)
172 IEC 60282 High-voltage fuses
173 IEC 60287 Electric cables - Calculation of the current rating
Fluids for electrotechnical applications - Unused
174 IEC 60296 mineral insulating oils for transformers and
switchgear
Standard colours for insulation for low-frequency
175 IEC 60304
cables and wires
Plugs, socket-outlets and couplers for industrial
176 IEC 60309
purposes - ALL PARTS
177 IEC 60331 Fire resisting characteristics of electric cables
Tests on electric cables under fire conditions- Part
178 IEC 60332-1-1
1: Test on a single vertical insulated wire or cable
Safety of household and similar electrical
179 IEC 60335-2-29
appliances; battery charges
180 IEC 60364 Low-voltage electrical installations
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Conduit systems for cable management - Outside
181 IEC 60423 diameters of conduits for electrical installations and
threads for conduits and fittings
Basic and safety principles for man-machine
interface, marking and identification – Identification
182 IEC 60445/60446
of equipment terminals, conductor terminations and
conductors
High-voltage alternating current contactors and
183 IEC 60470
contactor-based motor-starters
Stabilized power supplies, d.c. output. Part 4: Tests
184 IEC 60478
other than radio-frequency interference
Higher performance protocol for the standard
185 IEC 60488
digital interface for programmable instrumentation
Power cables with extruded insulation and their
186 IEC 60502 accessories for rated voltages from 1 kV (Um = 1,2
kV) up to 30 kV (Um = 36 kV) - ALL PARTS
Artificial pollution tests on high-voltage insulators to
187 IEC 60507
be used on a.c. systems
Classification of degrees of protection provided by
188 IEC 60529
enclosures (IP code)
189 IEC 60534 Industrial-process control valves
190 IEC 60584 Thermocouples
191 IEC 60598 Luminaries
Identification of apparatus terminals and general
192 IEC 60616 rules for a uniform system of terminal marking,
using an alpha-numeric notation
193 IEC 60617 Graphical symbols for diagrams (Part 1 to 13)
Secondary cells and batteries containing alkaline
194 IEC 60622 or other non-acid electrolytes - Sealed nickel-
cadmium prismatic rechargeable single cells
Secondary cells and batteries containing alkaline
195 IEC 60623 or other non-acid electrolytes - Vented nickel-
cadmium prismatic rechargeable single cells
Industrial-process measurement and control
196 IEC 60654-1 equipment - Operating conditions - Part 1: Climatic
conditions
Operating conditions for industrial-process
197 IEC 60654-2 measurement and control equipment. Part 2:
Power
Mechanical influences
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Corrosive and erosive influences
Insulation coordination for equipment within low-
200 IEC 60664
voltage systems
Switches for household and similar fixed-electrical
201 IEC 60669
installations
Mineral insulated cables and their terminations with
202 IEC 60702-1 a rated voltage not exceeding 750 V - Part 1:
Cables
Mineral insulated cables and their terminations with
203 IEC 60702-2 a rated voltage not exceeding 750 V - Part 2:
Terminations
Short-circuit temperature limits of electric cables
204 IEC 60724 with rated voltages of 1 kV (Um = 1,2 kV) and 3 kV
(Um = 3,6 kV)
Common test methods for insulating and sheathing
205 IEC 60811
materials of electric cables and optical cables
206 IEC 60851-1 Methods of test for winding wires
Electrical accessories - Circuit-breakers for over
207 IEC 60898 current protection for household and similar
installations - ALL PARTS
Low voltage switchgear and control gear (Part 1 to
208 IEC 60947
7)
209 IEC 60981 Extra heavy-duty electrical rigid steel conduits
Short-circuit temperature limits of electric cables
210 IEC 60986 with rated voltages from 6 kV (Um = 7,2 kV) up to
30 kV (Um = 36 kV)
Separating transformers, autotransformers,
211 IEC 60989
variable transformers and reactors
212 IEC 61000 Electromagnetic compatibility (EMC)
Residual current operated circuit-breakers without
213 IEC 61008 integral over current protection for household and
similar uses (RCCBs) - ALL PARTS
Electromechanical switches for electronic
214 IEC 61020
equipment
Preparation of documents used in
215 IEC 61082
electrotechnology
Cable trunking and ducting systems for electrical
216 IEC 61084
installations
217 IEC 61111 Live Working – Electrical Insulating Matting
218 IEC 61131 Programmable controllers ALL PARTS
Terminal markings for valve device stacks and
219 IEC 61148
assemblies and for power convertor equipment
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Low voltage switchgear and controlgear
220 IEC 61439.
assemblies (Part 1 to 2)
Adjustable speed electrical power drive systems
221 IEC 61800 Part 3: EMC requirements and specific test
methods- ALL PARTS
Communication networks and systems in
222 IEC 61850-SER
substations - ALL PARTS
223 IEC 62040 Uninterruptible power systems (UPS) - ALL PARTS
Class 0.5, 1 and 2 alternating-current watt-hour
224 IEC 62053-11
meters
High-voltage switchgear and controlgear - ALL
225 IEC 62271
PARTS
226 IEC 62305 Protection against lightning - ALL PARTS
Power electronics systems and equipment -
227 IEC 62578 Operation conditions and characteristics of active
in feed converter applications
228 BS 4444 Electrical Earth Monitoring
229 BS 5308, Part 1 Control and instrumentation cables
Reciprocating internal combustion engines BS

230 BS 5514
5514 or VDE.
231
Specification for Polyethylene Insulation and
BS 6234
Sheath of Electric Cables
232 BS 6651 Code of practice for protection of structures against
lightning
BS6739 Code of practice for instrumentation in process
233 control systems: installation design and practice
234 BS 7430:1998 Code of practice for earthing
BS 7671 Requirements for electrical installations. IEE Wiring
235 Regulations. Seventeenth edition
IEEE Std. General requirements for liquid immersed
236
C57.12.00: distribution, power, and regulating transformers
237 ISA SP71.04 G3 Corrosion Resistance specification
Process Instrumentation terminology
238 ISA 5.1/5.3
Roller bearings - Method of evaluating dynamic
239 ISO 281
load ratings
Roller bearings - Method of evaluating dynamic
240 ISO 281
load ratings
Reciprocating Internal Combustion Engines - Fire
241 ISO 6826
Protection
Reciprocating Internal Combustion Engine Driven
242 ISO 8528
Alternating Current Generating Sets – all relevant
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243 ISO 9001 Quality Control
Process Measurement Control Functions and
245 ISO 3511/1
Instrumentation Symbolic Representation
246 ISO 5167
differential devices
Measurement of fluid flow – Evaluation of
247 ISO 5168
uncertainties
Process measurement control functions and
248 ISO 3511/1
instrumentation symbolic representation
249 ISO 44 Degree of protection of enclosures
Measurement of water flow in closed conduits
250 ISO 4064/1
meters for cold potable water
252 ISO 7005/2 Instrumentation Flanges
International Telecommunication Union –
253 ITU-T G.652 Characteristics of a Single-Mode Optical Fibre
Cable
254 VDE 0871 Radio Interference Suppression
VDI/VDE
255 Rules for Control System Design
3501/2/3/7
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DUBAI MUNICIPALITY

SEWERAGE AND RECYCLE WATER PROJECTS DEPARTMENT
SECTION 18
ELECTRICAL & INSTRUMENTATION WORKS
DM/SRPD Section 18 Electrical & Instrumentation Rev 00 June
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Dubai Municipality
DM/SRPD Section 18 Electrical & Instrumentation Rev 00 June Page 1 of 4
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SECTION 18
ELECTRICAL AND INSTRUMENTATION WORKS
CONTENTS
18 ELECTRICAL AND INSTRUMENTATION WORKS 1
18.1 SCOPE OF ELECTRICAL WORKS SUPPLY AND SERVICES 1
18.2 MAINS POWER SUPPLY 3
18.3 EMERGENCY POWER SUPPLY 3
18.4 MV SWITCHBOARD AND MCC COMPONENTS 4
18.4.1 General Requirements 4
18.4.2 Design Considerations 6
18.4.3 Construction Requirements 7
18.4.4 MV Switching Devices 10
18.4.5 Isolating Facilities 13
18.4.6 Earthing 14
18.4.7 Terminals 14
18.4.8 Protective Devices 15
18.4.9 Instrument and Control Power Transformers 16
18.4.10 Auxiliary Circuits 19
18.5 LV SWITCHBOARD AND MCC COMPONENTS 20
18.5.4 SWITCHGEAR AND MCC COMPONENTS 34
18.6 DISTRIBUTION TRANSFORMERS 43
18.7 MEDIUM VOLTAGE MOTORS 52
18.8 LV SQUIRREL CAGE INDUCTION MOTOR 60
18.9 ELECTRIC ACTUATOR – INTEGRAL MOTOR CONTROL 66
18.10 DIESEL GENERATOR 73
18.10.2 Codes and Standards 74
18.11 DIRECT CURRENT SUPPLY SYSTEM 89
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18.11.3 Construction and Electrical Requirements 90
18.11.4 Performance Requirements 94
18.11.5 Auxiliary Equipment 96
18.12 UPS SYSTEM 98
18.12.3 Construction and Electrical Requirements 101
18.12.4 Materials 104
18.12.5 AC Distribution Sections 104
18.12.6 Performance Requirements 105
18.12.7 Auxiliary Equipment 107
18.13 FIELD MOUNTED COMPONENTS 109
18.13.2 Emergency Stop Pushbuttons 110
18.13.3 Isolators 110
18.13.4 Local Control Stations 110
18.13.5 Marshalling Panels and Junction Boxes 111
18.13.6 GRP Kiosk 112
18.13.7 Labeling and Name Plates 112
18.14 EARTHING 113
18.14.3 Equipment Earthing 116
18.14.4 Surge and Transient Protection 117
18.15 CABLES 117
18.15.1 General 117
18.15.2 XLPE PVC SWA PVC Cables 119
18.15.3 PVC Insulated Cables 120
18.15.4 PVC Insulated MICC Cables 120
18.15.5 Instrumentation and Pilot Cables 120
18.15.6 Telephone Cables 120
18.15.7 Optical Fiber Cables 120
18.16 DISTRIBUTION BOARDS 125
18.17 LIGHTING AND SMALL POWER 127
18.17.1 General 127
18.17.2 General Purpose Luminaries 130
18.17.3 Bulkhead Type Luminaries 130
18.17.4 Floodlighting Luminaries 130
18.17.5 Emergency Lighting 131
18.17.6 Luminaries for Hazardous Areas 131
18.17.7 Handlamps 131
18.17.8 Lamps 131
18.17.9 Wiring Devices 132
18.17.10 External Lighting on Buildings 136
18.17.11 Conduit 136
18.17.12 Wiring and Cabling 137
18.18 ROADWAY LIGHTING 138
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18.18.1 General 138
18.18.2 Columns 138
18.18.3 Lanterns 139
18.18.4 Roadway Lighting Controls 139
18.19 LIGHTNING PROTECTION 139
18.19.1 Building Lightning Protection 139
18.20 TELEPHONE SYSTEM 142
18.21 CABLE INSTALLATION 142
18.21.1 Cable Installation Requirements 142
18.21.2 Cable Installation in Buildings or External Structures 144
18.21.3 Cables Buried Direct in the Ground 144
18.21.4 Marking of Buried Cables and Joints 145
18.21.5 Installation in Cable Ducts 146
18.21.6 Cables in Concrete Trenches 146
18.21.7 Cable Entry Seals through Ducts and Rectangular Cut-Outs - Cable Transit
Systems 147
18.21.8 Steel Conduit Systems 148
18.21.9 Plastic Conduit Systems 148
18.21.10 Trunking Systems 149
18.21.11 Cable Trays and Ladder Racks 150
18.21.12 Cable and Core Identification 150
18.21.13 Cable Glands 150
18.22 DUCT BANKS AND DRAW PITS 151
18.22.1 General 151
18.22.2 Draw Pits 151
18.23 SCOPE OF INSTRUMENTATION CONTROL AND AUTOMATION (ICA) 152
18.23.1 Electrical Requirements for ICA 152
18.23.2 Supply Isolation 153
18.23.3 Environmental Requirements 153
18.23.4 Mode of Operation 155
18.23.5 Signalling and control 156
18.23.6 Instrumentation and Control panels 157
18.23.7 Field Mounted instrumentation 160
18.23.8 PLC's and Microprocessor Equipment 177
18.23.9 Control system Application Software 181
18.23.10 Local Operator Panels 184
18.23.11 Remote Telemetry Units (RTU's) 184
18.24 VENDOR LIST 188
18.24.1 List of Approved Manufacturer / Supplier 189

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18 ELECTRICAL AND INSTRUMENTATION WORKS

18.1 SCOPE OF ELECTRICAL WORKS SUPPLY AND SERVICES
a) The scope of electrical works shall include the preparation of shop drawing, related
detail engineering, supply, and installation, testing, commissioning and setting to work
a complete electrical and control system of the plant/station/installation etc.
b) Each piece of equipment belonging to the Electrical Works specified and required shall
be complete with necessary supports, sunshade, holding-down bolts, main
connections, secondary connections, auxiliary switches, process interlocks, safety
interlocks, terminal boards, fuses, links, small wiring, screens, guards, tags, labels,
indicators and sundries to complete the installation whether specified in detail or not.
c) All electrical equipment and systems shall be designed and installed in accordance
with the relevant International, British and European Standards and manufacturers’
recommendations, installation guidelines and instructions.
d) The Electrical Sub-Contractor shall be registered by DEWA and approved by the Dubai
Municipality to carry out electrical installation work of similar size and nature.
e) Testing and commissioning of equipment and services of specialized nature shall be

supervised by the manufacturer's technical representative(s).
f) The Contractor shall provide the complete works even if the Equipment or Services to
be provided are not mentioned, specifically including the following scope of incidental
supplies and services:
i. 400/230Vac Building and Site Services Switchgear and distribution Boards

ii. 230/230Vac and 24Vdc Sub-Distribution Panel boards for power supplies to
Control and Monitoring Systems
iii. UPS system for PLC/HMI
iv. UPS system for local SCADA system (if local SCADA system is specified in the
contract)
v. 48V DC battery and battery charger system for medium voltage switchgear (if
medium voltage switchgear is specified in the contract)
vi. Complete detail labelling of all installations
vii. Set of special tools and equipment for maintenance, inspection and repair
viii. MCC room door limit switches, high level klaxon and flasher etc.
ix. Training, inspection and supervision services by the Manufacturer
x. Spare parts for supplied equipment and panels – manufacturer’s
recommendation for 2 year operation
xi. Complete documentation as specified, etc.
g) Contractor to comply with local authorities requirements for fire protection, safety and
electrical work.
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h) Contractor should liaise with the authorities to acquire required inspections and work
completion certificates.
i) The scope of electrical and control works for the plant/station/installation shall include
but not be limited to:
i. Undertake all liaison work and obtain all necessary approvals by Dubai
Electricity and Water Authority (DEWA) for permanent electricity and water
supply connection.
ii. Undertake all liaison work and obtain all necessary approvals by Etisalat / Du for
the Telephone (PSTN / GSM) connection required for SCADA connectivity to
central control system at Dubai Municipality facility.
iii. Arranging and obtaining all necessary approvals with the Directorate of Civil
Defence, Ministry of Interior - UAE for the fire alarm, protection and fighting
system.
iv. Construction of substations (civil work) as required in accordance with the
details furnished by DEWA.
v. Connection to the new mains power supply provided by DEWA for this contract.
vi. The contractor shall conduct and submit an engineering analysis and
coordination study for the entire electrical system. The analysis shall include a
short-circuit analysis with protective device evaluation and a protective device
coordination study. In addition, the studies shall include motor starting study,
load flow/voltage drop study and harmonics analysis. The studies shall be
performed with the aid of a digital computer program and in compliance with the
latest applicable IEC 60909 standards.
vii. The studies shall oblige the contractor to optimize circuit usage, ensure proper
voltage profiles, correctly size, set protection and operating parameters.
viii. The harmonic analysis shall be performed by a computer aided circuit
simulation of the electrical system of pumping station. Total Harmonic Distortion
(THD) at the point of common coupling shall comply with the requirements of
IEC 61000 / IEEE519.
ix. Permanent standby generator system shall include all associated switchgear,
auxiliary panel, synchronization panel, fuel storage and transfer system and air
inlet (motorized louver +filter + silencer + fans) and outlet (motorized louver +
silencer) arrangement.
x. Low Voltage Panels complete with Active Harmonic Filter, Detuned Capacitor
Banks, Instrument Control and Automation panel / common control section
including PLC and RTU complete.
xi. Main Distribution Boards & Sub Distribution Boards.
xii. All field mounted electrical equipment including local isolators, emergency
pushbutton stations, local control panels, junction boxes.
xiii. All power, control, instrumentation and communications cabling systems,
including cables, containment, cable transits, fire seals, fixings, termination and
connection.
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xiv. All control system software development and programming and configuration of
existing SCADA central station for controlling and monitoring of
plant/station/installation constructed / modified under this contract.
xv. All control system hardware.
xvi. Fire alarm and suppression system.
xvii. Hazardous gas detection and alarm system – if specified.
xviii. Area lighting.
xix. Building services lighting and small power.
xx. Earthing system
xxi. Lightning protection systems for buildings / structures.
xxii. Any work which can be reasonably inferred as necessary for the safe,
satisfactory operation of each system, whether such work is specified or not.
xxiii. Supply and installation of cables, cable support systems, boxes and termination
points, for the motors, starters, controls for equipment supplied under this
contract.
18.2 MAINS POWER SUPPLY
a) The mains power will be provided by the Dubai Electricity and Water Authority (DEWA).
b) The civil infrastructure shall be designed and constructed to house DEWA supplied
equipment, in accordance with the requirements of DEWA.
c) The Contractor shall enter into negotiations with DEWA and procure the provision of
the mains supplies to the plant / station. In order to do this the Contractor shall compile
a complete assessment of the required maximum and average loads and all other
documents / information as required by DEWA.
d) The DEWA supply works will be undertaken under a separate contract let by the
Employer with direct payments expended from a Provisional Sum within this Contract.
The DEWA works entail installation of new intake substations with new switchgear.
e) The Contractor shall liaise with DEWA in the timing, installation and commissioning of
the new LV or MV supply and intake substation switchgear or RMU etc. Neither the
Employer nor the Engineer shall be responsible for any delays to the works due to the
Contractors late submission of information required to enable DEWA to carry out their
works.
f) The interface between the DEWA and the works undertaken as part of this Contract
shall be the Contractors connection terminals for receiving the DEWA supply cable(s).
18.3 EMERGENCY POWER SUPPLY
a) Emergency power shall be provided by a permanent or mobile diesel generator sets as

indicated on contract Single Line Diagram.
b) When the plant/station is specified with permanent diesel generator sets, the bulk fuel
tank shall be sufficient capacity to operate the generator at maximum rated capacity for
a minimum period of 3 days without replenishment of the bulk fuel storage tanks.
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c) The maximum allowable period of uninterrupted running shall be at least 7 days.
d) The generator shall be arranged for automatic start up and changeover of supply on
loss of mains supply to the plant / station. The system shall automatically return the
plant / station to mains supply on restoration of mains power.
e) The control shall be provided with the appropriate time delays to prevent spurious
operation due to surges on the mains and to allow for the appropriate operating regime
of the diesel engine.
f) The system shall start within 10 seconds of mains failure and connect to the load within
1 minute.
g) The diesel generator sets shall be installed indoors in the building designated for that
purpose. The Contractor shall provide adequate room heating, cooling and ventilation
to allow the set to start and operate under all external climatic and environmental
conditions prevailing in the project area.
h) Re-order alarms shall be provided on the fuel storage system.
i) The diesel generator sets shall be designed to prevent inadvertent parallel connection
to DEWA distribution network in all circumstances.
18.4 MV SWITCHBOARD AND MCC COMPONENTS
a) This specification covers the general requirements for the design, manufacture, testing
and supply of MV switchboards and Motor control centres. That is assemblies for the
control of voltages above 1KV up to and including 52KV.
b) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements. All
components utilised in the construction of this switchboard shall be of the latest design,
new and in current production. Materials and equipment shall be approved by the
appropriate authority where applicable.
c) Further to the international standards MV boards shall also conform to the local
standards and/or regulations (DEWA), when these are higher, more stringent or of
special nature.
d) The design of the electrical system and equipment shall ensure that all operating and
maintenance activities can be performed safely and conveniently. Even under extreme
conditions of major short circuit or malfunction there shall be no danger to persons in
the vicinity of the assembly.
e) The Contractor shall ensure complete selectivity of the entire fault current protective
system.
f) On re-assembly at site, all bus bar connections shall be re-torqued to the

manufacturers recommended settings and marked. A check sheet of torque settings
shall be logged for each connection. The check sheet shall be submitted to the
Engineer on completion of the assembly before testing and energize.
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g) The following protections and monitoring shall be provided for the electrical equipment.
Protection:
ANSI
Protections Feeder Busbar Transformer Motor Generator
Codes
Phase Over
50/51     
Current
Earth Fault 50N/51N     
Negative
Sequence / 46  
Unbalance
Phase Over 67N
Current / Earth 67/67N   
Fault
87T/87M
Differential 87T 87M 87M
/87B
Restricted Earth
64REF  
Fault
Overload 49/49T/38    
Motor Phase 37/48/

Over Current 51LR / 66
58/27,
Voltage    
59N
81H/81L/
Frequency    81R
81R
25, 27D 50N/51 32P &
(neutral 32Q, 32P &
Specific * - point), 27D / 32Q / 25,
50/51 (tank 47 50V/51V
earth), 27R
i. 25 - Synchro Check
ii. 27D - Positive Sequence Under Current
iii. 27R - Remnant Under Voltage
iv. 32P - Directional Active Over Power
v. 32Q - Directional Reactive Over Power
vi. 50V/51V - Voltage – Restrained Over Current
vii. 47 - Negative Sequence Over Voltage
viii. 81R - Rate of Change of Frequency
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Dubai Municipality

Monitoring:
Measurements Application Feeder Busbar Transformer Motor Generator

Current I1, I2, I3     
Peak Demand IM1, IM2,
    
Current IM3
TRIP I1, I2,
Tripping Current     
I3
U21, U32,
Line Voltage     
U13
Phase Voltage V1, V2, V3     
Residual
V0     
Voltage
Positive
Sequence Vd     
Voltage
Frequencies f     
P/Q, PM/Q,
Powers     
Cos Φ
Energies Ea/Er     
Temperatures   
18.4.2 Design Considerations
18.4.2.1 Ratings
a) The assembled switchgear and all its power circuit components shall be capable of
withstanding the thermal and dynamic stresses resulting from RMS and symmetrical
peak short circuit currents and earth fault currents expected and determined by the
electrical system design. Thermal capability shall be sufficient to allow these currents to
flow for a minimum of one second, without causing any deterioration or damage to the
assembly.
b) For standard voltages, frequencies and currents reference is made to IEC 60038,
60196 and 60059 respectively.
c) Medium voltage, current-carrying components shall furthermore be capable of carrying

their rated current continuously at rated voltage and under specified service conditions
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Dubai Municipality

without exceeding the permissible temperature limits when mounted in the completely
assembled switchboards.
d) Selected standard rating for switchboards shall be those listed in IEC publication
62271-100.
18.4.2.2 System Variation
All equipment and components of the MV boards shall be capable of continuous

operation at their full current and voltage ratings and without detriment or malfunction
at system continuous deviation of up to and including the following percentages of the
normal values.
Voltage: ± 10% according IEC 60038

Frequency: ± 5% according IEC 60196
Absolute total voltage and frequency variations: 10%

18.4.2.3 Performance Requirements
All components shall be capable of withstanding the dynamic, thermal and dielectric
stresses resulting from the test duties specified in IEC publication 62271-100.
18.4.2.4 Temperature Rise
The temperature rise of the MV distribution and motor control centre shall not exceed
temperatures indicated in IEC 62271-100.
18.4.3 Construction Requirements
18.4.3.1 Housing / Enclosure
a) All MV switchboards and motor control centres shall be manufactured and tested to the
requirements of IEC 62271-200.
b) All MV switchboards and Motor Control Centres shall be of a floor mounting, multi-
compartment withdrawable type metal enclosure. The MV switchboards and Motor
Control Centres shall be extendable in its design. They shall be suitably strengthened
for lifting during installation and shall be provided with suitable lifting facilities. Lifting
eyebolts shall be of the screw in type and shall be removed on completion of
installation, and replaced with suitable plugs.
c) The materials of construction shall be properly prepared and treated against rust or
corrosion. The switchgear and controlgear shall be self-supporting and suitable for front
entry and operation.
d) The front of the MV boards shall be provided with a plastic or equivalent line mimic
diagram illustrating the main circuit and its components.
e) The painting shall be suitable for the specified service conditions. Unless specified
otherwise painting shall be of manufacturer's standard. Manufacturer to provide
particulars procedures of paint and finish colour.
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f) MV switchboards and Motor Control Centres shall be provided with adequate bottom
plates to prevent access by vermin.
g) The degree of protection shall be in accordance with IEC publication 60529 and shall
be of minimum ingress protection as follows:
i. For the enclosure: IP4X

ii. For the partitions : IP2X
h) All components requiring periodical maintenance shall be easily accessible.
18.4.3.2 Internal Arrangement
a) The switchboard shall comprise a busbar system and consist of one or more sections,
each having one incoming feeder panel placed as indicated on one line drawings of the
electrical load. Each section shall be equipped with a busbar connected voltage
transformer for metering supply, preferably to be mounted in the incoming feeder panel
or in a separate measuring panel. In case the total load for metering and control
exceeds the standard rating, a second busbar connected voltage transformer shall be
provided for supply control only.
b) The current rating of the incoming feeders and the busbars shall in general be of equal
value for each part of a combined panel or as indicated on the drawing.
c) All incoming switches and bus couplers shall be equipped with facilities for padlocking
both in the "in" and in the "out" position.
d) The lay-out of the operational front and the location of the components of the assembly
shall be arranged in a logical and systematic sequence and standardized throughout.
e) Alphanumeric notation, generally in accordance with IEC 60445, shall be used for
identification and marking of phases, conductors and terminals.
f) The system of construction for the MV distribution and motor control boards shall be a
factory-built assembly of a standard well tested design of the draw-out type.
g) All incomers, bus couplers and outgoing feeders shall be operated through three
positions i.e. In-Out-Test. In all three positions, limit switches and indications shall be
available for each position.
18.4.3.3 Interchange-ability
a) Electrically identical components shall be of one type and make.
b) Withdrawable sub-assemblies containing one or more components with identical

functions and capacities shall be mechanically interchangeable.
c) Withdrawable sub-assemblies with identical functions but of different capacities might

be mechanically interchangeable provided the sub-assembly can be adapted easily for
its new capacity.
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18.4.3.4 Anti-Condensation Precautions
a) Effective precautions shall be taken to prevent the formation of harmful condensation

inside the enclosure, under both operating and non-operating conditions and service
conditions.
b) 230 V - 1 phase space heaters shall be provided. The space heaters shall be controlled
by a thermostatic switch and shall be wired to outgoing terminals.
c) The heating device shall be of sufficient capacity to raise the internal temperature by
5oC above the ambient temperature. The heater shall be covered safely to avoid
accidental contacts and heater terminals shall be adequately shrouded.
18.4.3.5 Arcing Faults
a) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements and shall be fitted with gas exhaust chamber,
flap and top chimneys.
b) The design and construction of the MV distribution and motor control boards shall be
such as to provide the highest possible degree of personnel protection against
radiation, overpressure and hot gases.
18.4.3.6 Insulation
a) A Solid-Air-Solid insulation system where failure of one solid layer does not lead to
voltage breakdown is preferred.
b) MV components of switchboards shall be suitable for an exposed electrical system with

unearthed neutral, in accordance with IEC publication 62271-100.
18.4.3.7 Busbar Systems
a) Bus-bars shall be of high conductivity electrolytic copper with joints by means of non-
corrosive high tensile steel bolts, nuts and washers, and secured against loosening.
Insulated bus-bars are preferred. Bus-bars and assembly shall be suitable for
extension to the left or to the right as required.
b) Bus-bars shall be accessible for maintenance purposes, etc.
18.4.3.8 Compartments and Partitions
a) Adequate compartments and partitions shall be provided to allow easy maintenance

operation e.g. fuse replacement.
b) Main circuit compartments shall always have individual overpressure relief.
18.4.3.9 Rating Plates and Nameplates
a) Switchgear shall have a rating plate permanently fixed in the front of the equipment
giving at least the following information:
i. Rated voltage and frequency.

ii. Rated SC capacity and current capacity of busbars.
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iii. Standard to which equipment conforms.
iv. Year of manufacture.
v. Manufacturer's name, type and serial number.
vi. Weight.
b) Rating plates shall be made of corrosion-resistant metallic material and have indelible
inscriptions in English language.
c) Enamelled plates are not acceptable.
d) Each panel shall be provided with nameplates, mounted on the front of a non-
removable part.
e) Circuit identification nameplates shall be placed on the front and back of each
switchgear frame
f) All components (switching devices, contactors protection relays, instruments etc.) shall
be fitted with a rating plate in accordance with the relevant IEC requirements. All
functional units shall be clearly labelled to identify the service. All relays, meters,
switches etc. shall be labelled in accordance with the wiring diagrams.
g) The details of label shall be as specified in LV switchgear section of this document.
18.4.4 MV Switching Devices
18.4.4.1 Type
a) MV switching devices shall be of draw-out type which is tested and certified by an

official authority to meet the requirements of the national/local regulations.
b) Switching devices shall be vacuum type circuit breaker.
c) The circuit breakers shall be electrically operated, 3-pole, draw-out type, with electric
motor and manual charging of a spring type stored energy operating mechanism. The
power circuit breaker shall be provided with self-aligning line-side and load-side
disconnecting devices.
d) Mechanical interlocks shall be provided on all boards to prevent connecting or

disconnecting the circuit breaker while closed and to prevent the closing of the circuit
breaker unless the separable contact are in full contact or separated by a safe
distance.
e) For motor feeder panels vacuum type circuit breakers are preferred.
f) The type of switching device and its operating mechanism shall be selected in
accordance with its duty and the number of load operations.
g) The following switching devices shall be provided as a minimum:
i. ON-OFF indicators
ii. Motorised spring charging
iii. Anti-pumping
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iv. Emergency 'OFF' pushbutton
v. Closing/trip coil suitable for control voltage
vi. Blocking for manual switch 'ON' facility
vii. Breaker carriage earthing
viii. Earth switch interlock
ix. Padlock arrangement
18.4.4.2 Control Mechanism
a) Rated voltages for closing, tripping, control and auxiliary circuits shall be selected from
IEC 62271-100.
b) Control mechanism of switching devices may be of the following types:
i. Electromagnetically operated with DC control supply;

ii. Spring-operated hand charged in case of local control only;
iii. Spring-operated power charged.
c) All switching devices shall open automatically, be trip-free and have their energy for the
opening operation stored prior to the completion of the closing operation. Furthermore
they shall be provided with a local manual-operated tripping feature protected against
inadvertent tripping.
d) The power charged spring-operated mechanism shall not require more than 25
seconds for spring charging.
e) Power charged spring-operated mechanism of remote controlled switching devices

shall be charged when the switching device is in its normal service position.
f) Switching devices for motor panels shall be protected against "pumping".
g) All electrical charging and electromagnetic mechanisms as well as the closing control
components shall be capable of operating when the auxiliary or control supply is
between 85% and 105% of its rated value.
h) Control voltage and trip voltage shall be as follows:
i. The breaker motor charging range shall be (48VDC).

ii. The trip voltage shall be (48VDC).
iii. The close voltage shall be (48VDC).
iv. Close and trip circuits for each breaker shall be separately fused. Fuse blocks
shall be dead front, pull-out type, which provides the control power
disconnecting means.
i) Each switching device shall be provided with visual mechanical indicators, one marking
the closed position with "I" and/or a red flag and the open position with "O" and/or a
green flag, and in case of a stored energy closing mechanism one marking whether the
operating mechanism is charged or discharged. These indicating devices shall be
directly driven by the switching mechanism.
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j) The switchboard manufacturer shall ensure that all required information is available to
him before preparation of his detailed logic/control scheme drawings.
18.4.4.3 Disconnectors
Disconnectors (isolators) are not permitted, even with safety interlocks, except when
used for the separation of fixed and moving parts.
18.4.4.4 Earthing Devices
a) Three-phase earthing facilities at the cable sides and for the bus-bar system of each
section shall be provided.
b) Integrally mounted three-phase earthing switching devices shall be provided for each
type of MV switching device.
c) These devices shall be capable of making and carrying the prospective short-circuits
current at the point of earthing. The earthing devices shall be suitable for local, manual
operation only.
d) Padlock facilities for locking in the open and closed position shall be provided.
e) When earthing devices are to be applied in a compartment it shall not be possible in

the following conditions:
i. To insert a portable earthing device in the closed position.

ii. To insert a withdrawable switching device into the service position of the
compartment concerned.
iii. To close a fixed-type switching device in the compartment concerned.
f) Generally, circuits shall not be earthed automatically, i.e. when withdrawing the
switching device the earthing device has to be inserted deliberately.
g) Outgoing circuits for motor starting may be earthed automatically when the switching
device is being withdrawn.
h) Clear instructions, preferably pictorial, shall be submitted showing the proper methods
of how and where to fit the earthing devices.
18.4.4.5 Current Chopping
a) Switching devices shall not cause switching surge voltages which exceed the insulation
level of the connected equipment. Motors switching needs special care and switching
devices shall be appropriately designed.
b) Vacuum switching devices shall be equipped with ZnO over-voltage protection devices.
18.4.4.6 Auxiliary Contacts
a) Each switching device shall be provided with at least 4 make and 4 break auxiliary
contacts directly driven by the switching mechanism.
b) These contacts shall be completely wired up to terminal blocks in the secondary

terminal compartment.
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c) The rated making and thermal-breaking capacities of these contacts shall be:
Making capacities Thermal-breaking capacities

16A at 500 V AC and power factor 0.3 1A at 500 V AC and power factor 0.3
1.7A at 110 V DC inductive 1A at 110 V DC inductive
4A at < 60 V DC inductive 2A at < 60 V DC inductive
18.4.5 Isolating Facilities
18.4.5.1 Isolation of Main Circuits
a) Switch panels shall be provided with safe means of isolating the circuit side from the
busbar side.
b) Panels containing combinations of fuses and contactor shall be equipped with isolating
facilities permitting safe changing of fuses by hand.
18.4.5.2 Interlocks
a) Interlocks in accordance with IEC 62271 shall be provided to prevent unsafe operation
of the switchboard.
b) They shall permit operating the switching device only when:
i. The isolating device in fully operating position; the switching device is in a

specifically provided test position with the isolating device in the closed position
and the control and auxiliary circuits operative but with panel control facilities
only.
ii. They shall mechanically interlock the isolating device in its closed position when
the switching device is closed. Alternatively, they shall cause tripping of the
switching device upon attempted operation of the isolating device.
18.4.5.3 Safety Shutter Devices
a) The panel shall be fitted with a set of shutters to cover each 3-phase group of
stationary isolating contacts, i.e. both on the busbar and on the circuit side.
b) The shutters shall open or close automatically by a mechanical drive from the switching
device when the latter is being racked in or out.
c) Each set of shutters shall be equipped with padlocking facilities in its closed position.
When padlocked, the shutters shall prevent access to the stationary isolating contacts.
d) Shutters on the busbar side shall be painted red and shall be clearly labelled
"BUSBARS" in large white letters.
e) Shutters on the circuit side shall be painted yellow and shall be labelled. “Isolating
Contacts for Secondary Circuits”.
f) The connection in the secondary circuits between the fixed and the moving parts of
panels shall be by means of self-aligning contact.
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g) These connections shall be maintained when the moving portion of the equipment is in
the test position.
18.4.6 Earthing
a) Earthing shall be in accordance with IEC 62271; colour coding of protective conductors
shall be in accordance with IEC 60446.
b) A main earth bar shall be fitted along the whole length of the switchboard. This shall be
made from hard-drawn, high-conductivity copper and be capable of carrying the short-
circuit rating of the board but have a cross section of at least 125 mm².
c) The earth bar shall be bolted to switchboard frame and equipped with convenient
facilities for connecting of all parts of the switchboard which require earthing.
d) Joints in the main earth bar shall be bare copper and bolted with galvanized steel bolts,
nuts and washers, secured against loosening.
e) For direct connection to the station earthing grid, earthing bolts (M12) with nuts and
spring washers shall be provided at both ends of the main earth bar.
f) In addition to ensure adequate electrical continuity between all metal parts of the
switchboard and its cables and the main earth bar particular care shall be taken to
ensure the followings:
i. Housings of withdrawable switching devices shall be positively earthed in the

service position by appropriate earthing connections;
ii. Band joints of compound-filled busbar chambers shall be suitably earthed to the
frame of the switchboard;
iii. The earth connections of voltage transformers and current transformers shall be
made directly from the terminal board to the earth bar.
g) Means shall be provided of ensuring that the earthing connection of each withdrawable
switching device and voltage transformer to the main earth bar is made prior to its
primary connections.
18.4.7 Terminals
18.4.7.1 General
a) Each panel shall be provided with appropriate facilities for the independent terminals to
connect the MV main cable and the LV auxiliary cables.
b) The terminal compartments for MV and LV connections shall be effectively segregated,

see IEC 62271.
c) The terminals shall be so arranged that all connections can be made safely, even when
the assembly is energized.
d) Suitable terminating facilities of adequate dimensions and thermal rating shall be

provided for each conductor.
e) Inside the compartments separate terminals or bolts, one for each cable, are required
for earthing purposes.
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f) Efficient means to prevent strain on the actual conductors and cable connection shall
be provided.
18.4.7.2 Terminals for MV Cables
a) Cable termination shall be suitable for the specified cable.
b) For PVC or XLPE type cables, dry type cable termination is preferred. When two or
more cables are required, a suitable marshalling box may be required to obtain
uncluttered straight terminal connections.
c) Single-core cables: The terminal box and its cable entries on a relevant panel shall be
suitable for the specified cable.
d) Single conductor entries shall be mounted in non-magnetic plates. The end sleeves or
glands shall also be of non-magnetic material.
18.4.7.3 Terminations for Auxiliary LV Cables
a) Terminal blocks fitted with tubular type contacts with non-loosening screws shall be
provided for termination of auxiliary LV cables including that required for wiring
between cubicles or panel sections. Crimped conductor ferrules are required at
terminal blocks to ensure sound contact. Non-screw type terminal blocks are not
permitted. Within the panel compartments suitable clamping devices shall be provided
for securing of the cables.
b) Terminals in current measuring circuits shall be special purpose with suitable bridging
links and measuring facilities.
c) Specified auxiliary contacts for remote circuits shall be wired and connected to an
accessible terminal block in the vicinity of the cable entries.
d) Termination compartments for auxiliary and control cables shall have adequate
dimensions, with ample accommodation for the required number of terminals and
cables.
e) Two or more conductor terminations on one terminal are not acceptable unless the
terminals are designed for more than one conductor.
f) Metal cable glands suitable for the cables specified shall be included in the supply of
the assembly.
18.4.8 Protective Devices
a) Selection of relays shall be in accordance with the relevant circuit requirements.
b) All protection relays shall be of static type of approved make. Means shall be provided
for secondary injection testing of relays without disconnecting wiring.
c) All protective relays, auxiliary relays, indicating instruments, recording instruments,

indicating lights, transducers, etc. shall be housed in the Low Voltage Compartment.
The Low Voltage Compartment shall isolate the above mentioned equipment such that
in the event of a fault, the equipment will be protected from the forces created by the
fault. A multi-function, 3-phase microprocessor based relay and control package will be
used. Door-mounted protective relays will be draw-out type whenever practical.
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d) Protective relays and test devices shall be semi-flush mounted. The relays shall be so
arranged that they can be tested in position on the panel and readily withdrawn from
the panel for inspection or replacement.
e) The relays will be provided with targets that can be externally reset
f) Switchgear device function numbers shall be in accordance with ANSI Standard

C37.20.
g) An ABB DPU200R distribution protection relay or equivalent shall be provided with the
following functions:
i. 3-phase over current protection (time and instantaneous)

ii. Ground over current (time and instantaneous)
iii. Multi-shot reclosing
iv. High set instantaneous
v. Ammeter, demand and peak demand ammeters
vi. Event recording
vii. Accumulation of breaker interrupting duty
viii. Continuous self-checking
ix. RS-232 and RS-485 communications ports for remote terminal connection.
h) The protective relay shall be dustproof flush-mounted / removable type, provided with
calibrating and testing facilities. Current transformer terminals of the relays shall be
automatically short-circuited at withdrawal of the relays.
i) MV motor protection shall be through comprehensive motor protection relay with

provision for protection against negative phase sequence, earth fault, over load,
stalling, RTD protection for alarms and trip to be incorporated.
18.4.9 Instrument and Control Power Transformers
18.4.9.1 General
a) The contractor/supplier/manufacturer (whatever) shall use an experienced protection

engineer to design the protection circuits including CTs, VTs, protection relays and
tripping circuits.
b) All voltage and current transformers shall be cast resin type.
18.4.9.2 Current Transformers
a) CT nameplates shall be located on the CT housing and information provided shall be

including rating, accuracy class and part number and manufacturer detail. The CT
winding shall terminate on a screw type terminal on the CT housing and shall be wired
to shorting terminal blocks.
b) Each current transformer shall have a primary rating as required for the circuit fault
rating.
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c) Rated output capacity of the transformers shall be matched to cover the burden
required by the equipment connected and be selected from the range of standard
values.
d) Rated primary current shall preferably be selected from the range of standard values.
e) Rated secondary current shall be either 5 or 1A; for remote metering 1A only is
acceptable.
f) Ratings and accuracies shall be in accordance with BS EN 60044-1 and IEC 60044-1
for the metering and relay applications.
g) Generally, measuring current transformers shall be Class 3, except those for

measuring the supply of third parties, which shall be Class 1.
h) The over-current limit factor shall be < 5 in order to prevent damage of instruments at
maximum fault current.
i) Protective current transformers are to be Class 5 P.
j) Each current transformer shall have a short-circuiting device (shorting type terminal
blocks). The first termination of each current transformer shall be at the short-circuiting
device terminal blocks where the ground connection is also made.
k) Low voltage ring core type CT’s will be bushing-mounted, located behind the shutters
and accessible from the front. Bushing design shall accommodate up to four standard
accuracy CT’s per phase for all ratings.
l) Secondary terminals of current transformers shall be wired up to a terminal block with

short-circuiting links, located at an accessible place. One side of the secondary winding
of each current transformer shall be connected at this terminal block to the earth bar.
18.4.9.3 Voltage Transformers
a) Voltage transformers will be mounted on a draw-out unit in an auxiliary enclosure,

which disconnects them from the primary circuit safely.
b) Voltage transformers shall be mounted in a separate draw-out compartment (truck

assembly) and so arranged that the unit can be withdrawn from the operating position
via a raking device with the door closed. In the withdrawn position, the fuses shall be
completely disconnected from service and all exposed parts shall be visibly grounded.
c) The voltage transformers compartment shall incorporate extension rails to allow

changing MV fuses and general maintenance without the need to take the truck
assembly completely out of its compartment.
d) Voltage transformers shall be connected to the line or load via solid copper rod, bus or
shielded cable.
e) An impact resistant viewing window shall be on the front of the voltage transformer
door.
f) Each transformer shall be protected with current-limiting MV primary fuses, and shall
be designed to withstand the basic impulse level of the switchgear.
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g) The secondary voltage of measuring and protection transformers shall be 110/√3 V.
h) Rated output capacity of the transformers shall be matched to cover the burden
required by the equipment connected, and preferably be selected from the range of
standard values.
i) Generally, measuring voltage transformers are Class 0.5, except those for measuring
the supply of third parties which shall be Class 0.2.
j) Protective voltage transformers shall be of Class 3 P.
k) The winding connection is depending on the metering and protection system

connection.
l) At HV side, high-rupturing capacity, short-circuit current-limiting fuses shall be provided

in accordance with IEC 60282-1;
m) Fuses shall be readily accessible and suitable precautions shall be taken to enable
safe removal and replacement of fuses.
n) At LV side, Industrial ZED-type cartridge fuses shall be used.
o) The connection between transformer and fuse base shall be as short as possible.
p) All protective fuses shall be capable of handling the inrush currents for all service
conditions, without abnormal ageing or deterioration.
q) Voltage transformers for automatic voltage regulators shall have no fuses at all, but
shall be connected within the protective zone of the differential protection of the
generator.
18.4.9.4 Control Power Transformers
Control power transformers shall be dry type with disconnecting type current limiting
primary fuses and fused 120 volt secondary. Transformers up to 15kVA single phase
(or fuses above 15kVA) shall be mounted on a truck assembly, which is moved
between the connected and disconnected position via closed door racking and utilising
the same raking device as the circuit breaker.
18.4.9.5 Ammeters
a) Ammeters shall be flush-mounted, square type (96 x 96 mm). They shall have an
element rated at 1 or 5 ampere.
b) Ammeters in the motor circuit shall have an overload scale of 5 x In.
18.4.9.6 Voltmeters
a) Voltmeters shall be flush-mounted, square type (96 x 96 mm).
b) They shall have the following full-scale readings:
i. For 3 or 3.3 kV: 0 -4,000 volts

ii. For 6 or 6.6 kV: 0 -8,000 volts
iii. For 10 or 12 kV: 0 - 15,000 volts
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iv. For 15 or 17.5 kV: 0 - 20,000 volts
18.4.9.7 Watt-hour Meters
Watt-hour meters shall have cyclometric registers. Watt-hour meters for motors may be
of the single-element, balanced-load type.
18.4.9.8 Counters
Each switching device shall be provided with an operation counter.
18.4.9.9 Accuracy
Ammeters and voltmeters shall be of Class 1.5 and watt-hour meters shall be of Class
2.5 as specified in IEC publication 51 and 521. Power factor meters shall be class 1.5.
18.4.10 Auxiliary Circuits
a) Control devices, control buses, local control, instrument cables and wiring on the
equipment shall be installed at the factory. Cables shall be enclosed in earth metal
cable ways when routed through a high voltage compartment. The wires shall be neatly
bundled and tie wrapped where applicable, protected from rubbing against door flanges
or other parts of the enclosure.
b) Control relays, auxiliary contacts and small mechanisms shall be enclosed and
protected but shall be accessible for maintenance.
c) Auxiliary circuits shall be clearly grouped and be protected adequate. All current wires
shall be at least 2.5 mm² others 1.5 mm² of the PVC type and be able to withstand
2500 V impulse test. All wires shall be connected to terminals individually and clearly
identified at both ends by ferrules of isolating material or plastic code markers in
accordance with the wiring diagram(s).
d) Colour coding of secondary wiring shall be in accordance with IEC 60446. Wiring
between two terminals shall be continuous; joints or interconnections are not allowed.
e) To accommodate and support the secondary wiring, covered plastic channels,

insulated tubes or plastic strips shall be used.
f) Secondary wiring shall never be mounted direct to metal. The filling factor for channels
shall not exceed 70%. Where supporting of a wire is not feasible the wire or part of it
shall be as short as possible.
g) Terminal blocks shall be conveniently located for external connection without accessing
the high voltage compartments. Terminal blocks will be clearly marked for wiring. A
wire label at both ends will identify each internal interconnecting wire. Terminal blocks
to be Klippon or equivalent. Terminal blocks for current circuits to be shorting type or
equivalent.
h) All circuits shall be protected by miniature circuit-breakers of the airbreak-type or

cartridge-type fuses.
i) Contacts for remote alarm shall be normally closed.
j) Protective devices shall have protective action indication.

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18.5 LV SWITCHBOARD AND MCC COMPONENTS
a) This specification covers the general requirements for design, manufacture, testing and
supply of Low-voltage switchgear and controlgear assemblies. Unless specified
otherwise Low-voltage switchgear and controlgear assemblies shall conform in design,
material, construction and performance to the latest editions of the IEC standards
b) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements. All
components utilised in the construction of this switchboard shall be of the latest design,
new and in current production. Materials and equipment shall be approved by the
appropriate authority where applicable.
c) Further to the international standards the Low-voltage switchgear and controlgear

assemblies shall also conform to the local standards and/or regulations (DEWA), when
these are higher, more stringent or of special nature.
d) The design of the electrical system and equipments shall ensure that all operating and
maintenance activities can be performed safely and conveniently. Even under extreme
conditions of major short circuit or malfunction there shall be no danger to persons in
e) The Contractor shall ensure complete selectivity of the entire fault current protective
system.
f) On re-assembly at site, all bus bar connections shall be re-torqued to the

manufacturers recommended settings and marked. A check sheet of torque settings
shall be logged for each connection. The check sheet shall be submitted to the
Engineer on completion of the assembly before testing and energization.
g) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements. The design and construction of the Low-voltage
switchgear and controlgear assemblies shall be such as to provide the highest possible
degree of personnel protection against radiation, overpressure and hot gases.
h) The MCC panel middle sections shall be equipped with terminal strips serving as
connection compartment for the control signal connections to and from the control
system. On one side of the terminal strips the control wiring from the motor
compartments will be connected on the other side the control signal cables to the ICA
panel / common control section will be connected.
i) All circuit breakers rated 800A and above shall be ACB of the withdrawable type.
j) MCCs shall have an end section for control and instrumentation with RTU / PLC
controller and HMI operator screen for access to instrumentation information and local
alarms of the equipment concerned. This shall provide local operator functions
(including alteration of set points) and is intended for the main running of the Plant /
station where the plant / station is not specified with local SCADA.
k) The Plant / stations shall be monitored and controlled (start, stop of individual pumps
and inhibiting the station as whole while in auto mode) from Dubai Municipality central
SCADA station. The requirement of RTU and configuration of plant / station to Dubai
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Municipality existing SCADA central control station shall be similar to the existing plant
/ stations of the network in terms of its functionality and connectivity.
l) The main LV Distribution switchboards shall provide the following functions:
i. Control of mains/generator supply auto-changeover, including mains and

generator automatically operated ACBs, supply monitoring and changeover
control system.
ii. Power distribution to services including building services DBs,
iii. DEWA metering
iv. Digital power monitor
m) As a minimum, the following protection shall be provided (for comprehensive
requirement refer to MV Switchboard section of this document):
i. Mains incomer: Combined over current and unrestricted earth fault IDMTL,
restricted earth fault and auxiliary trip from medium voltage protection
equipment (as required).
ii. Generator incomer: Combined over current and unrestricted earth fault relay.
iii. Main MCC feeders: Combined over current and unrestricted earth fault relay.
iv. Services distribution and spare feeders: Combined over current and unrestricted
earth fault relay
18.5.2.1 Ratings
a) Low-voltage switchgear and controlgear assemblies shall be rated on the basis of

voltage, current, frequency and the symmetrical breaking capacity of incorporated LV
automatic switching devices as defined in appropriate IEC publication.
b) For standard voltages, frequencies and currents reference is made to IEC 60038 and
60059.
c) Low voltage, current-carrying components shall furthermore be capable of carrying

their rated current continuously at rated voltage and under specified service conditions
without exceeding the permissible temperature limits when mounted in the completely
assembled boards.
d) Unless otherwise specified the switch board shall be natural air cooled.
18.5.2.2 System Variation
a) All equipment and components of the Low-voltage switchgear and controlgear

assemblies shall be capable of continuous operation at their full current and voltage
ratings and without detriment or malfunction at system continuous deviation of up to
and including the following percentages of the normal values.
i. Voltage ± 10%
ii. Frequency ± 5%
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stresses resulting from prospective short-circuit currents without damage or injury of
personnel.
18.5.2.4 Temperature Rise
The temperature rise of the Low-voltage switchgear and controlgear assemblies shall
not exceed temperatures indicated in IEC 60947 part 1 and part 2.
18.5.3.1 Housing / Enclosure
a) All LV switchgear (less than 1000vac) and control gear shall be constructed in
accordance with the following standards:
i. IEC 61439 LV switchgear and controlgear assemblies.

ii. IEC 60947 LV switchgear and controlgear.
iii. BS 1432:1987 Copper for electrical purposes.

b) The enclosure / panel shall be with internal form of separations according to IEC 61439
Form 4, type 6.
c) Busbar compartment shall be fitted with a removable cover, the removal of which
necessitates the use of a tool. A warning label shall be provided on each such cover.
d) Compartment containing a functional unit shall be fitted with a door which can be
opened only after all live parts above 50 V rms ac or 50 V dc have been disconnected
from the supply. The switch disconnector should also be provided with auxiliary
contacts to disconnect any control voltages sourced external to the starter remaining
energized (e.g. from duty standby changeover circuits). This is with the exception of
24Vdc control supplies to the auto control interposing relays.
e) It shall be possible to padlock the switch-disconnector in the open position to prevent

operation during maintenance of external apparatus.
f) The degree of protection for low voltage assemblies for location in purpose designed
switch room with controlled environment shall have a minimum degree of protection of
IP54 to IEC 60529. For outdoor location the degree of protection shall not be less than
IPW55.
g) All internal components shall be mounted on removable steel mounting boards which
shall be finished in the same manner as the rest of the switchboard. The components
shall be laid out neatly on the mounting board and labelled, allowing sufficient space for
the interconnection cabling terminations and cable containment. Cable boxes, gland
plates and terminations shall be arranged to facilitate easy access for installation and
connection of cables and cable circuit testing.
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h) Cable gland plates shall be manufactured from sheet steel for multicore cables and
non-ferrous metal for single core cables. Gland plates shall be mounted to provide a
minimum of 300mm straight cable length below the gland to facilitate installation.
i) All switchboards and MCCs shall be arranged for bottom cable entry only, unless
otherwise specified.
j) Adequate space shall be provided for the termination of oversize cable conductors and
multiple terminals shall be provided where circuits require parallel connected cables.
k) The enclosure shall be manufactured from steel sheet of minimum thickness 2 mm,
folded and welded to form a robust and rigid structure. Over-lapping surfaces of the
sheet shall be completely sealed by welding and all welds that are visible when covers
are in place shall be ground flush to give a neat appearance.
l) Alternatively overlapping surfaces after coating may be joined by non-corrodible rivets,

which shall not be visible, when covers are in place.
m) The finish should also be to a standard colour finish agreed with the Engineer or
otherwise specified, and shall be applied to all LV switchgear, control panels, PLC /
RTU panels and motor control centres throughout the installation.
n) Each transport unit shall be provided with roof eyebolts for lifting. Lifting eyes shall be
removable and replaced with bolts after installation.
o) Unless otherwise approved, floor-mounting enclosures shall not exceed 2500mm in

height including plinth and Busbar enclosure.
p) Where two or more enclosures are fitted together, they shall form a flush fronted
continuous suite of uniform height.
q) Switch and motor starter enclosures shall be logically grouped to reflect, as far as
possible, the process with which they are associated.
r) Unless otherwise approved, instruments and meters, relays, control devices and
indicator lights shall be mounted not less than 300mm and not greater than 2100mm
above finished floor level.
s) Front of panel mounted components shall be arranged in a neat, functional and logical
manner and shall be mounted flush with the front of the enclosure.
t) Indicating instruments controls and relays mounted on different enclosures but having
similar functions shall, where practical, be located in a physically similar position.
18.5.3.2 Access
a) The arrangement of equipment within enclosures shall permit easy access for
installation and maintenance. All switchboards and motor control centres shall be
designed and installed so as to provide full front, side and rear access.
b) Access from the front of an enclosure shall be through a hinged door or, for
withdrawable apparatus, by removal of the withdrawable unit. Enclosure doors and
withdrawable units shall be lockable in the service position.
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c) All equipment required for the safe removal and return of the withdrawable equipment
shall be provided. This shall include trolley units for transporting a withdrawable unit
and lifting facilities where the unit weight exceeds the manual lifting regulations.
d) Where rear access is required for maintenance of operational equipment and

components, lockable lift-off hinged doors shall be provided. The hinges of lift-off
doors shall be designed so that one shank engages before the other for ease of fitting.
e) Access to other switchgear compartments containing busbars and similar primary

power conductors shall be by bolted cover plates.
f) Front access doors shall open at least 120o and shall be fitted with a numbered locking
handle or handles with three keys. Locking combinations requiring different keys shall
be approved before manufacture. Doors shall be secured to ensure firm pressure on
the seal around the whole periphery to maintain the units required IP rating.
18.5.3.3 Safety
a) Electrical equipment shall be designed and constructed to provide a safe working

arrangement for operational and maintenance personnel.
b) Where access to low voltage enclosures is necessary with equipment energized from
an external source, all such equipment and terminals shall be shrouded to prevent
accidental contact and warning labels shall be fitted. Shrouds shall have a minimum
degree of protection IP30.
c) Covers fitted to enclosures in which live conductors are installed shall be fitted with a
warning label.
d) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements.
e) Integral Switchboard shall permit safe access to fuse carriers and miniature circuit
breakers without the need for isolation. All live connections when fuse carriers and
plug-in type miniature circuit breakers are removed shall be fully shrouded.
18.5.3.4 Earthing
a) Low voltage assemblies shall be provided with a continuous earth busbar that shall
extend over the full length of the assembly. Each cubicle shall be bonded to the earth
busbar.
b) The earth busbar shall be installed in a manner to provide unrestricted access. The
earth busbar shall be provided with two terminal assemblies for connection to the
electrical system main earth terminal.
c) All steelwork parts shall be equi-potentially bonded. A positive earth connection shall
be provided to all enclosure doors, removable gland plates and removable covers via a
welded stud not less than 8mm. Earthing via the door hinge shall not be provided as an
earth connection.
d) A removable connection shall be provided between the main neutral busbar and the
earthing busbar (TN-S distribution system). This connection shall be located in the
incoming panel
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18.5.3.5 Busbars and Busbar Connections
a) Busbars and busbar connections shall be of hard drawn high conductivity tinplated
electrolytic copper correctly rated for the specified voltage, short-time current and
frequency and insulation level.
b) Insulated coloured busbars are preferred. Busbars shall be suitable for extension to the
left or to the right as required.
c) Busbars shall be accessible for maintenance purposes, etc.
d) Busbars and busbar connections shall form part of a fully type-tested assembly and
shall comply with the performance criteria given in IEC 61439-1.
e) Busbars & primary conductors shall be tinned copper hard drawn, high conductivity
99.9% purity. Moulded PVC shrouds shall be provided over joints. Expose edges of the
busbars due to cutting shall tin re-coated. Busbars shall be continuously rated for an
ambient temperature of 50oC. The busbars shall be rated at 50 or 65 kA for 1 second
depending upon the rating of upstream transformer. Throughout the length of the board
the busbars shall be of uniform cross sectional. The busbar joints are to be made by
means of bolts and nuts with spring washers’ type DIN 6796
f) Busbars and primary conductors shall be contained in segregated compartments

accessed only by bolted removable cover plates.
g) Busbars shall be colour coded at each switchboard section access point using shrink
wrap sleeve.
h) Busbar supports shall be resin monoblock mouldings or similar approved.
i) Busbars and busbar connection arrangements shall have been type tested by an
independent testing authority to verify thermal, dielectric and short-circuit withstand
performance.
j) Busbar and busbar connection systems whose performance cannot be verified will not
be accepted.
k) Low voltage assemblies rated at 160A or below may be manufactured without a type
tested busbar assembly where the assembly has a maximum of eight outgoing circuits.
In this case, the internal distribution shall be provided by a suitably fault rated
distribution block and internally cabled feeder cables. In this arrangement, feeder
cables shall be segregated from outgoing circuits.
18.5.3.6 Internal Wiring
a) Power wiring (400V, 230V) shall be a minimum of 2.5mm² cross section, single or multi
core, stranded or flexible conductors and insulation grade 1000V, in accordance with
BS 6231. Power wiring shall be sized according to the maximum anticipated current
demand for the relevant power circuit.
b) Control wiring (230V, 24V) shall be a minimum of 1.0mm² tinned electrolytic annealed
copper stranded conductor, insulation grade 600V, in accordance with BS 6231).
Control wiring shall be sized according to the maximum anticipated current demand for
the relevant control circuit.
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c) Signal wiring (4-20mA, RS232/485) shall be a minimum of 1.0mm² tinned electrolytic
annealed copper stranded conductors and overall screen, suitable for the signalling
application as recommended by the manufactures of the signalling equipment.
d) Wire selection shall be determined so as not to exceed the recommended insulation

operating temperatures under the prevailing ambient temperature and load current
conditions.
e) Internal wiring shall be colour identified as follows:
i. Power wiring (400V, 230V)

red, yellow, blue or all black with red,
Phases of AC power circuits
yellow, blue sleeves at wire ends
Neutral of AC power circuits black
Protective earth conductor green/yellow
ii. Control wiring (230V, 48, 24V)

AC control circuits Grey
DC control circuit White
Alarm and volt free indication circuits White
Circuits interconnecting components between

Orange
different panel compartments
Telemetry Connections Violet

iii. Signal wiring (4-20mA, RS232/485)

Outer sheath screened twisted pair tinned
electrolytic annealed copper stranded grey
conductor
Inner cores of twisted pair or other signal
(As signalling standard)
cable
Inner cores of twisted pair for 4-20ma circuits Red (positive) / black (negative)
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f) All wiring shall be installed in a neat systematic manner in plastic cable. Trunking shall
be routed to ensure component access is not impeded.
g) Each cable or wire shall be fitted with a full ring interlocking type identification ferrule at
each end. The numbering shall read left to right on vertical terminal banks and bottom
to top on horizontal terminal banks. All terminals should be fitted with numbered labels
for identification. The wiring identification shall correspond with the wiring diagram.
h) Where wiring passes through metalwork the access hole shall be fitted with a suitable
grommet.
i) At enclosure break points, interposing terminal blocks shall not be provided each side
of the break.
j) Wiring on to hinged doors or plates that are subject to movement shall be run in helical
binding and shall be supported securely at both ends of the moving section.
k) Wiring associated with instrumentation and electronic equipment that could be affected
by power frequency interference shall be screened and/or physically segregated.
l) Crimped-on type terminal connectors shall be fitted to all cable and wire ends. These
shall be fitted using suitably sized ratchet operated (or hydraulic for large power cables)
crimping tools. Hand compression crimping pliers or other hand tools shall not be
used.
m) Cable trunking, tray and other supports for accommodating and supporting switchboard
and control board wiring, shall be fixed by means of screw fasteners to the board
structure; fixing by adhesive will not be permitted.
18.5.3.7 Labelling
a) Labels shall be colourless transparent plastic materials not less than 3 mm thick with
bevelled edges to half the thickness. Each shall be reverse engraved in Arabic and
English the engraving being filled white and the reverse side painted blue unless
otherwise detailed. Main labels shall be provided as detailed and subsidiary labels are
provided for each item on the face of the board, stating what it indicates or controls.
Any item, which is not isolated at the board, shall, in addition, be provided with a
warning label "Danger Live Terminals Isolate Before Maintenance" with flash and
voltage in red letters on white background in Arabic and English.
b) A drawing giving label sizes and a list of inscriptions shall be submitted to the
Employer’s Personnel for approval before manufacture. All labels shall be fixed before
the panel can be energized.
c) All external labels shall be affixed with chrome-plated nuts and bolts with slotted holes
to allow for expansion of the label. All internal labels shall be engraved multi-layered
plastic to an approved design affixed with chrome-plated nuts and bolts or a permanent
adhesive.
d) The switchboard shall have, at regular intervals along its length, external warning
labels in accordance with BS 5378 Part E1. The inscription shall be formed in black
characters on a yellow background.
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e) A data rating plate of a durable and easy to read nature shall be fixed in a prominent
position on each switchboard giving the following information:
i. Manufacturer’s name, and country of origin

ii. Equipment type (e.g. FORM 4 DISTRIBUTION SWITCHBOARD AND MOTOR
CONTROL CENTRE)
iii. Details of system voltage, phases, wires and frequency (e.g. 400 VOLT 3
PHASE 4 WIRE 50 HERTZ), Rated fault current (e.g. 65 kA 1 SEC), Busbar
rating (e.g. 1600 AMP), Year of manufacture (e.g. 2012), Manufacturer’s serial
number (e.g. ABC123).
f) Each compartment door shall carry an engraved label, with a minimum letter height of
4mm giving the equipment tag reference and duty (e.g. PMP–003, STORM PUMP
No.3) and shall state the full load current of the motor.
g) Each control switch, pushbutton and indicator shall be identified local to the device by
its duty (e.g. HAND/OFF/AUTO, START and RUNNING).
h) All internal components shall each be identified with permanent plastic (black and
white) labels, with a minimum letter height of 4mm, attached to a non-removable part of
the panel. The identification on these labels shall directly relate to a relevant reference
on the appropriate schematic diagram.
i) Where Switchboard are provided, each board shall include a rectangular circuit chart
either laminated or enclosed in a transparent protective cover attached to the inside of
the relevant door, showing the following information:
i. Designated number of each way.

ii. Circuit reference.
iii. Rating of the protective device.
iv. Circuit description.
j) All circuit information provided on circuit charts shall be typed or of a permanent
typeface. Handwritten circuit cards shall not be provided at any project stage.
k) All equipment not isolated by the main incoming switch, or relevant compartment
incoming switch, shall be shrouded and identified by a warning label with black
characters on a yellow background and entitled “DANGER 400V-ISOLATE
ELSEWHERE” (referring to relevant voltage) and the location of the isolating device.
l) All keys supplied for the equipment shall include engraved identification discs of a
durable material. The discs shall be engraved with the associated equipment
identification number or title.
18.5.3.8 LV Motor Starters
a) LV Motor starters shall be of intelligent type and shall be of the combination as defined
in IEC 60947: Part 4. Theses shall generally comprise:
i. Motor duty type Moulded Case Circuit Breakers / Air Circuit Breakers with
magnetic trip unit with adjustable threshold
ii. AC contactor
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iii. Digital Motor protection Relay
b) The rated operational current of the starter (Ie) shall be not less than the full-load
current of the motor. The starter shall be rated for un-interruptible duty.
c) Short-circuit co-ordination of the combination shall be Type 2 fully coordinated as

defined in Clause 7.2.5 of IEC 60947-4-1 for a prospective short-circuit current not less
than the value determined by the Contractor’s electrical system design.
d) The features of intelligent starters shall be fully utilized by employing bus system to
convey all parameters to PLC/SCADA controller for motor control and monitoring.
e) Flexible and modular motor management system for low-voltage motors shall be
provided. The system shall be connected with higher level automation systems via
PROFIBUS DP or other approved protocol by engineer. The motor management
system should provide the protection, monitoring and control functions for every motor
feeder. The motor management system shall provide a high degree of detail on the
status and performance of each motor component. The information of actual motor
current, motor direction, phase status and overload status shall be displayed on a
simple-to-read graphic display on an ICA panel HMI.
f) In the event communication to the PLC/SCADA controller is disrupted, the motor

should run locally. The motor management system shall execute its own logic
internally, making local control of the motors possible as a back-up solution for failsafe
requirement of the operation. Sufficient number of on board I/O shall be provided to
allow direct connection and monitoring of local field devices.
g) Thermal overload relays shall be Type 3c as defined in Clause 4.7.2 of IEC 60947-4-1.
Time current characteristics shall be supplied by the Manufacturer on 28 mm x 56 mm
logarithmic decades. These curves shall have a tolerance not exceeding + 10%.
h) Starters shall be suitable for both automatic and non-automatic methods of control.
When opening by overload relay involves energising an auxiliary relay from the control
supply, the pick-up voltage of this auxiliary relay shall be below the drop-out voltage of
the contactor.
i) Motor starter control circuits shall be 230Vac, derived from an individual integral starter
control transformer (isolating).
j) Where assisted start motor starters are required in order to reduce motor starting
currents, these shall be as follows:-
i. Electronic soft starters (motors including and more than 5kW).

ii. Variable speed drive (determined by process requirements).
k) Assisted soft start operation shall be automatic with integral contactor bypass.
Assisted soft start shall be selected in order to provide 120% of the required duty of the
equipment to be controlled, under conditions of continuous running.
l) All electronic boards of soft starters shall be conformal coating. Conformal coatings
shall be 1-2 mm. thick polymeric films that cover or encapsulate printed circuit
assemblies and connectors, which shall protect the assemblies from airborne
contaminants and corrosion by sealing out the contaminants and humidity. The
conformal coating shall meets or exceeds the following standards:
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i. ANSI/ISA-S71.04-1985, Class G3 environments
ii. IEC 60654-4 Class 1 and 2 environments
iii. UL746E
m) Contactors shall be provided with auxiliary contacts to provide all required control
signalling functions and shall be provided with two additional spare normally open and
two spare normally closed contacts.
n) The operating mechanism of the fuse combination unit shall be mounted on the front of
the cubicle, operated by a pistol grip type handle. The mechanism shall be interlocked
with the door to prevent opening when in the on position. The mechanism shall be pad
lockable in the off position.
o) Each intelligent starter shall be provided with the following controls and indications as a
minimum:-
i. Door interlocked breaker.

ii. Intelligent Overload Keypad
iii. Running/stopped Lamp
iv. Interlock healthy Lamp
v. 2 no. Fault Lamps
vi. Local /Manual Selection/lamp
vii. Emergency Stop Healthy Lamp
viii. Trips rest pushbutton
ix. Lamp test pushbutton.
x. Auto control via the control system.
xi. Ammeter with selector switch
xii. Hour run meter
xiii. Emergency stop push button
p) All control signals to the PLC/SCADA controller shall be via the control bus link.
q) Each starter shall be provided with a test facility which shall energise the control circuit
when operated. The test switch shall be arranged to automatically release when the
starter door is closed. The test facility shall enable the control circuits to be operated
for testing purposes with the main motor circuit isolated.
r) Each starter shall be provided with the facility to disconnect the main feeder breaker of
the starter via a remote emergency stop pushbutton. Where such push button is not
installed connection facility shall still be provided, but linked out. All emergency stop
operations shall require resetting of the breaker.
s) Each starter shall be provided with the facility to disconnect the controls via a remote
early break contact on an isolator located adjacent to the motor.
t) Where a motor is supplied with auxiliary protective devices (e.g. thermistor protection
or moisture protection), the protective relays and associated controls shall be
incorporated into the design of the starter.
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u) Submersible motor starters shall have control unit supplied by the manufacturer to
provide protection against moisture, high winding temperature, etc.
v) Where a motor is supplied with an anti-condensation heater, an on/off switch shall be

provided on the front of the starter to isolate the heater. The heater shall be switched
via an auxiliary contact on the main contactor operating so that the heater is energised
whenever the motor is off.
18.5.3.9 Variable Speed Inverter Drives
a) The VSD shall be designed to have a site rating at least 20% above the installed motor
nameplate rating at 40oC. It is to be noted that the motor which are to be supplied
under this contract shall be de-rated for 50oC ambient.
b) VSD system efficiency shall be a minimum of 96% at 100% speed & 100% load.
System efficiency shall include VSD, input transformer or line reactor, harmonic filter
output filter and DC choke. Control power supplies, control circuits, cooling fans or
pumps, shall be included in all loss calculations.
c) The VSD shall be of a well tested and proven design which ensures maximum safety to
personnel, maximum service reliability and economic operation for an operational
lifetime of at least 20 years.
d) The VSD shall be capable of maintaining a minimum true power factor (Displacement
P.F. X Distortion P.F.) of .98 from 30-100% load.
e) All electronic boards of Variable speed inverter drives shall be conformal coating.
Conformal coatings shall be 1-2 mm. thick polymeric films that cover or encapsulate
printed circuit assemblies and connectors, which shall protect the assemblies from
airborne contaminants and corrosion by sealing out the contaminants and humidity.
The conformal coating shall meets or exceeds the following standards:

iii. UL746E
f) The backup protection shall comprise an ultra-rapid semiconductor fuse and electronic
type overload relay.
g) The system should be provided with LOCAL/REMOTE-PC MODE, ON/OFF control by

key switch for local and remote/AUTO operation. All data shall be kept in non-volatile
memory to save them upon power failure conditions. Battery backed up memory is not
preferable. All drive parameters read out values shall be selectable on the
alphanumeric keyboard. Parameter setting should also be made possible on the panel
with password protection facility.
h) The VSD shall utilize sensor less direct vector control or full vector control, with pulse
tachometer feedback, for optimum performance of dry installed pump set.
i) The VSD system shall be designed for a Mean Time Between Failures (MTBF) of
100,000 hours.
j) The converter panel(s) shall form an integral part of the complete L.V. Board as far as
possible especially for smaller size converters.
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k) The converter sound pressure shall not exceed 80 dB (A), at any location 1 m distant
from the converter under any load and/or frequency condition within the operational
speed range of the VSD.
l) The system may include critical speeds which could include the following amongst
others
i. Minimum motor speed for flow to occur

ii. Minimum speed as specified by the motor supplier
iii. Maximum speed as specified by the motor supplier
m) The VSD shall be designed to run through the minimum critical speeds of the whole
system in the shortest time possible.
n) The drive control system shall be designed to ensure that the drive operates in a stable
manner under all operating conditions, including hydraulic conditions such as surges or
pump run-out.
o) The estimated total running up time shall be stated by the manufacturer at rated
voltage at the line terminals of the frequency converters. The pump & motor inertia
shall be estimated or be based on data given in IEC 60034-12, Table III.
p) The operation speed range of the VSD shall be 20-100% of the rated maximum speed.
q) The VSD shall have at least:
i. 120% Max. Rated torque for 10 sec. for starting and re-starting.
ii. 110% Max. Rated torque for 60 sec. for starting, re-starting and acceleration.
iii. During continuous operation, the VSD shall be capable of developing sufficient
torque under load conditions to respond to 20% alteration in set point within a
time of not more than 30 sec.
iv. The minimum time interval between set point changes will be not less than 30
sec.
r) Each drive shall be supplied with an operator keypad to provide access to the drive for
programming and manual control of the drive. The operator keypad shall be flush
mounted in the door of the inverter compartment so that it can be accessed without
opening the door or isolating the drive.
s) Other door mounted controls shall be provided as follows:-
i. Door interlocked MCCB / ACB.

ii. Running lamp.
iii. Stopped lamp.
iv. Available lamp.
v. Fault/tripped lamps as required.
vi. Hand/off/auto selector switch.
vii. Hours run meter.
viii. Stop and start manual pushbuttons.
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ix. Emergency stop pushbutton.
t) Manual speed control of each drive shall be selected via the operator keypad, not via a
separate panel mounted potentiometer.
u) The drives shall be installed in accordance with the manufacturer’s installation guides
and shall be provided with adequate cooling and ventilation to prevent the drive from
overheating during normal operation. The cooling fans shall be low noise type. They
should delay off upon stopping of the motor.
v) Cables from variable speed inverter drives to motors shall be earthed and screened as
necessary in accordance with the manufacturer’s recommendations for the specific
application.
w) The type/model of drive shall be selected in order to minimise the overall effects of
Harmonics in order that the site complies with the IEC 61000 / IEEE519 and /or the
requirements of DEWA. Where final installed Harmonics exceeds the standard either in
total Harmonic distortion or at any particular harmonic frequency, then the Contractor
shall install appropriate equipment to correct the deficit in order to comply with the
directive. Harmonic distortion shall be kept to a level such that both equipment and
cables suffer no harmful effects, overheating or incorrect operation.
x) All drives shall incorporate Radio Frequency filters. The rectifier device shall be IGBT
type. VSD shall comply with the latest edition of IEC 61800-3:2004 Harmonic
Guidelines. The VSD shall be PWM rectifier (Active Front End) with Selective Harmonic
Elimination and AC line reactor and harmonic filter.
y) LV drives shall be installed within an MCC enclosure and shall be supplied with the
following controls:
i. Motor duty type Moulded Case Circuit Breakers / Air Circuit Breakers with
magnetic trip unit with adjustable threshold
ii. Main AC contactor feeding the drive, to be energised when the drive is selected
for operational duty, either hand control or duty or standby auto modes and in
test mode
iii. Control circuits separately protected and isolated via MCBs.
iv. Ventilation for compartment shall be separately protected via an MCB.
v. Interposing control relays for remote operation as specified for LV motor
starters.
vi. Anti-condensation heater with controlling thermostat and separate MCB.
vii. Circuits for motor anti - condensation heater and motor protective devices.
viii. Test circuit for operation of the inverter under no load conditions, e.g. with the
motor disconnected.
z) The drives shall be programmed to incorporate the minimum and maximum speed
settings operable in auto and manual modes. These shall be set in accordance with
the appropriate hydraulic conditions and duty of the drive. In auto this shall be via field
bus communications.
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aa)Automatic control of the speed of the drive shall be via a 4-20mA signal from the
equipment control system. This shall operate over the selected speed range of the
drive.
bb)Protection shall be provided as follows:-
i. Short circuit and overcurrent protection equivalent to meet the requirements of

IEC 60947-4-2 Type 2 coordination.
ii. Phase failure and phase reversal protection.
iii. Over and under voltage.
iv. Earth fault protection as per DEWA requirement.
v. Output fault (e.g. Loss of phase, phase imbalance).
vi. Motor over temperature protection.
cc) All necessary signals shall be provided to connect to the equipment control system. As
a minimum the following shall be provided via field bus communications:-
i. Running/stopped.
i. Available for auto control.
ii. Fault.
iii. Run/stop interposing relay(s) 24Vdc.
iv. Protection interposing relay(s) 24Vdc.
v. Remote speed indication 4-20mA opto-isolated in the drive or compartment.
vi. Remote speed control 4-20mA from equipment control system.
18.5.3.10 Mimic Diagram
The front of the LV Switchboard shall be provided with a plastic or equivalent line mimic
diagram illustrating the main circuit and its components.
18.5.4 SWITCHGEAR AND MCC COMPONENTS
18.5.4.1 Low Voltage AC Contactors
a) Contactors shall be indoor air-break electro-magnetic mechanical switching devices

complying with the recommendations of the following standards:
i. IEC 60947-4-1 LV switchgear and Controlgear.

ii. BS 5424: Part 3 Contactors.

b) The number of poles shall be as required by the Contractor’s design or as specified in
the Particular Requirements. All contactors shall be rated for uninterrupted duty and
intermittent duty Class 12 with on-load factor of 60% and utilisation category AC-3.
c) The rated operational voltage (Ue) shall be not less than 400V ac and the rated
insulation voltage (Ui) shall be not less than 660V ac.
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d) The rated operational current (Ie) shall not be less than the rated operational current
(Ie) of the starter.
e) All contactors shall be of the block type designed for easy replacement of coils and
contacts. In the position of rest the contactor shall be in the open position and shall
give its rated performance in any mounting position. All terminals shall be accessible
from the front.
f) Contactors should be provided with auxiliary contacts to provide all control circuit
switching requirements.
g) Test certificates shall be supplied for the following type tests to IEC 60947-4-1.
i. Temperature-rise Limits (Sub-clause 8.3.3.3).

ii. Dielectric properties (Sub-clause 8.3.3.4).
iii. Operation and operating limits (Sub-clauses 8.3.3.1 and 8.3.3.2).
iv. Rated making and breaking capacities (Sub-clause 8.3.3.5).
v. Performance under short-circuit conditions (Sub-clause 8.3.4).
vi. Conventional operational performance (Sub-clause 8.3.3.6).
vii. Ability of contactors to withstand overload current (Sub-clause 8.3.5).
viii. Short-circuit tests shall be certified by ASTA, KEMA or PEHLA.
h) The following routine tests shall be carried out on all contactors to IEC-60947-4-1 and
test certificates shall be supplied:
i. Operation test (Sub-clause 8.3.6.2).

ii. Dielectric tests (Sub-clause 8.3.6.3).
18.5.4.2 Fuse-Combination Units for Motor Circuits
a) Fuse-combination units, comprising a combination of a switch-disconnector and a fuse-

switch, on ac motor circuits shall be indoor air-break mechanical switching devices
complying with IEC 60947-3.
b) The number of poles shall be as required by the Contractor’s design or as otherwise

specified.
c) The rated insulation voltage (Ui) shall be not less than 660 V ac and the rated
operational voltage (Ue) shall be not less than 400 V ac.
d) The rated operational power at 380 V for uninterrupted duty and utilisation category
AC-23B shall be not less than the motor rating. The rated thermal current (Ith) and the
corresponding (Ithe) with the equipment mounted in the control gear shall be entered in
the Technical Schedule.
e) The rated fused short-circuit current with the maximum rating of motor circuit fuse-link
listed in Clause E1.20 shall be adequate for the short-circuit conditions specified.
f) Independent manual operation shall be used for both closing and opening operations.
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g) All fixed contacts shall be shrouded to prevent accidental contact by maintenance
personnel.
h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.6, (IEC 60947-3). Test
8.3.6 shall be performed with the maximum rating of motor circuit fuse-link listed in
Clause E1.20 and shall be certified by ASTA, KEMA, PEHLA or other authority
approved by the Project Manager.
i) Routine tests listed in Clause 8.4 (BS EN 60947-3) shall be carried out on all
equipment and test certificates shall be supplied for all routine tests.
18.5.4.3 Fuse-Combination Units for Distribution Circuits
a) Fuse-combination units comprising a combination of a switch-disconnector and a fuse-

switch, on ac distribution circuits shall be indoor air-break mechanical switching
devices complying with IEC 60947-3.

specified.
operational voltage (Ue) shall be not less than 400V ac.
d) The rated operational current (Ie) for uninterrupted duty and utilisation category AC-
23B shall be required by the Contractors design or as otherwise specified. The rated
thermal current (Ith) and the corresponding (Ithe) with the equipment mounted in the
control gear shall be entered in the Technical Schedule.
e) The rated fused short-circuit current shall be adequate for the short-circuit conditions
specified.

personnel.
h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.6, (BS EN 60947-3).
Type test 8.3.6 shall be certified by ASTA, KEMA, PEHLA or other authority approved
by the Project Manager.
i) Routine tests listed in Clause 8.4 (IEC 60947-3) shall be carried out on all equipment
and test certificates shall be supplied for all routine tests.
18.5.4.4 Switch Disconnector
a) Switch-disconnector shall be indoor air-break mechanical switching devices complying

with IEC 60947-3.

specified.
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d) The rated operational power at 380 V for uninterrupted duty and utilisation category
AC-22B shall be as required by the Contractors design or as otherwise specified. The
rated thermal current (Ith) and the corresponding (Ithe) with the equipment mounted in
the switchgear shall be entered in the Technical Schedule.
e) The rated short-time withstand current and the rated short-circuit making capacity shall
be adequate for the short-circuit conditions specified.

personnel.
h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.5, (BS EN 60947-3).
Test 8.3.5 shall be certified by ASTA, KEMA, PEHLA or other authority approved by
the Project Manager.
i) Routine tests listed in Clause 8.4 (IEC 60947-3) shall be carried out on all equipment
and test certificates shall be supplied for all routine tests.
18.5.4.5 LV Fuses for AC Power and Control Circuits
a) All LV fuses for use on ac power circuits and directly connected control circuits shall be
of the general purpose type rated not less than 400 V and shall comply with IEC
60269:1999 for Low voltage fuses.
b) Motor circuit fuse links may have two current ratings: a continuous current rating and a
rating on which their time/current and cut-off characteristics are based (e.g. 100M160).
c) Fuse holders and bases used on motor circuits shall have a breaking capacity to match
the highest rating of motor circuit fuse link which can be accommodated.
d) Test certificates, for type tests in accordance with Clause 8 of BS EN 60269: Part 1
shall be supplied. Short-circuit tests shall be certified by ASTA, KEMA or PEHLA.
e) The preferred ratings for fuse links are as follows:
General Purpose
Fuse Link Motor Circuit Fuse Link
Fuse Link Rating Fuse Holder or
Dimensions Rating (gM)
(gG) Base Rating
Reference Amps
Amps
A2 2 up to 32 32M35 up to 32M63 32
A3 35 up to 63 63M80 up to 63M100 63
A4 80 up to 100 100M125 up to 100M200 100
B2 125 up to 200 200M250 up to 200M315 200
B3 250 up to 315 315M355 up to 315M400 315
C1 355 up to 400 400M500 450
C2 450 up to 630 630M670 630
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18.5.4.6 Low Voltage AC Circuit Breakers (Fault Level above 10 kA)
a) Circuit-breakers used on low voltage ac systems having a fault level in excess of 10 kA

shall be steel cassette mounted indoor trip-free air-break mechanical switching devices
complying with IEC 60947-2.
b) Circuit breakers shall be 3 pole or 4 pole as required by the application or as otherwise

specified.
d) Circuit breakers shall be of utilisation category B.
e) The rated current (In) and the rated service short-circuit breaking capacity (Ics) shall be
as required by the design or as otherwise specified.
f) The rated short time withstand current (Icw) in kA and the rated short time in seconds
shall be as required by the design or as otherwise specified.
g) The closing operation during switching shall be performed by one of the following
methods.
i. Independent manual closing

ii. Dependent power closing (solenoid energised from main circuit and a
removable lever solely for dependent manual mechanical operation).
iii. Stored energy closing (spring charged by electric motor and manual means with
both electric and manual release).

h) Circuit-breakers shall be fitted with manual opening release, either inverse time-delay
over current release and instantaneous short-circuit current release (direct or indirect)
or shunt opening release. Time current characteristics on 28 x 56 mm logarithmic
decades shall be supplied by the manufacturer and approved by the Project Manager.
The voltage for the shunt opening release shall be independent of the main circuit
voltage and, unless specified otherwise in the Particular Requirements, shall be 30V
dc.
i) Two auxiliary contacts of each kind (N/O and N/C) shall be provided for future use.
j) Circuit-breakers shall be designed to be maintained in accordance with BS 6423.

Operational performance capability of circuit breakers shall be in accordance with
Clause 7.2.4.2 of BS EN 60947-2.
k) Test certificates shall be supplied for type tests described in Clause 8.1.2 and Clause
8.1.3 of IEC 60947-2. Type tests to Clauses 8.3.4, 8.3.5 and 8.3.6 shall be certified by
ASTA, KEMA, PEHLA or other authority approved by the Project Manager.
l) Routine tests described in Clause 8.1 and Clause 8.4 of IEC 60947-2 shall be carried
out on all circuit breakers and test certificates shall be supplied.
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m) Factory testing of circuit breakers in switch and control gear shall include primary
injection testing of the protective relay/circuit breaker combination.
18.5.4.7 Indicating Instruments and Meters
a) Indicating instruments shall be of the industrial class. They shall be continuously rated,
heavy duty, flush mounted type, with black bezels and anti-reflex dial glass and shall
be to BS 89.
b) Ranges shall be selected to show normal equipment operation between 50% and 75%
of full scale deflection.
c) Instrument sizes shall be not less than 96x96 mm for incoming supply requirements
and not less than 72x72 mm for other instruments.
d) Compressed upper scale indicators shall be provided for motor starter current
indicators for motor starting purposes.
18.5.4.8 Indicating Lamps
a) Indicating lamps shall be 22.5mm diameter standard incorporating high intensity multi-
cluster light emitting diodes. Where necessary the assembly shall incorporate a
transformer. LED assemblies shall have a maximum operating voltage of 24V ac/dc in
control panel and 230Vac in motor starters and drives.
b) Filament type lamps of circular or rectangular pattern shall only be used where
specified for special purposes. Lamp voltage shall not exceed 24V ac/dc and the lamp
shall be replaceable from the front without the use of a tool.
c) Indicating lamps shall comply with IEC 60947, Part 5.
d) Indicating lamps shall be coloured in accordance with BS EN 60073. The lens

colouring shall be within the lens material and not in an applied coating and shall be
provided in accordance with the following table:
Indicator
Meaning Application
Colour
Danger electrical circuit Isolator or circuit breaker closed
Red energised, (unsafe to work on protective system energised
or enter equipment) (e.g. CO2 fire system)
Motor or pump running.
Green Equipment in normal operation
Valveopen
Caution (change of state from Equipment tripped. (Do not
Amber
normal operation) work on until made safe.)
Equipment available for control.
Motor or pump stopped,
White Information valve closed.
Isolator or circuit breaker open
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e) A test facility enabling all lamps and LEDs to be tested whilst the equipment is in
service and without affecting operation shall be provided. Lamp test shall be achieved
by incorporating ‘push to test’ action on each indicator or by providing a separate lamp
test pushbutton where the number of lamps on an enclosure door exceeds two. The
lamp test pushbutton shall be mounted on the same enclosure door as the lamps.
18.5.4.9 Pushbuttons
a) Pushbuttons shall comply with IEC 60947: Part 5. Unless otherwise specified, colours
of the buttons shall comply with IEC 60073.
b) Pushbuttons shall be flush mounted and have normally closed and normally open
contacts as required and shall be coloured as follows:-
Pushbutton Colour Application

Black Lamp test or circuit test
Blue Reset
Green Close or start
Red Open or Stop or emergency stop
Yellow Alarm accept
Blue others as required (inc. process control)
c) Emergency stop pushbuttons shall be of the latched type with quarter turn release and
shall be of the mushroom head type. Emergency stop pushbuttons shall be connected
in control circuits so they are effective under all equipment operating conditions.
Resetting of the pushbutton shall not automatically re-energise the isolated equipment.
18.5.4.10 Terminal Blocks
a) Terminal blocks shall be of the shrouded DIN rail mounted type. Terminal mouldings
shall be in polyamide 6.6 or equivalent approved non-brittle material.
b) Terminals shall be of the pillar indirect pressure type compliant with IEC 60947, Part 7.
Screw less terminals will not be accepted.
c) DIN mounting rails shall be of zinc coated and yellow passivated steel channels. The
same style of DIN rail shall be used across the site.
d) At least 20% spare terminals shall be provided at all blocks.
e) No more than one conductor may be connected to one side of a terminal. Where
duplication of terminal connection is required, multiple solid bridge linked terminals
shall be provided.
18.5.4.11 Control and Selector Switches
a) Manually operated control and selector switches for equipment control and circuit
selection purposes shall conform to IEC 60947, Part 5.
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b) Control and selector switches shall have a rotary action. All switch positions and
functions shall be clearly labelled.
c) Contacts of all switches shall be shrouded.
18.5.4.12 Anti Condensation Heaters
a) Unless otherwise specified, each switchboard and control gear panel and circuit
compartment shall be provided with an anti-condensation heater. Alternatively, low
voltage multi-compartmented switchgear may be provided with a common heater
located at the base of each panel if appropriate to the manufacturer’s standard design,
and providing there is adequate means of internal conduction.
b) Heaters shall be mounted as low as possible in enclosures and panels. Heaters shall
be located to ensure free air flow over the heating element and to have no detrimental
effect on temperature sensitive devices or adjacent cabling.
c) Heaters shall be fitted with a safety guard the surface temperature of which shall not
exceed 60°C.
d) Heaters shall be rated to ensure condensation does not occur under the ambient air
temperature and relative humidity conditions prevailing at the location where
enclosures and panels are installed.
e) Individual panel heaters shall be complete with protective device, ON/OFF switch and
thermostat.
f) Heater circuits not isolated by the enclosure switch-disconnector shall have all live
terminals fully shrouded and a warning label fitted.
18.5.4.13 Current Transformers
a) Current transformers shall comply with IEC 60044 and shall be of the wound primary or
ring type as dictated by output, accuracy, short-time current and space considerations.
b) Unless otherwise specified, the rated insulation level shall be as the associated
switchgear, the accuracy class shall be 1.0 for metering, 3.0 for indicating instruments
and 5P for protection.
c) The rated secondary current, rated output, accuracy limit factor for protection
application, and frequency shall be as required for the application. The accuracy class
and excitation characteristics of protection circuit current transformers for differential
and zoned earth fault protection shall be that required to provide protection system
performance and operational stability for power system through fault and switching load
conditions.
d) The secondary winding(s) of each current transformer or of each set of star-connected

three phase current transformers shall be earthed at one point only, via a bolted link.
The link shall be located in the instrument wiring chamber.
e) Separate current transformers shall be used for metering and protection. Indicating
instruments may be supplied from current transformers associated with non-unit
protection.
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f) Multi-ratio current transformer tappings shall be connected to link-boards located in the
instrument wiring chamber. Connection options shall be clearly labelled.
g) Ring type current transformers shall be fixed to prevent movement under normal
service and through-fault conditions, and shall be easily removed.
18.5.4.14 Protection Relays
a) Protection relays shall be mounted on the front of the switchgear or relay panel in such
a position that operation and maintenance can be conveniently carried out. Auxiliary
relays may be mounted internally and shall be located to be readily accessible.
b) Protection relays shall be contained in a dust proof case with a clear front cover
providing a minimum protection classification IP52 to IEC 60529.
c) Relays shall have provision for testing the operation and calibration without
disconnecting the permanent wiring by integral or separately mounted plug-in test
terminal assemblies.
d) Relays shall be flush, solid state type. Each relay shall have an indicator device to
show the relay has operated and its specific operating function. Each indicator shall be
hand resettable. Resetting devices shall not require the removal or opening of the
relay. It shall not be possible to operate or adjust the relay settings without opening the
case.
e) Protection relays shall be of the solid state module pattern.
f) Multiple function modular relays shall incorporate plug board or similar approved
function and characteristic changing devices.
g) All relay protection elements shall have controls for protection set point and time setting
adjustment. Relay characteristics, functions and settings shall be clearly indicated on
the relay element front plate.
h) Protection relays shall comply with IEC 60255-21.
18.5.4.15 Control Relays
a) Relays for switchgear applications shall be selected from a range of standard industrial
control devices dependent on size, current capacity and duty. They shall conform to
IEC 60255.
b) Relays for general applications, shall be of the 8, 11, or 14 pin plug in type. They shall
have break before make contacts, and clear indication of the operational status.
Appropriate DIN rail mounted bases shall be provided for connection, complete with
proprietary retaining clips.
c) The operating mechanism shall give consistent results under fluctuating voltage
conditions with “pull in” and “dropout” parameters as follows:-
i. Pull in - by 85% of nominal voltage.

ii. Drop out - less than 60% nominal voltage.
d) Relay coils shall be continuously rated, and capable of sustaining a voltage 10% in
excess of nominal voltage without reduction in life.
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18.5.4.16 Residual Current Circuit Breakers
a) Residual Current Circuit Breakers shall comply with IEC 61008-1 and IEC 61008-2.
b) Residual Current Circuit Breakers shall be double pole for single phase and four pole
for three phase and neutral circuits.
c) RCCBs shall include provision for testing the residual current tripping function with a
test pushbutton and manual reset.
18.5.4.17 Power Monitoring Device
a) Microprocessor based power monitoring device should be provided and the same shall
be connected onto an open communications bus back to the PLC/SCADA controller.
b) The Power monitor should provide numerous display measurements and programming
characteristics.
i. Current (Per Phase, Neutral, Average, Positive, Negative Sequence & Percent
Current Unbalance)
ii. Voltage (Per Phase, Neutral, Average, Positive, Negative Sequence & Percent
Voltage Unbalance
iii. Phase Rotation
iv. Frequency in Hz
v. Power ( kW, KVAR, KVA & kWh)
vi. Power Factor (True ,Displacement, Distortion PF)
c) It shall be possible to configure and monitor the power monitor through an in-built
keypad as well as through the communication Network. It should be possible to provide
password interlock to protect from the unauthorized users.
18.6 DISTRIBUTION TRANSFORMERS
a) The transformer shall be of a standard, well tested and proven design which ensures
maximum safety to personnel, maximum service reliability and economic operation for
their operational lifetime. Design and construction shall be simple and shall provide
good accessibility to components and parts.
b) Further to the international standards, transformers shall in any case conform to the
local standards (DEWA), if these are higher, more stringent or of special nature and
shall be previously approved by DEWA.
c) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements.
d) All components utilised in the construction of distribution transformer shall be of the

latest design, new and in current production. Materials and equipment shall be
approved by the appropriate authority where applicable.
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e) In case Transformer terminal box is provided with Current Transformers then relevant
IEC standard for Current Transformer is also applicable.
f) The transformers supplying Variable Speed Drives shall be of convertor duty

transformer. These transformers shall be design, manufactured and tested in
accordance with the following standard.
i. IEC 61378-1: 1997, Converter transformers, Part 1, Convertor transformers -

Part 1: Transformers for industrial applications
ii. IEEE Std, C57.18.10-1998, Practices for Semiconductor Power Rectifier
Transformers
g) In case standard distribution transformers are used for special convertor applications,
all applicable de-rating should be applied.
h) Transformers feeding frequency converters shall be provided with static screening to

suppress the radio frequency interference (RFI).
i) Unless otherwise specified the transformer shall be suitable for indoor installation.
Ventilation requirement for indoor installation of oil immersed sealed / dry type
transformers shall be specified by the manufacturer.
a) Transformers kVA and voltage rating shall comply with the preferred values of the
standards specified. Unless otherwise specifically stated to the contrary the rated kVA
shall be based on natural air cooling. Voltage insulation of windings shall be for
unearthed system.
b) The nominal primary voltage shall be 30kV or 11kV, 50Hz and the highest voltage for
equipment shall be 36KV or 12kV.
c) The nominal secondary voltage shall be 6.6KV or 3.3KV or 400/230V, 50Hz. The
neutral point shall be earthed.
d) The normal voltage ratio of the transformers at principal tapping shall be 11000/400
Volts / 11000/3300 Volts / 11000/6600 Volts or 30000/400 Volts / 30000/3300 Volts /
30000/6600 Volts.
e) For oil immersed sealed and dry type transformers, manufacturer shall indicate the
base rating of the transformer for operation in an ambient of 40ºC and furnish the
de-rating factors for equipment rating at 50ºC ambient temperatures.
f) The short circuit impedance shall be strictly in compliance with the DEWA standard
specification and requirements. The tolerance shall be ±10.0% of the declared value at
principal tapping and ±15.0% of the declared value at other tappings.
g) Temperature rise of the oil immersed sealed type transformers shall not exceed the
values specified by DEWA, when operating continuously at the maximum kVA ratings,
at the rated voltage, frequency and climatic/installation specified conditions.
h) The primary winding connection shall be Δ connection (3-phase 3-wire) and the
secondary winding connection shall be Y (3-phase 4-wire) connection. Unless
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otherwise specified or required by the electrical system design the Vector group shall
be Dyn11.
i) All transformers with their accessories shall be designed and manufactured to reduce
noise pressure and vibration to acceptable level. The average surface noise pressure
level of transformers shall not exceed the values specified in DEWA standard
specification or IEC. The transformer shall be subjected to sound level measurement
as per IEC 60076-10.
a) Transformer core shall be of robust design adequately braced to prevent displacement

due to electromagnetic stresses of short circuits, and the mechanical shocks of normal
moving and handling of the transformer without any need for special shipping braces.
b) The core shall be constructed of the best quality low loss; cold-rolled grain oriented
steel laminations conforming to the latest edition of IEC 60404. The core shall be
assembled in a manner which reduces vibration and minimize inherent noise. Both
sides of individual stampings shall be coated with an insulating material which shall be
resistant against oil and temperature. The complete core shall be effectively earthed.
c) The core laminations shall be evenly secured to prevent settling of the core and
minimize noise and vibration when transformer is in operation.
d) The flux density in any part of the core shall not exceed 1.72 Tesla at nominal voltage
and frequency. Thickness of a lamination shall not exceed 0.3mm (M5).
e) The core plates shall be insulated from one another to minimize the core loss and the
core shall be held together by bolts and clamping plates all of which shall be
adequately insulated. The completed core and winding assembly shall be provided with
lifting eyes to facilitate its removal from the transformer tank and shall be adequately
braced and supported to prevent movement during transit or service.
f) The core construction shall be such that removal and replacement of the coils would
require the removal of minimum possible number of core laminations.
18.6.3.2 Tank or Enclosure
a) For oil immersed sealed type transformers the tank, cover, radiators and any
other attached compartments, shall be rigid steel construction.
b) Radiator tubes or fins shall be so arranged that external cleaning and repainting can be
carried out at site without dismantling.
c) For sealed type transformers the tank cover shall be welded with continuous joint.
Bolted connection with tack-welded bolts is not acceptable. After filling the tank with oil
the filling orifice shall be permanently sealed in a tamperproof manner.
d) The tank cover, radiators etc. shall have adequate strength to withstand without
deformation due to the internal pressure of the oil, air and gas under operation
conditions.
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e) Pressure relief valves, when specified, shall be fitted and set to operate at static
pressure of less than the hydraulic test pressure of the tank.
f) There shall be an oil level mark inside the tank that indicates proper oil level at 30°C of
ambient temperature.
g) The transformer undercarriage shall be provided with bi-directional rollers to allow

longitudinal and transverse movement on flat surfaces.
18.6.3.3 Tank finish
a) The painting process of steel parts shall ensure that no corrosion takes place under.
The painting process of steel parts shall ensure that no corrosion takes place under
severe climatic conditions prevailing in Dubai. Prior to the painting of the tank and the
cover shall be sand-blasted or shot-blasted for removal of mill and welding scale. The
painting shall be made with a single coat of one-pack epoxy paint. The finishing paint
shall be made with two or three coats.
b) The primer coat shall contain rust inhibitor, both oil and heat resistant. Secondary coats
shall contain resistant components of salt spray, chemicals and humidity.
c) Minimum thickness of coats shall not less than average 60μm and shall not less than
80% at any point. The outside colour of the tank shall be painted in grey.
18.6.3.4 Gaskets
All the gaskets used for sealing the tanks and connected external parts shall be made
of NBR (Nitrile (Acrylonitrile) Butadiene Rubber) or better that totally prevents the
leakage of oil and ingress of humidity and air to the oil and windings under all operating
conditions. The minimum thickness shall be 6mm. The gaskets shall not have any joint
and shall withstand insulation oil. It shall not have variation of characteristics caused by
temperature variation.
18.6.3.5 Windings
a) The windings shall be made of best soft drawn copper having high conductivity and
complying with the requirements of the latest edition of IEC 60228. The windings shall
be designed to meet the three fundamental requirements: mechanical, thermal and
electrical.
b) The windings shall be capable of sustaining short circuit forces.
c) All windings shall be fully insulated according to IEC 60076 for standard insulation level
and for a system highest voltage of 36KV or 12kV. And windings shall be wound with
adequate bracing and securing tapes in order to achieve a strong, self supporting
structure. Adequate cooling ducts shall be provided to ensure that temperature rise is
within the permissible limits at normal operating conditions.
d) The HV and LV windings shall be separated without difficulty for replacing each
winding.
e) The neutral point of star connected windings shall be brought out separately to a
terminal on the respective winding side.
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f) The winding coils shall be adequately braced to prevent distortion of the windings or
movement of the coils on the core limbs under short circuit condition or normal moving
and handling of the transformer.
g) All windings shall be fully insulated and the insulation shall be free from any
composites likely to soften, shunt or collapse during service. The insulating material
shall be of a type that does not shrink, disintegrate, carbonize or become brittle in hot
oil for oil immersed transformer.
h) Insulation varnish treatment shall be accomplished by vacuum impregnation.
18.6.3.6 Oil and Fillings
a) Mineral oil for immersed sealed type transformers shall be Shell DIALA B, D or AX
alternative oils complying IEC 60296.
b) Oil shall be dried prior to filling of the transformer which shall be performed under
vacuum.
c) PCB synthetic liquids (Poly Chlorinated Biphenyls) or other chlorinated hydro carbons
with trade names Askarel, Pyranol, Clapnen, Pyralene, etc. are not acceptable and
shall not be used.
d) Instructions for cleaning and filtering of the liquid used shall be furnished with
each transformer.
e) The dielectric strength of oil or synthetic liquid shall be more than 125kV/cm.
f) Oil immersed sealed type transformers shall be filled with the oil at the manufacturer’s
works. The brand and type of oil shall be stated on the rating plate.
18.6.3.7 Terminals
a) To provide a 4-wire system, the low voltage star point connections shall be brought out
on a separate terminal.
b) Terminals shall be marked in accordance with the connection diagram marked on the
rating plate.
c) The stems and bushing of the terminals shall be sealed in leak proof manner into the
tank wall or cover, rotations of terminal stems shall be prevented by effective locking.
d) External terminals for the connection of cables shall be provided with bolted type
conductor connections of adequate dimensions and ratings and if two or more
conductors per terminal are required, provision shall be made to accommodate the
same.
e) All bushings shall be self-contained and shall be sealed into the enclosure air/gas and
liquid tight with non-deteriorating gaskets suitable for the liquid used.
f) All transformers shall be provided with external earthing terminal. This shall be either a
threaded bolt or bolted clamp. The minimum diameter shall be 8 mm.
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18.6.3.8 Cable Boxes
a) Cable entries into the boxes shall be located such that conductors can be clamped
straight into the terminal connectors with minimum of bending inside box.
b) Extension pieces bolted to the actual terminal with additional bolted conductor clamps
in line with the cable entry may be required.
c) Single core type cables shall be glanded to non-magnetic plates.
d) The transformer shall have HV and LV cable boxes. The HV and LV cable boxes shall
be mounted on opposite sides of the tank and arranged for cables entering vertically
from bottom.
e) All cable boxes shall be completely sealed and provided with sealing glands to suit
cables. HV cable box shall be suitable for terminating a three (3) core XLPE up to
300mm2 cable via 1 gland.
18.6.3.9 Terminations and glands
a) Cable terminations for lower voltages shall be with double compression type glands.
Single core cable entries shall be mounted on non-magnetic plates.
b) For star point earthing an extra gland, suitable for PVC insulated cable shall be
provided.
c) The glands shall be electrically separated from cable box, and the dielectric
characteristics of the insulation between gland and cable box shall meet the
requirements listed below.
i. Power frequency withstand voltage: 2 kV at least

ii. Impulse withstand voltage: 6 kV at least
d) Cable clamp supports shall be provided by the manufacturer.
18.6.3.10 Off-Load Tap Changers
e) Tap changing on the MV winding shall be done by externally hand operated off-load
tap changing switch.
f) The HV winding of the transformers shall have 5 tapping positions they are principal
tapping and ± 2.5%x2 tapping positions operated by an off-circuit tapping switch clearly
marked position indicator. Tapping position shall be visible at the safe distance. Tap
changer shall have locking device.
g) Switching position of No. 1 shall correspond to maximum plus tapping. The contacts of
the tap changer shall be of robust and shall have sufficient surface area. Insulating
sleeves for the transformer tapping shall be in crepe paper or better.
h) The switch shall preferably satisfy the following requirements:
i. The switch shall be operable by its handle without the need of additional tool
and without risk to personnel safety.
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ii. The contact changing shall be positive snap action arranged so that it is
impossible for the contacts to be left in a position where the circuit remains
interrupted.
iii. The stops shall be robust type to prevent overrunning.
iv. Padlocking of the switch shall be provided.
v. Tap positions shall be clearly marked.
vi. The driving rod through the tank cover or wall shall be sealed to prevent leakage
of air, gas or liquid under all service conditions.
18.6.3.11 Earthing
a) MV cable boxes shall have an earthing terminal of adequate dimensions for the cable
earthing wires. LV cables boxes shall have earthing terminals of adequate dimensions
for each cable earthing sheath wire.
b) For connection to the external earthing network, the enclosure shall have earthing pads
with threaded holes for connection to a 70 sq mm stranded copper earthing cable.
18.6.3.12 Fittings and Accessories
a) The following shall be provided for all transformers as a minimum:
i. Pressure relief device - alarm / trip signal

ii. Winding temperature indicator with contacts.
iii. Oil temperature indicator with contacts (for oil immersed sealed transformers).
iv. Oil level switch with contacts (for oil immersed sealed transformers).
v. Lifting lugs for lifting the entire transformer.
vi. Skid under base with bi-directional rollers.
vii. Rating plate.

b) Cabling / wiring on the transformer shall be run through cable trays fitted on
transformer.
c) Lifting lugs for lifting tank cover with or without core and coil assembly. If without,
further lifting lugs for core a coil assembly shall be provided.
d) A pressure relief device of sufficient size, capable of functioning without electrical

power shall be provided for the rapid release of any pressure that may be generated
within the tank and which might result in damage to the equipment. It shall also be
capable of maintaining the oil tightness of the transformer under all conditions of
normal service. The device shall operate at a static pressure of less than the hydraulic
test pressure for transformer tanks and shall be designed to prevent further oil flow
from the transformer following its operation.
e) Valves shall be of the fully sealing full-way type suitable for minimum and maximum
temperatures specified without any deterioration. Valves to open when turned counter
clockwise. All valves opening to atmospheres shall be fitted with blanking plates.
f) Explosion vents with single diaphragm to be provided.

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g) Cooling system of the transformers shall be natural circulation of oil and air (ONAN).
h) Detachable radiators with valves to be provided and shall be through connected to the
main tank. Radiator thickness to be 1.20mm (minimum) and shall be fitted with lifting
lugs machined, flanged inlet and outlet pipes.
i) Plugs shall be fitted at the top and bottom of each radiator for filling and draining. The
oil circuit of all coolers shall be provided with the following as appropriate to tank
mounted on separate bank coolers:-
i. Valve at every point of connection to the transformer.

ii. Valve at the bottom of every cooler of main oil connection.
iii. Loose blanking plates to permit the blanking off of the main oil connection to the
top of each cooler.
iv. A 50 mm oil filtering valve at the top and bottom of each cooler, the bottom
valve shall also function as a drain valve.
j) A thermometer pocket fitted with a captive screwed cap on the inlet and outlet oil
branches of each cooler.
k) Where M.V. cables shall be terminated in a cable box, an air insulated disconnecting
chamber with removable links shall be provided. The disconnection chamber shall have
a removable cover and the design of the chamber shall be such that ample clearances
are provided to approach the terminations of the disconnecting links, and also
facilitates either the transformer or each cable to be subjected separately to high
voltage tests.
l) Cable termination box shall be provided with suitable arrangement to provide

supporting structure from floor.
m) Cables boxes for 6.6 kV and below need not be attached with disconnecting link
chambers.
n) Terminal boxes to be provided with bushings with Air clearance and creepage suitable
for outdoor mounting type transformer.
o) An earthing terminal shall be provided in each disconnecting or sealing end chamber to

which the connections from the transformer or reactor winding can be earthed during
cable testing.
p) Terminals shall be marked in a clear and permanent manner.
q) Oil temperature indicating (OTI) devices shall be fitted with one set of contacts
adjustable over the range 60oC to 110oC for initiating a DC operated alarm.
r) Winding temperature indicating (W.T.I.) devices shall indicate the temperature of the
hottest spot of the winding and shall have a load-temperature characteristic
approximating to that of the main winding. Two sets of contacts shall be provided for
initiating of alarm and trip relays.
s) Separate Current Transformer shall be used for W.T.I.
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t) Temperature indicating devices shall incorporate a dial and a pointer indicator and a
separate pointer to register the maximum temperature reached.
u) The capillary connected sensing bulbs of temperature indicators shall be positioned in

separate oil-tight pockets arranged in the top oil.
v) The temperature indicating devices shall be so designed that it shall be possible to

move the pointers by hand for the purpose of checking the operation of the contacts
and associated equipment. The working parts of the instruments shall be made visible
by the provision of dials and glass fronted covers.
w) The characteristics of the winding temperature indicating devices shall be forwarded to

the DM/Engineer for approval prior to the delivery of the transformers and shall also be
included in the operating and maintenance instructions.
x) All temperature indicators shall be housed in the marshalling kiosk or box and shall be
mounted so that they will not be affected by vibration.
y) HV bushings shall be plug-in type which are connected with elbow connector or tee
connector. They shall be mounted on the tank and sealed by cable box. The minimum
phase to phase clearance and phase to earth clearance shall not be less than those
stated in Table 5 of IEC 60076-3. HV bushings shall be connected with three core
XLPE insulated 300mm2 copper cable.
z) The plug-in type HV bushings shall be installed in a manner to prevent ingress of

moisture and to facilitate easy connection with heat shrinkable or pre-moulded
connectors.
aa)Current rating of plug-in type HV bushings shall be 200A and number of bushings shall
be 3 Nos. Dimensions of HV bushings shall comply with IEC specification.
bb)LV bushings including neutral bushing shall be outdoor porcelain type conforming to
IEC 60137. They shall be mounted on tank and sealed cable box. Bushing palms shall
be made of brass be suitable for the bolting of conductor compression lugs of
termination for indoor use. The minimum phase to phase clearance shall not be less
than those stated in Table 5 of IEC 60076-3.
cc) The porcelain shall not engage directly with the hard metal and gaskets shall be
interposed between them and the surface in contact with the gasket shall be unglazed.
They shall be installed in a manner to prevent ingress of moisture and to facilitate easy
removal.
dd)In case of overhead line connected transformers, bushing shall suitable with creepage
for outdoor and to be provided with arcing horns. Bushings to be provided for earthing
the neutral.
ee)A separate box shall be provided to accommodate neutral C.T. for restricted fault relay.
ff) All bushings shall be marked with symbols as per rating plate and connecting diagram.
gg)The rating plate(s) shall be of non-corrosive material. Enamelled plates are not
acceptable.
hh)The rating plate(s) shall give the following information:
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i. The international specification to which the transformer conforms to.
ii. Vector group and winding connection.
iii. Percentage tapping positions of rated voltage.
iv. Rated MV voltage at zero tapping.
v. Rated LV voltages at no load and full load at above condition.
vi. Rated ambient temperature.
vii. Rated kVA at self air cooling at above conditions.
viii. Rated full load current and short circuit current withstand for 3 seconds.
ix. Impedance Voltage at principal tap.
x. Rated reactance.
xi. Make, type, volume, and weight of insulation liquid.
xii. Enclosure class of transformer.
xiii. Lifting weight of the core and winding assembly.
xiv. Lifting weight of the entire transformer with liquid.
xv. Transformer type, make, serial number, year of manufacture and purchase
order number.
18.7 MEDIUM VOLTAGE MOTORS
a) This specification covers the general requirements for Medium Voltage, 3-phase
squirrel case, induction type motors.
b) All motors shall be from a reputed and approved manufacturer and shall comply with
the requirements of the relevant Contract. They shall be complete with terminal boxes,
cable glands and with heaters and monitoring instruments. Motors of the same type
must be fully interchangeable and shall comply with IEC motor standard dimensions.
Unless otherwise specified and/or approved, AC motors shall be of the squirrel cage
type, provided with either deep slots or double squirrel cages.
c) The general construction shall be stiff and rigid, no light metal alloy casings will be
accepted. All precautions shall be taken to avoid any type of corrosion and electrical
ionisation effects taking place between different kinds of metals.
d) All motors for fire pump applications shall conform to the requirements specified under
NFPA 20.
e) The motor efficiency classification should be IE2 in accordance with IEC 60034-30.
f) Surface treatment of motor shall correspond to corrosion category C4M specified by

ISO/EN 12944:2, suitable for industrial area with high humidity and aggressive
atmosphere.
g) The power factor for MV motors shall be not less than 0.84 under full load.
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h) The installed motor output shall be 1.15 times the required power at the shaft of the
driven pump at its duty point unless specified otherwise.
i) The motor shall be de-rated to the ambient temperature of 50 Deg C.
j) All MV pump set shall be provided with condition monitoring system as specified
elsewhere in contract document.
k) The condition monitoring system offered shall be as per recommendations of the pump
manufacturer and necessary co-ordination with the instrument manufacturer to ensure
compatibility of the system offered and same shall be the responsibility of the
equipment supplier / manufacturer.
l) The make and model no. selected for the vibration monitoring system shall be subject
to approval by DM/Engineer.
18.7.2.1 Insulation Level
a) MV motors shall be suitable for continuous operation on systems with the neutral at
near earth potential.
b) They shall also be suitable for operation on unearthed systems with one line at earth
potential for infrequent periods of short duration, e.g. as required for normal fault
clearance.
18.7.2.2 Sound Pressure Level
a) The sound pressure produced by motor operating at rated voltage and frequency at
either no load or full load shall not exceed 82 dB(A) under free field conditions at 1.0 m
from the motor.
b) The sound pressure produced by the combined pump and motor at full load shall not
exceed 85 dB (A) at 1.0 M from the equipment.
18.7.2.3 Bearing Vibration Velocity
a) The effective velocity of vibration measured on the bearing on a horizontal plane

through the shaft centre line of horizontal motors shall be in accordance with IEC
60034-14 but in any case shall not exceed the following:
i. when free suspended, the vibration shall not exceed 1.8 mm/s RMS
ii. when rigid mounted, the vibration shall not exceed 2.8 mm/s RMS
b) The vibrations limits above shall apply to all operating temperatures between ambient
and maximum and all operating load conditions between no-load and full load.
c) For two pole motors, the contribution of the twice the supply frequency i.e. 100 Hz to
the overall vibration shall not exceed 1.4 mm/s RMS.
18.7.2.4 Bearing Vibration Amplitude
a) The unfiltered double amplitude (peak-to-peak) of the shaft vibration including shaft
run-out relative to each bearing shall not exceed the following:
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i. 15 um at 50 Hz
ii. 7 um at 100 Hz
b) The vibration limits above shall apply to all operating temperature conditions from
ambient to maximum temperature and all operating load conditions from no-load to full-
load.
18.7.2.5 Duty Type and Starting Duty
a) Unless otherwise specified, motors shall be designed for continuous running duty type
S1, with 3 years continuous operation without stopping the motor for maintenance
purposes.
b) The starting duty of the motors shall be suitable for more than 5000 starts for lifetime
and should not be less than 300 starts per year.
18.7.2.6 Operation with Variable Frequency Drives
a) Motors to be used with frequency converters shall be specially designed to meet all the
stringent requirements of the frequency converters.
b) Motors for use with variable frequency inverter type speed controllers shall be rated for
continuous running over the specified speed range. The motor shall take into account
the increase in heat, vibration and noise from the inverter output, reduced cooling at
lower speeds and effect on bearings lubrication and critical motor speeds.
18.7.2.7 Starting Conditions
a) Motors shall be suitable for three (3) direct on-line (DOL) starts per hour equally
spaced. Furthermore, they should be suitable for two successive starts per hour with
the motor already at running temperature under the following conditions:
i. Motor terminal voltage : 85% of rated voltage

ii. Load torque : varying with the square of the speed from
zero to rated motor torque
iii. Inertia : 125% of own inertia
iv. Pull out torque : >160% of the rated torque
b) To ensure successful re-acceleration, the motor torque shall be minimum 110% of the
torque required by the driven equipment under load conditions, over the entire rpm-
range and with the motor terminal voltage at 85% of the rated voltage. The
manufacturer shall state the total running-up time from standstill (RT) based on the
above-mentioned conditions.
c) The motor starting current in DOL starting shall not exceed 600% of the full load
current at rated voltage and frequency. The manufacturer shall also give the allowable
running-up time (ART) of the motors offered. ART may be calculated based on the
same conditions as mentioned for the starting requirements above.
d) All motors shall be suitable for restarting against full residual voltage.
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18.7.2.8 Running Conditions
a) MV Motors shall be capable of operating continuously under rated output conditions at

any frequency between 48 and 52 Hz and/or with any voltage variation between 90%
and 110% of the nominal voltage. Motors shall be capable of delivering the maximum
torque as required by the driven machine when running at 70% nominal voltage for a
period of 10 seconds without injurious overheating and maintain stable operation limits.
b) The pull-out torque for intermittently loaded motors shall be 200% of the rated torque.
c) After a loss of voltage up to 3 seconds, motors must be capable of reaccelerating their

driven equipment in less than 10 seconds under a voltage of 70%.
18.7.2.9 Critical Speed
Motors with a rigid, sub critical rotor bearing system shall have the first critical speed
not lower than 125% of the rated speed. Motors with a flexible, overcritical rotor
bearing system shall have the first critical speed below 80% of the rated speed and the
second critical speed shall not be lower than 125% of the rated speed.
18.7.3.1 General
a) Adequate provisions shall be made to avoid difficulties caused by condensation under

site conditions specified.
b) All motors shall be provided with anti-condensation heaters.
c) Each motor shall be provided with eye bolts, lugs or extension pieces for hoisting.
d) All motors shall be provided with an earthing bolt of at least 8 mm diameter, tapped into
the frame or an earth stud inside the cable box.
e) When air inlets are protected by a screen, such a screen shall be of corrosion-resistant
material. Galvanised steel mesh wire is not acceptable.
18.7.3.2 Construction and Mounting
a) For general information reference is made to IEC 60034-7.
b) Dimensions of foot-mounted motors and mounting flanges shall be in accordance with

IEC 60072.
18.7.3.3 Enclosures
b) The minimum acceptable degree of protection is IP-54 for the motor and auxiliaries, IP-
55 for the terminal boxes.
c) Vertical motors with downwards shaft shall be provided with a canopy covering the air-
inlet of the fan cooling. For vertical motors with upwards shaft the sealing of bearing
housings shall be such that no water can penetrate the motor via the shaft.
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d) To determine the type of enclosure appropriate to a possible dangerous atmosphere,
the area in which the motor will be used will be classified to the degree of probability of
the presence of a dangerous atmosphere according to IEC 60079-10.
18.7.3.4 Stator
a) All motors shall have their windings delta-connected unless otherwise stated
elsewhere.
b) Both ends of each phase winding shall be brought out to a terminal of adequate
current-carrying capacity. The connection shall be made in the terminal box by
removable links.
c) Classification of materials for the insulation of motor windings in relation to their thermal
stability in service shall conform to IEC 60085.
d) Temperature rise by resistance at rated load shall not exceed the value as specified in
the IEC publications.
e) The use of magnetic slot wedges is not allowed. When the use of magnetic type slot
wedges is unavoidable they shall be of the iron powder type, fully guaranteed by the
manufacturer and subject to DM/Engineer approval. Laminated or wire type wedges
are not acceptable.
f) The insulation of motors shall be class H, with class B temperature rise for starting and
steady state operation at full load. The insulation shall not contain shellac or asphaltic
components. Insulation shall have high mechanical and electrical strength, Low Loss
factor, impervious to moisture, vermin and chemical substances.
g) The stator winding shall be suitably braced to withstand the forces due to direct-on-line
starting at 110% nominal voltage and where applicable, occasional transfer from the
nominal supply to an auxiliary supply with 100% residual voltage at the motor
terminals.
h) Inter-phase connections inside the machine shall be made at the non-driving end and
the winding connection and tails shall be non-hygroscopic. Non-hygroscopic materials
shall be used to the maximum extent. Both ends of each phase winding shall be
brought out to terminals of adequate current carrying capacity.
i) The stator winding shall be of sufficient cross-sectional area to withstand the maximum
prospective fault current for the period of time determined by the protective devices.
18.7.3.5 Rotor and Fans
a) The external fan shall be of non-corroding materials or be treated with a corrosion-

resistant coating. Rotor and fans shall be dynamically balanced with the half key in
position at the free shaft end.
b) The rotor winding shall be designed to give trouble free continuous service including
repeated direct-on-line starting. The rotor shall be subjected to a 120% over speed test
in workshop for 2 minutes to show that there is no winding dislocation.
c) When the motor manufacturer has to supply the coupling or when a coupling half is
made available, the balancing has also to be done with this coupling half mounted on
the shaft. If for balancing additional weight is required, this material shall not be of lead
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or similar soft material. The fans shall be located by driving keys, or by studs, which are
off pitched so that it is impossible to assemble them incorrectly.
d) The flow of cooling air shall be in the direction of the driving end of the motor to prevent
contaminated warm air from the driven unit being drawn into the cooling system of the
motor.
e) If directional fans are fitted, the direction of rotation for which the motor is designed
shall be permanently indicated by means of an arrow. A painted arrow is not
acceptable.
f) The shafts ends shall be provided with a suitably threaded hole or holes to facilitate the
assembly or removal of coupling and bearing faces.
g) Shaft extension, keys and key ways shall be in accordance with IEC 60072.
18.7.3.6 Motor Ventilation
a) Unless otherwise specified all motors shall be of the totally enclosed fan cooled type,
protection class IP 54 according to IEC recommendation 60034-6 and 60529.
b) Where motors are installed outdoors a weather-proof design shall be chosen. Unless
otherwise specified all motors shall be of the natural air cooled self ventilating type.
Generally the cooling air shall be drawn from the end of the motor that is not connected
to the load.
c) In design calculation for the motor cooling system the site ambient condition shall be
taken as reference and the motor nameplate ratings shall be based on these figures.
d) Where cooling tubes are used for air-to-air heat exchangers, such tubes shall be made
of stainless steel 316Ti.
e) At least one drilled hole shall be provided at the lowest point of the casing for draining
condensed moisture. Motors shall be equipped with automatically controlled heating
resistors for protection against internal condensation of moisture during standstill
periods. Such AC heater shall suitably be fixed inside the winding covers; the leads
shall be led to a separate LV terminal box. Each MV motor shall be provided with 3
Nos. of double element (one active + one spare) space heaters rated for single phase
230V, 50 Hz AC power supply.
18.7.3.7 Bearing
a) Self lubricating ball and roller bearing with solid races shall be provided for MV motors.
b) The B-10 lifetime for ball and roller bearings of straight coupled motors shall be in
excess of 40,000 hours and shall be calculated in accordance with ISO R281. The
calculation shall take full account of internally generated forces (e.g. magnetic forces)
with the worst aggregate of dimensional tolerances as obtained during manufacture.
When external forces are imposed on the motor shaft and the B-10 lifetime calculation
shall then take this into account. A reduction to 32,000 hours is allowed in this case.
c) The motor shall be suitable for continuous operation for at least 25,000 hours without
stoppage for maintenance.
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d) All motors shall be equipped with a type of lubrication which permits greasing while the
motor is running and which prevents over lubrication. Additionally, the bearings shall be
fitted with grease nipples permitting the use of a universal grease gun.
e) Where sleeve bearings are used, they shall be of the self or forced lubricating type. If
forced lubrication is required it shall be arranged common to both the motor and the
driven machine and provisions shall be made to ensure lubrication during start-up and
shut-down operations without the necessity to start an auxiliary lube oil pump. Self-
lubricated bearings shall be equipped with an easily accessible lubrication pot with
overflow pipe and oil collecting vessel.
f) Self lubricated bearing shall be equipped with an easily accessible lubrication pot with
overflow pipe and oil collecting vessel.
g) The sleeves bearing shall be designed such as to permit the immediate formation of an
oil film during the first shaft rotations. These shall likewise be possible after sustained
stand still periods of at least six months.
h) Sleeve bearing shall be designed for easy removal and check without dismantling the
whole bearing. All bearings shall be carefully protected against soil or duct penetration
and oil leakages.
i) Motors shall be fitted with excess grease collecting sumps, which shall be easily
removable and replaceable.
j) In case of independent bearings, motor and bearing pedestals shall be fitted on

common base plate.
k) For motors equipped with ball or roller bearings, adequate means are to be provided
during stand still periods to prevent the brinelling effect. During transport and shipping
such motors shall receive a special bearing insert.
l) Unless otherwise specified, vertical motors shall be either ball or roller thrust bearings
designed to withstand all thrust forces to support the motor and the driven equipment.
Thrust bearings shall each have sealed lubrication system capable of re-lubrication in
service where ball or roller bearings cannot be used, specially designed bearings (such
as Kingsbury thrust bearing) must be employed.
m) Necessary provision shall be made to prevent damage to bearings by shaft currents, by

insulating the drive and non-drive end bearings and their associated connections, the
insulation at the drive end bearing being bridged by a removal copper strap.
18.7.3.8 Shafts and Couplings
a) Unless otherwise specified the motors shall be provided with a free shaft extension of
cylindrical shape with key and keyway according to IEC recommendation 60072-1.
b) The motor-half-coupling shall be pressed on the motor shaft and shall be balanced
together with it. A coupling guard shall be provided.
18.7.3.9 Terminal Boxes and Earthing
a) The terminal boxes shall be of ample sizes to enable connection to be made in a

satisfactory manner. Cable supports shall be provided with terminal boxes.
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b) The terminal boxes with the cables installed shall be suitable for connection to supply
systems having the short-circuit capacity and fault clearance time determined by the
upstream motor protective devices.
c) Terminal boxes shall be sized so that feeder cables can be connected to motor leads
without damage to the cable or the leads.
d) The terminals leads, terminals, terminal boxes and associated equipment shall be
designed to withstand future short-circuit level of 500MVA.
e) Unless otherwise specified or approved, the terminal box shall be positioned on the
right hand side of the motor when viewed from the driving end and shall permit turning
by 90 and 180 degrees.
f) A permanently attached connection diagram shall be mounted inside the terminal box
cover giving the desired direction of rotation. If motors are suitable for only one
direction of rotation this shall be clearly indicated.
g) Terminal boxes shall be robust design and totally enclosed (IP 55) to prevent the
ingress of moisture and dust. All joints shall be flanged with gaskets of neoprene or
similar material. Terminal boxes or parts thereof shall consist either of grey cast iron,
light metal alloy or galvanised steel.
h) Terminal boxes of MV motors shall be of the phase segregated type. Opening of the
terminal box cover shall not expose the internal part of the motor.
i) Terminal boxes shall be fitted with an approved cable sealing and dividing box and a
pressure relief diaphragm located to direct flames and/or hot gases away from
personnel.
j) The cable sealing box shall be amply sized to fit with the number and kind of cables
used as advised by the contractor. The neutral point ends of MV motor windings shall
be brought out to a second terminal box and shorting with shoring link may be used for
connection of the feeder cable.
k) All winding ends shall be brought out to terminal blocks or stud type insulators.
l) All six terminal of the winding shall be brought out.
m) Space heaters shall be completely wired with leads brought to a terminal box separate
from power and RTD terminal boxes.
n) For earthing purposes each motor shall have two (2) adequately sized bolts with
washers at the lower part of the frame. In addition each terminal box shall likewise
contain one earthing bolt.
o) The resistance of the wire from motor to common earth shall not exceed 0.1 Ohm.
18.7.3.10 Lifting and Installation Dispositions
a) All motors shall be provided with one or more lifting eye-bolts, rings or lugs capable of
supporting the total weight of the motor. If lugs are concealed by enclosure, name-
plates shall be attached to both sides of the motor warning against improper lifting.
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Dubai Municipality

b) The equipment to be supplied shall include all accessories necessary to the installation
of the motors (e.g. dowel holes, anchor bolts, etc.).
18.7.3.11 Wiring
All secondary wiring shall be of the heat resistant type silicone rubber insulation
reinforced and protected with metal braid. All wiring for measuring and monitoring is to
be brought to one common terminal box.
18.7.3.12 Rating Plates and Marking
a) Manufacturer’s serial number of the motor shall be die-stamped on a non-removable

part of the frame. This number shall also be shown on the rating plate. The direction of
rotation of motors shall be clearly indicated by means of arrow located on the non-
driving end shield of the motor.
b) The rating plate or plate shall be stainless steel, fixed to a non-removable part of the
frame, and shall be marked with the appropriate items in accordance with IEC 60034-1,
whereby the values given shall be those actually measured.
c) In addition to these items the following information shall be indicated:
i. Type of enclosure in accordance with IEC 60034-5 (IP classification)

ii. Locked rotor torque in % of rated torque
iii. Locked rotor current in % of rated current
iv. Allowable running-up time in seconds (ART)
v. Bearing type, size, fit, re-greasing period and type of grease
vi. Net weight
vii. Purchase order number
18.8 LV SQUIRREL CAGE INDUCTION MOTOR
d) This specification covers the general requirements for Low Voltage, 3-phase squirrel
cage, induction type motors.
e) All motors shall be from a reputed and approved manufacturer and shall comply with
the requirements of the relevant Contract. They shall be complete with terminal boxes,
cable glands and with heaters and monitoring instruments. Motors of the same type
must be fully interchangeable and shall comply with IEC motor standard dimensions.
Unless otherwise specified and/or approved, AC motors shall be of the squirrel cage
type, provided with either deep slots or double squirrel cages.
f) The general construction shall be stiff and rigid, no light metal alloy casings will be
accepted. All precautions shall be taken to avoid any type of corrosion and electrical
ionisation effects taking place between different kinds of metals.
g) All motors for fire pump applications shall conform to the requirements specified under
NFPA 20.
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Dubai Municipality

h) The motor efficiency classification should be IE3 (Premium efficiency) in accordance
with IEC 60034-30.
i) The installed motor output shall have minimum of 1.15 times the required power at the
shaft of the driven pump at its duty point unless specified otherwise.
j) The motor shall be de-rated to the ambient temperature of 55o C.
k) All LV pump set above 200KW shall be provided with condition monitoring system.
l) The condition monitoring system offered shall be as per recommendations of the pump
manufacturer and necessary co-ordination with the instrument manufacturer to ensure
compatibility of the system offered and same shall be the responsibility of the
equipment supplier / manufacturer.
m) The make and model no. selected for the vibration monitoring system shall be subject
to approval by DM/Engineer.
n) Surface treatment of motor shall correspond to corrosion category C4M specified by

ISO/EN 12944:2, suitable for industrial area with high humidity and aggressive
atmosphere.
o) The motor shall have a minimum thermal capability of 10 starts per hour, under normal
start-up condition with a supply voltage during starting of 80% of rated voltage.
p) All motor above frame size 160 shall be supplied with slide rails.
q) All motors above frame size 280 shall be supplied with silencer.
18.8.2.1 Noise Level
The noise level produced by motors operating at rated voltage and frequency at either
no load or full load shall be below the established industrial limits and shall meet IEC
publication no. 60034-9.
18.8.2.2 Vibration
The effective velocity of vibration measured on the bearing on a horizontal plane

through the shaft centre line of horizontal motors shall not exceed the values as given
in IEC 60034-14 for the completely assembled motor, running on no-load at rated
voltage and speed.
18.8.2.3 Cooling
b) Air-to-air cooling is preferred (TEFC).
c) Where cooling tubes are used for air-to-air heat exchangers, such tubes shall be made
of corrosion-resistant material or treated to render the material corrosion-resistant.
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18.8.2.4 Operation with Variable Frequency Drives
a) Motors to be used with frequency converters shall be specially designed to meet all the
stringent requirements of the frequency converters.
b) Motor bearing shall be of insulated type with insulated inner and outer races. Where
directed by engineer for special applications motors shall be provided with hybrid
bearing – bearing with non-conductive ceramic rolling elements.
c) Motors for use with variable frequency inverter type speed controllers shall be rated for
continuous running over the specified speed range. The motor shall take into account
the increase in heat, ventilation, winding insulation, shaft seals, vibration and noise
from the inverter output, reduced cooling at lower speeds and effect on bearings
lubrication and critical motor speeds.
18.8.2.5 Rating and Duty Type
a) Rotating electrical machines rating and performance shall be as per IEC 60034 – part1.
b) Motor shall be selected for continuous running duty (Duty type S1) as stipulated in IEC
60034.
18.8.2.6 Starting Performance
a) Locked rotor, pull-up and breakdown torque shall be in accordance to IEC 60034-12.
b) Locked rotor current shall not exceed the values specified in IEC 60034-12.
18.8.2.7 Starting Conditions
a) Except where a motor is used with a Variable Frequency Drive, motors shall be
suitable for star/delta (or soft starter) or direct on-line starting as specified elsewhere.
b) The maximum torque of the motor must be at least 30% higher than the load torque
over the whole duty range.
c) The manufacturer shall state on the motor data sheet the total running-up time from
standstill (RT) based on the above-mentioned conditions.
d) The manufacturer shall also give the allowable running-up time (ART) of the motor.
This ART may be calculated based on the same conditions as mentioned for the
starting requirements above.
e) All motors shall be suitable for restarting against full residual voltage.
18.8.3.1 General
a) The motor shall be manufactured for horizontal installation.
b) For general information reference is made to IEC 60034-7.
c) Motors for Fire Protection Systems shall be constructed in accordance with relevant
Fire Protection System Standards (NFPA, BS, UL, FM etc.).
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Dubai Municipality

18.8.3.2 Enclosures
b) The minimum acceptable degree of protection is IP-54 for the motor and auxiliaries, IP-
55 for the terminal boxes.
c) The motor installed in outdoor location shall be of IPW-55, and shall be additionally
provided with effective sunshade.
d) When air inlets are protected by a screen, such a screen shall be of corrosion-resistant
material. Galvanized steel mesh wire is not acceptable.
18.8.3.3 Stator
a) Both ends of each phase winding shall be brought out to a terminal of adequate
current-carrying capacity. The connection shall be made in the terminal box by
removable links.
b) Classification of materials for the insulation of motor windings in relation to their thermal
stability in service shall conform to IEC 60085.Non-hygroscopic materials shall be used
to the maximum extent. Winding insulation shall be thermal class H or better to BS EN
60085 and the maximum temperature shall not exceed that permitted for thermal class
B. The winding shall be provided with over temperature sensors such as thermistor,
bimetal, PT100.
c) Temperature rise by resistance at rated load shall not exceed the value as specified in
the IEC publications.
d) The use of magnetic slot wedges is not allowed. When the use of magnetic type slot
wedges is unavoidable they shall be of the iron powder type, fully guaranteed by the
manufacturer. Laminated or wire type wedges are not acceptable.
18.8.3.4 Rotor and Fans
a) The external fan shall be of non-corroding materials or be treated with a corrosion-

resistant coating.
b) Rotor and fans shall be dynamically balanced with the half key in position at the free
shaft end.
c) When the motor manufacturer has to supply the coupling or when a coupling half is
made available, the balancing has also to be done with this coupling half mounted on
the shaft.
d) If for balancing additional weight is required, this material shall not be of lead or similar
soft material.
e) The flow of cooling air shall be in the direction of the driving end of the motor to prevent
contaminated warm air from the driven unit being drawn into the cooling system of the
motor.
f) If directional fans are fitted, the direction of rotation for which the motor is designed
shall be permanently indicated by means of an arrow. A painted arrow is not
acceptable.
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Dubai Municipality

g) The shafts ends shall be provided with a suitably threaded hole or holes to facilitate the
assembly or removal of coupling and bearing faces.
h) Shaft extension, keys and key ways shall be in accordance with IEC 60072.
18.8.3.5 Anti Condensation Heaters
a) Anti-condensation heaters shall be fitted to all motors with frame number 112 and
above except motors with Type Ex ‘e’ and Type Ex ‘N’ protection for use in hazardous
areas.
b) All motors without heaters shall be fitted with drain holes with removable plugs.
18.8.3.6 Lifting Facilities
Each motor above 25 kg in weight shall be provided with eye bolts, lugs or extension
pieces for hoisting.
18.8.3.7 Terminals
a) Terminal connections shall be constructed in such a way that direct contact between
screws, bolts or nuts and the conductor is avoided.
b) The terminals shall be alphabetically or numerically marked (e.g. U, V, W or 1, 2, 3) in

such a way that if the supply cyclic phase sequence in time corresponds to the
alphabetical or numerical sequence of the terminal markings, then direction of rotation
of the motor shall be clock wise when facing the driving end.
18.8.3.8 Terminal Box
a) A terminal box of sturdy metal construction shall be provided with ample space for
connecting the cable. The enclosure shall be IP 55. In view of the maximum acceptable
voltage drop, large numbers of cables in the same trench and short-circuit rating of the
system; the prescribed cable size can be larger than considered normal by the
manufacturer.
b) Consequently a larger cable connecting box than manufacturer's standard may be

required.
c) The design shall be such that small items cannot be dropped into the motor frame. The
method of fixing the box and its component parts to the motor frame shall be in
accordance with the type of motor enclosure.
d) Inside the terminal box an earthing bolt of adequate dimensions shall be fitted for
connection of the cable earthing. This bolt is additional to the external equipment
earthing bolt.
e) The terminal box must be adequately weatherproofed with a gasket of suitable non-
sticking re-usable non-hygroscopic material. The use of paint, grease or plastic
compounds for this purpose is not acceptable.
f) Motor’s heaters, thermistors or other temperature detectors or such devices

connections must be brought out to terminal boxes separated from each other and from
the main cable terminal box.
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g) The terminal boxes shall be provided with cable sealing end boxes or cable glands
suitable for the cables.
18.8.3.9 Cable Entries
a) All types of cable connections shall allow for removal of the motor without breaking or
stressing the supply cable sealing.
b) It is preferred that the end sleeve or gland assembly, complete with the cable, can be
withdrawn from the box in such a way that the cable termination can be prepared
outside the box.
c) Where a cable entry with sealing chamber is used, the latter shall be of the detachable
type.
18.8.3.10 Bearings
a) In general, motors shall be equipped with two ball bearings, wherever possible grease-
packed and preferably sealed for life. In connection with high radial forces, however,
the application of a combination of ball and roller bearings may be necessary.
b) Ball and roller bearings shall be grease-lubricated.
c) The B-10 lifetime for ball and roller bearings of straight coupled motors shall be in
excess of 40,000 hours and shall be calculated in accordance with ISO R281. The
calculation shall take full account of internally generated forces (e.g. magnetic forces)
with the worst aggregate of dimensional tolerances as obtained during manufacture.
d) The motor shall be suitable for continuous operation for at least 25,000 hours and the
construction of the bearing housing shall be such that re-lubrication, if required, can be
carried out without stopping the motor.
e) The bearing shall then be designed in such a way that it is impossible to over-grease
the bearing and a suitable "grease relief valve" must be fitted, which makes it possible
to re-lubricate the motor bearings as many times as necessary to arrive at an operating
time of 25,000 hours. The grease relief device or valve must be approved by the
bearing manufacturer.
f) When bearings are used which have to be re-lubricated, a minimum re-lubrication

interval is required of 4,000 hours for horizontal motors, and 2,000 hours for vertical
motors, independent of the actual number of running hours.
g) Motors for use with variable frequency inverter type speed controllers shall be provided
with insulated bearing on the motor side.
18.8.3.11 Protective Systems
a) Submersible motor starters shall have control unit supplied by the manufacturer to
provide protection against moisture, high winding temperature, etc.
b) Motors shall be protection by means of temperature-sensitive thermistors embedded in

the windings.
c) Thermistors shall be of the positive temperature coefficient (PTC) type and be supplied
complete with auxiliary equipment by the motor manufacturer under his full guarantee.
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18.8.3.12 Rating Plate
a) Manufacturer's serial number of the motor shall be die-stamped on a non-removable

part of the frame. This number shall also be shown on the rating plate.
b) The rating plate or plates shall be made of a corrosion-resistant metallic material, fixed
to a non-removable part of the frame, and shall be marked with the appropriate items in
accordance with IEC 60034-30, whereby the values given shall be those actually
measured.
c) In addition to these items the following information shall be indicated:
i. The standard specifications to which the motor conforms.

ii. Locked rotor current in percent of rated current.
iii. Locked rotor torque in percent of rated torque.
iv. Allowable running-up time in seconds (ART).
v. Enclosure protection class.
vi. Enclosure protection class (IP).
vii. Frame size (according to IEC 60072).
viii. Bearing type, size, fit, re-greasing period and type of grease.
ix. Net weight.
d) When special features are involved, a separate plate showing the appropriate
instructions shall be fixed to the motor frame, e.g. limited end float.
18.9 ELECTRIC ACTUATOR – INTEGRAL MOTOR CONTROL
a) The electric actuators for valves, gates and penstocks etc. shall be of a standard, well
tested and proven design which ensures maximum safety to personnel, maximum
service reliability and economic operation. Design and construction shall be simple and
well laid-out and shall provide good accessibility to components and parts.
b) The actuators shall be suitable for use on a nominal 400 V, 3 phase and 50 Hz power
supply and are to incorporate motor integral reversing starter, local control facilities and
terminals for remote control and indication connections housed within a self-contained,
sealed enclosure.
c) The electrical actuator shall be designed as per VDE 0530 / IEC 60034 / EN ISO 5210 /
EN ISO 5211.
d) All electronic boards of electrical actuator shall be conformal coating. Conformal

coatings shall be 1-2 mm. thick polymeric films that cover or encapsulate printed circuit

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iii. UL746E
e) The electrical actuator control/wiring/termination compartment shall be remotely
mounted on an independent support (physically isolated from the valve/motor
assembly) as directed by engineer due to high vibration on the pipeline or machine.
f) In order to maintain the integrity of the enclosure, setting of the torque levels, position
limits and configuration of the indication contacts etc. shall be carried out without the
removal of any actuator covers over an Infra-red interface. Sufficient commissioning
tools shall be provided with the actuators and must meet the enclosure protection and
certification levels of the actuators. Commissioning tools shall not form an integral part
of the actuator and must be removable for secure storage/authorised release. In
addition, provision shall be made for the protection of configured actuator settings by a
means independent of access to the commissioning tool.
g) The actuator shall include a device to ensure that motor runs with the correct rotation
for the required direction of valve travel with either phase sequence of the three phase
power supply connected to the actuator or signal the wrong phase sequence.
h) Except in the case of the supply of an actuator to be retrofitted to an existing valve, all
electric actuators shall be supplied as an integral part of the valve or penstock to be
controlled, complete and fully tested before shipment.
i) The actuator shall be sized to guarantee valve closure at the specified differential
pressure. The safety margin of motor power available for seating and unseating the
valve shall be sufficient to ensure torque switch trip at maximum valve torque with the
supply voltage 10% below nominal. The operating speed shall be such to give valve
closing and opening at approximately 10 - 12 inches per minute unless otherwise
stated. Actuator opening and closing rates shall be set so as not to impose
unacceptable surge pressures on pipe-work.
j) The electric actuator shall be capable of functioning in the specified climatic conditions.
k) Actuators for hazardous area applications shall meet the area classification, gas group
and surface temperature requirements specified elsewhere.
l) Actuator designed for potentially explosive atmospheres shall be qualified by a test

authority ATEX 94/9/EC or NEC (approval by FM) or the CEC (approval by CSA).
m) Actuator installed outdoor shall be provided with an effective stainless steel sunshade.
n) Actuator shall be provided with adjacent local isolator switch (which can be padlocked
in off position) to make sure that the actuator circuit can be completely de-energised for
service or maintenance purposes.
o) Painting and coating shall be suitable for corrosive/humid environment to

Manufacturer's standard finish.
p) Each actuator must be performance tested and individual test certificates shall be
supplied free of charge.
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18.9.2.1 Motor
a) The motor shall be totally enclosed non-ventilated type, 3 phase squirrel cage, Class H
insulated with a class B temperature.
b) For short-time duty type, the motor shall be of S2-30 at 50°C or thrice the valve
stroking time, whichever is longer, at an average load of at least 33% of maximum
torque required by the valve.
c) For intermittent duty type, the motor shall be of S4 and the running time for modulating
actuators should be at least 25 %. The mechanics and motor have to be designed as to
be able to withstand the high number of starts without any deterioration in control
accuracy.
d) Electrical and mechanical disconnection of the motor should be possible without

draining the lubricant from the actuator gear case.
e) Following protection shall be provided for the motor.
i. Motor shall be de-energized in the event of a stall when attempting to unseat a

jammed valve;
ii. Motor temperature shall be sensed by a thermostat to protect against
overheating;
iii. Single phasing and incorrect phase sequence protection.
iv. Phase rotation correction
18.9.2.2 Gearing
a) The actuator gearing shall be totally enclosed in an oil or grease-filled gear case
suitable for operation at any angle. All gearing must be of metal construction. The drive
shall incorporate a lost-motion hammer-blow feature. The output shaft shall be hollow
to accept a rising stem, and incorporate thrust bearing of the ball or roller type at the
base of the actuator. The design shall be such as to permit the gear case to be opened
for inspection or disassembled without releasing the stem thrust or taking the valve out
of service. Partial turn actuator’s drive gear shall be self-locking to prevent the valve
back-driving the actuator.
b) The gear case shall be provided with provision for installing polycarbonate cover for
rising stem and its supporting system. The polycarbonate cover shall be calibrated for
penstocks fully closed/open positions. The length of the stem shall be sufficient to
adequately protrude through gear assembly even in fully closed position.
18.9.2.3 Hand Wheel
a) A hand wheel shall be provided for emergency operation, engaged when the motor is
declutched by a lever or similar means, the drive being restored to power automatically
by starting the motor. The hand wheel or selection lever shall not move on restoration
of motor drive. Provision shall be made for the hand/auto selection lever to be locked in
both hand and auto positions. It should be possible to select hand operation while the
actuator is running or start the actuator motor while the hand/auto selection lever is
locked in hand without damage to the drive train.
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b) Clockwise operation of the hand wheel shall give closing movement of the valve unless
otherwise stated in the data sheet. For linear valve types the actuator hand wheel drive
must be mechanically independent of the motor drive and should be such as to permit
valve operation in a reasonable time with a manual force not exceeding 400N through
stroke and 800N for seating/unseating of the valve.
18.9.2.4 Drive Bushing
a) The actuator shall be furnished with a drive bushing easily detachable for machining to
suit the valve stem or gear box input shaft.
b) The drive bush shall be positioned in the detachable base of the actuator to facilitate
the use of standard length valve system. Thrust bearing, when housed in separate
thrust base, should have sealed for life type.
18.9.2.5 Torque and Turns Limitation
c) Torque switches shall be provided for the mechanical disengagement of the valve at its
extremes of operation in the event of excess torque. The torque settings shall be set at
commissioning to suit the operating criteria of the valve and actuator.
d) Torque and turns limitation to be adjustable as follows:
i. Position setting range – multi-turn: 2.5 to 100,000 turns, with resolution to 15

deg. of actuator output.
ii. Position setting range – direct drive part turn actuators: 90 +/-10, with
resolution to 0.1 deg. of actuator output.
iii. Torque setting: 40% to 100% rated torque.
e) Measurement of torque shall be from direct measurement of force at the output of the
actuator.
f) A means for automatic “torque switch bypass” to inhibit torque off during valve
unseating and “latching” to prevent torque switch hammer under maintained or
repeated control signals shall be provided.
18.9.2.6 Remote Position Indication
a) Four contacts shall be provided which can be selected to indicate any position of the
valve, with each contact selectable as normally-open or normally-closed. The contacts
shall be rated at 5A, 230V AC, 30 V DC.
b) As an alternative to providing valve position any of the four above contacts shall be
selectable to signal one of the following:
i. Fully open;
ii. Fully close;
iii. Travelling in motion;
iv. Actuator fault;
v. Remote control available
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c) Contact-fewer transmitters shall be provided to give 4-20mA analogue signal
corresponding to valve travel and position for remote indication.
18.9.2.7 Local Indication
a) The actuator shall include a position indicator with a display from fully open to fully
close. Red, green and yellow lights corresponding to OPEN, CLOSED and
INTERMEDIATE/ FAULT positions shall be included on the actuator.
b) Red, green, and yellow lights corresponding to open, closed, and intermediate valve
positions shall be included on the actuator display when power is switched on. The
digital display shall be maintained and updated during hand wheel operation when all
power to the actuator is isolated.
c) The digital display shall be capable of indicating real time torque and valve position
simultaneously, both being displayed in 1% increments of valve position and actuator
rated torque. In addition torque shall also be displayed in horizontal bar graph form.
18.9.2.8 Integral Starter and Transformer
a) The reversing contactor starter, control transformer and local control shall be built into
the valve actuator and suitably housed to prevent breathing and condensation build-up.
The starter shall be suitable for 60 starts per hour, and must comprise mechanically
and electrically interlocking reversing contactors rated according to the motor size, with
coils fed from a control transformer with a suitable rating.
b) The common connection of the contactor coils shall be grounded at the transformer so
that the contactors may drop out in the event of a leakage to ground. The primary
winding shall be separated from the secondary winding by a grounded screen.
c) The control transformer shall have taping as
i. 230 AC contactor coils.

ii. 24V DC output for remote controls
iii. Supply for all the internal electrical circuits.
d) Primary and secondary windings shall be protected by easily replaceable cartridge type
fuses.
18.9.2.9 Integral Pushbuttons and Selector
a) Integral to the actuator shall be local control for OPEN, CLOSE and STOP, and a
Local/Remote selector switch pad lockable in any one of the following three positions:
b) Local control only, off (no electrical operation) remote control plus local stop only. It
shall be possible to select maintained or non-maintained local control.
c) The local control shall be arranged so that the direction of valve travel can be reversed
without the necessity of stopping the actuator.
18.9.2.10 Control Facilities
a) The necessary wiring and terminals shall be provided in the actuator for the following
control functions:
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b) Removable links for substitution by internal interlocks to inhibit valve opening/closing.
c) Connections for external remote controls fed from an internal 24V DC supply to be
suitable for any one or more of the following methods of control:
i. Open, Close and Stop.

ii. Open and Close.
iii. Two-wire control, energize to close (or open), de-energize to open (or close).
d) Selection of maintained or push-to-run control for modes (i) and (ii) above shall be
provided and it shall be possible to reverse valve travel without the necessity of
stopping the actuator. The starter contactors shall be protected from excessive current
surges during travel reversal.
e) The internal circuits associated with the remote control and monitoring functions are to
be designed to withstand simulated lightning impulses of up to 2kV.
f) Provision shall be made for operation by distributed control system utilising the
following network systems.
i. Modbus
ii. Profibus
iii. Foundation Fieldbus
iv. DeviceNet
18.9.2.11 Monitoring facilities
a) Facilities shall be provided for monitoring actuator operation and availability.
b) Monitor (availability) relay, having one change-over contact, the relay being energized
from the control transformer will de-energise under any one or more the following
conditions:
i. Loss of main or customer 24V DC power supply

ii. Actuator control selected to local or stop
iii. Motor thermostat tripped
iv. Actuator internal fault
c) Actuator text display indication of the following status/alarms:
i. Closed Limit, open limit, moving open, moving closed, stopped

ii. Torque trip closing, torque trip opening, stalled
iii. ESD active, interlock active
iv. Thermostat trip, phase lost, 24V supply lost, Local control failure
v. Configuration error, Position sensor failure, Torque sensor failure
vi. Battery low, power loss inhibit
d) Integral data-logger to record and store the following operational data:
i. Opening last /average torque against position

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ii. Closing last /average torque against position
iii. Opening motor starts against position
iv. Closing motor starts against position
v. Total open/closed operations
vi. Maximum recorded opening and closing torque values
vii. Event recorder logging operational conditions (valve, control and actuator)

e) The data-logger shall record relevant time and date information for stored data.
f) Data-logger data is to be accessed via non-intrusive IrDA communication. Sufficient

standard intrinsically safe tools shall be provided for downloading data-logger and
actuator configuration files from the actuators and subsequent uploading to a PC. The
actuator manufacturer shall supply PC software to enable data-logger files to be
viewed and analysed.
18.9.2.12 Wiring and Terminals
a) Internal wiring shall be of tropical grade PVC insulated stranded cable of appropriate
size for the control and 3-phase power. Each wire shall be clearly identified at each
end.
b) The terminals shall be embedded in a terminal block of high tracking-resistance

compound, or the use of multi pin plug and socket.
c) The terminal compartment shall be separated from the inner electrical components of
the actuator by means of a watertight seal.
d) The terminal compartment of the actuator shall be provided with a minimum of 3

threaded cable entries which shall be delivered fitted with blanking plugs for protection.
e) All wiring supplied as part of the actuator to be contained within the main enclosure for
physical and environmental protection. External conduit connections between
components are not acceptable.
f) A durable terminal identification card showing plan of terminals shall be provided

attached to the inside of the terminal box cover indicating:
i. Serial number
ii. External voltage values
iii. Wiring diagram number
iv. Terminal layout
18.9.2.13 Enclosure
a) Enclosure of the actuator shall be O-ring sealed, watertight to IP 68 fully protecting the
motor and all the other internal electrical elements of the actuator from ingress of water
and dust.
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b) The Actuator assembly enclosure and local control station shall be rated to IP68
designed to be fully submerged up to 7 meters for at least 72 hours if the installation is
done below ground level or in underground chamber.
c) The actuators assemble installed in Electrical apparatus for potentially explosive

atmospheres (hazardous areas) shall be and tested in accordance with the Standard
IEC 60079 and certificates of conformity, certificates of assurance and certificates of
component approval shall be provided.
d) An effective stainless steel sun shade shall be provided for the actuator installed
outdoors.
e) Enclosure of the actuator must allow for temporary site storage without the need for
electrical supply connection.
f) All external fasteners shall be stainless steel.
18.9.2.14 Nameplate
a) The nameplate shall be of corrosion resistant material fixed to a non-removable part of

the motor actuator. Nameplate shall give the following information:
i. Manufacturers name
ii. Serial number and year of manufacture
iii. Rated ambient temperature
iv. Rated power
v. Rated voltage, phase, frequency
vi. Rated full load current
vii. Insulation class
viii. Rated starting current
ix. Enclosure class and protection

18.9.2.15 Start-Up Kit
Each actuator shall be supplied with a start-up kit comprising installation instructions,
electrical diagram and sufficient spare cover screws and seals to allow for any site
losses during the commissioning period.
18.10 DIESEL GENERATOR
a) This specifications covers the general requirements for the design, manufacture,
delivery and testing of prime rated diesel engine driven generators for automatic mains
standby applications.
b) While it is not intended to give the full details of design and construction of generators,
this specification sets the minimum acceptable requirements.
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c) If there are conflicts between this specification, data sheet and project specification and
international standards specified in this document, then the more stringent
requirements shall prevail.
d) It is required that the equipment manufacturer shall have an authorized dealer in Dubai,
UAE equipped fully with service and spare parts facilities, and competent manpower for
testing, commissioning and maintenance.
e) The generator prime rating shall be provided that will be the kVA rating for continuous
running at variable load for unlimited periods with 10% overload available for 1 hour in
any 12 hour period.
f) The specified prime power rating shall be available after de-rating for maximum
ambient temperature of 55oC.
g) The Diesel Generator system shall be composed but not limited to the following
components:
i. Diesel Generator engine driven generator

ii. Day and Bulk fuel (double skinned) storage system in line with NFPA 37
iii. Fire suppression system for bulk fuel system
iv. Jettison tank system for day tanks
v. Diesel Engine Starting system
vi. Local circuit breaker panel
vii. Neutral Grounding Resistor (NGR) panel
viii. Acoustic treatment of building
ix. Air intake and Exhaust (generator building) system
x. System Control Panel
xi. Fire suppression system as per civil defence / NFPA 30 and NFPA 37
requirements etc.
18.10.2 Codes and Standards
18.10.2.1 IEC Standards
a) Unless specified otherwise, the Diesel generator set shall conform in design,
construction, material and performance to the latest following editions of the IEC codes
and standards.
IEC 60204 Electrical equipment of industrial machines

IEC 60034 Rotating electrical machines
IEC 60034-1 Part 1: Rating and performance
IEC 60034-2 Part 2: Methods for determining losses and efficiency of
rotating electrical machinery from tests
IEC 60034-5 Part 5: Degree of protection by enclosure for rotating
machinery
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IEC 60034-6 Part 6: Methods of cooling rotating machinery
IEC 60034-7 Part 7: Symbols for types of construction and mounting
arrangements of rotating electrical machinery
IEC 60034-8 Part 8: Terminal marking and direction of rotation of rotating
machines
IEC 60034-9 Part 9: Noise limits
IEC 60034-11 Part 11: Built-in thermal protection
IEC 60034-22 Part 22: AC generators for reciprocating internal combustion
engine driven generating sets
IEC 60050 International Electrotechnical Vocabulary chapter 411
IEC 60072-1 Dimensions and output ratings for rotating electrical machines
– Frame numbers 56 to 400 and flange numbers FF 55 to FF
1080 and FT 55 to FT 1080
IEC 60072-2 Dimensions and output ratings for foot mounted electrical
machines with frame numbers 355 to 1000
IEC 60038 IEC Standard Voltages.
IEC 60044 Instrument Transformers.
IEC 60060 High Voltage Test Techniques
IEC 60071 Insulation co-ordination.
IEC 60076 Power Transformers
IEC 60099 Surge Arrestors.
IEC 60255 Electrical relays
IEC 60439 Low voltage switchgear and control gear assemblies
IEC 60529 Classification of degrees of protection provided by enclosures
IEC 60715 Dimensions of low voltage switchgear and control gear
IEC 60934 Circuit breakers for equipment
IEC 60934 Low voltage switchgear and control gear
IEC 60085 Thermal evaluation and classification of electrical insulation
18.10.2.2 Other standards
a) Reciprocating internal combustion engines BS 5514 or VDE.
b) Reciprocating Internal Combustion Engines - Fire Protection ISO 6826
c) Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets

– all relevant ISO 8528
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Dubai Municipality

18.10.2.3 Local standards
Further to international standards, the complete equipment shall also conform to the
Civil Defence standards and/or regulations of the DEWA, if these are higher, more
stringent or of special nature.
18.10.3.1 General
a) The engine, radiator, alternator and auxiliary components shall be mounted on a

common base frame. The starting battery shall be supplied loose for positioning
adjacent to the starter motor.
b) The complete unit shall be designed for free standing operation on a flat level surface
(isolated foundation) and shall be supplied with anti-vibration mountings.
c) The isolated foundation shall be provided for generator set to reduce both active and
passive vibrations. Further, vibration isolation mountings are required to reduce the
transmission of vibration and shocks
d) The base frame shall be of fully welded construction of rolled steel section or folded
steel plate designed to provide a sturdy support to complete assembly and fitted with
lifting points to aid handling.
e) All exposed moving parts such as fans, couplings, drive belts, etc. shall be guarded in
accordance with relevant standards.
f) Oil drip trays, with drainage facility, shall be provided below the engine to prevent floor
contamination.
g) Engine should be accessible otherwise a permanent maintenance and access platform

shall be provided.
18.10.3.2 Diesel Engine
Type:
a) The engine shall be air or water-cooled, single block design, four stroke cycle
compression ignition diesel. Two stroke engines are not acceptable. Diesel engines
requiring premium fuels will not be accepted. The engines shall be suitable for the
locally available distillate fuels. The engine type shall have been in commercial
operation for a period of not less than 1 year.
b) The engine shall be of the 4 stroke, water cooled direct injection compression ignition
type with an in-line or vee cylinder configuration. The engine may be naturally aspirated
or turbo-charged. The nominal speed shall not exceed 1500rpm.
c) The engine shall be rated in accordance with IEC 60034-1 (prime rated) and shall be
capable of continuous operation at rated output plus a 10% overload for 1 hour in any
12 consecutive hours running. All chain and gear drives shall be located in oil-tight
cases and shall be pressure lubricated.
d) The diesel engine and alternator rating shall be sized for the load characteristics. The
sizing of the generator shall take account of all of the following types of loads:
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Dubai Municipality

i. Continuous running of all motors; starting of the largest motor with all other
motors running on full load;
ii. Non-linear loads (VSD, UPS, rectifiers, discharge & fluorescent lighting, switch-
mode power supplies etc.)
iii. Large linear loads (heating, boilers)
iv. Loads requiring stability voltage, frequency and waveform within specified
tolerances to ensure correct operation
e) Torsional vibrations of the complete rotating system shall be within the limits specified
in Lloyds Register of Shipping Rules and Regulations over a range minus 5 percent to
plus 10 percent of the rated speed.
f) The engine shall accept full rated load within a maximum of 20 seconds from initiation
of the starting sequence when starting from cold at the minimum specified ambient air
temperature. The initial step load shall be not less than 40 percent of the full load
value.
g) Instruments as follows shall be provided:
i. Lubricating oil pressure gauge.

ii. Lubricating oil temperature gauge.
iii. Cooling water temperature gauge.
iv. Tachometer.
v. Battery charge ammeters for electric start engines.
vi. Engine stop pushbutton.
vii. Day tank and bulk tank volumetric measuring system
viii. Other instruments as considered necessary by the engine manufacturer.

h) Devices shall be fitted and arranged to stop the engine under the following conditions: -
i. Oil pressure low.

ii. Oil temperature high.
iii. Coolant temperature high.
iv. Over speed.
v. Fuel low.
Governing
a) Engine governing shall be of the electronic type having a droop characteristic

adjustable over the range 0 to 5%. The governor shall be Type 1 to BS 5514 and shall
be Accuracy Class A1 or better. The maximum transient speed change shall not
exceed 5 percent with the maximum step load application. Provision shall be made for
remote adjustment.
Cooling System
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a) An engine-mounted, heavy duty, closed circuit, tropicalized folded core radiator with
blower type fan shall be sized to maintain safe operation at 55oC maximum ambient
temperature.
b) Radiator shall be sized for 110% of the engine full load rating and continuous loading at
maximum ambient temperature.
c) The radiators shall be mounted on the generating set base frame the fan shall be
driven by vee belts from the engine crankshaft. Where specified for larger capacity
generator remote radiator shall be provided.
d) All exposed hot or moving parts and in particular, fans, belt drives, couplings and
flywheels, shall be guarded in accordance with BS 5304 and to ensure safe operation.
e) To permit the adjustment and inspection of drives, apertures with secured cover plates
shall be provided in the guards at appropriate points.
f) Engine mounted radiators shall be provide with a flange for the fitting of flexible
ducting.
g) Engine driven pump(s) shall circulate the jacket water and lubricating oil if appropriate
through the radiator sections. The coolant shall be circulated by an engine driven pump
having a pressure gauge on the outlet pipework.
h) A thermostatically controlled diverter or by-pass valve shall be fitted in the engine

cooling water discharge pipe work, with a return to the circulating pump suction, to
maintain the circulating water at the optimum temperature irrespective of load. A dial
type indicator showing the coolant temperature at the hottest point of the cooling
system shall be provided.
i) The cooling system shall be provided with plugged valves as necessary to enable all
parts to be drained.
j) The flexible connecting section between radiator and fixed, (silencer) exhaust louvers
and intake louvers (actuated, intake fans, silencer, sand filter and sand trap) shall be
sized and located to provide sufficient intake air for engine combustion and to provide
required air flow through the radiator.
k) The generator room ventilation system shall be provided to dissipate the radiated heat
from generator building. The ventilation system for generator room shall be complete
with a sound attenuation system, electrically operated fans and motorised louvers with
manual override facility, which will open automatically 5 seconds prior to engine start-
up and close automatically 30 seconds after the engine shut down to protect the unit
from dust. The inlet and outlet opening shall be provided with multi-plate flap air shutter
which shall be driven by servo motors and shall be provided with weather protective
coating. It shall be not possible to start the engine if the inlet louvers are not opened
and the engine in operation shall shut-down in the event of closing the inlet louver
manually or due to any fault. Gravity type louvers not acceptable.
l) Generator room ventilation opening shall be provided with silencers comprising non-
inflammable, water repellent and abrasion resistant baffles, damping to a free-field
overall sound pressure level of maximum 85 dB(A) at 1 m distance from generator
room. Air filter system shall be provided for particles ≥ 10 μm. The air filter media class
shall be of G3 to standard EN 779, with approximately 85% average synthetic dust
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weight arrestance for the air inlet opening of the generator room. Safety switch for high
back pressure supervision shall be provided.
Engine air intake system
a) Engines shall be suitable for uninterrupted running on specified prime power rating (in
accordance with ISO8528, ISO3046) over a prolonged period, the following features:
i. Extra heavy duty “Desert” centrifugal type air filter with pre-cleaner alarm.
ii. Dry air cleaner with changeable filter element.
iii. Service indicator to optimize changing of filter.
Engine exhaust System
a) Engines shall be provided with a complete exhaust system comprising rigid and flexible
pipe-work, stainless steel bellows, silencer(s) and all necessary brackets, hangers, wall
sleeves and plates and sundries for a complete installation. Pipe wall thickness shall
not be less than 3mm.
b) Silencers shall be of the residential type.
c) The first section of exhaust from the engine manifold shall include a flexible bellows
unit. The next section of pipe shall be supported to allow movement without imposing
forces on the manifold.
d) Exhaust support brackets shall be designed to allow for pipe expansion and contraction
movement.
e) Bends in the exhaust pipe-work shall be kept to a minimum and shall be of the long
radius type.
f) Where the exhaust pipe passes through a wall, a wall sleeve and plates shall be fitted.
The annular space between the pipe and sleeve shall not be less than 25mm. The
space between the pipe and sleeve shall be filled with heat resistant material.
g) Exhaust terminations shall not be located in close proximity to air inlet grills or opening
windows were exhaust gas can re-circulate into the building. The exhaust outlet shall
be arranged to prevent the ingress of water.
h) For long exhaust runs, a water drain point or condensation trap shall be fitted near to
the engine.
i) Exhaust pipe inside rooms/enclosures shall be lagged with heat resistant material and
shall be provided with aluminium cladding so as to have a surface temperature not
exceeding 60°C.
j) The lagging shall be clad with aluminium sheet secured by stainless steel band clips.
k) Exhaust pipe shall be sized so that it is sufficient to ensure that exhaust back pressure
does not exceed the maximum limit as specified by the generator set VENDOR.
Fuel System
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a) Microprocessor based fuel injector should be provided. The electronic fuel injector shall
provide high pressure fuel injection at all engine speeds, electronically controlled
injection timing and variable injection intensity during one injection.
b) Inlet and outlet fuel connections to engine should be through suitable flexible lines. An
engine mounted Dual in-line fuel filters, fuel pressure gauge and engine fuel priming
pump shall be provided.
Lubrication system
a) The lubrication shall be forced feed type equipped with a gear driven lube oil pump with
a coarse strainer on the suction side. A full flow filter of nominal micron rating not
greater than 10 and having a pressure operated by-pass valve shall be provided on the
delivery side. Manual lubrication of any part of the engine shall not be accepted. The
lubrication system shall not require priming prior to starting the engine.
b) The engine lubricating oil dipstick shall be easily accessible and minimum and
maximum levels shall be clearly marked.
c) The engine sump shall have an easily accessible drain point or drainpipe, fitted with a
BSP plug.
d) The filters should be easily replaceable. Heat exchangers for oil cooling should be
engine mounted. Lubricating oil filters shall be Dual in-line type.
Starting system
a) The starting battery shall be of the nickel-cadmium or lead acid type installed on a non-
corrodible tray or stands and shall have a terminal cover of insulating material. The
battery shall have sufficient capacity for three consecutive start attempts each of 10
seconds duration. In addition, the battery shall have sufficient capacity after the three
start attempts to supply the maximum demand of the control panel for a minimum
period of 24 hours.
b) The battery charger shall employ transistor controlled magnetic amplifier circuits to
provide continuous taper charging and shall maintain rated output voltage within +/- 1%
from no-load to full load with boost/float control. It should be rated at minimum 8 Amps
and be short-circuit proof to withstand the starting inrush current.
c) In the "Float" charge mode the charger shall automatically maintain the battery in a fully
charged condition whilst supplying standing loads. In the "Boost" charge mode, the
charger shall be capable of fully charging the battery from a fully discharged condition
in a period not exceeding 6 hours.
d) The charging characteristics for the nickel-cadmium vented type battery shall minimize
electrolyte gassing.
e) The charger shall be complete with:
i. Incoming supply On/Off switch.

ii. Supply On indication.
iii. Output voltmeter.
iv. Output ammeter.
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v. Float/Boost Charge selector switch.
vi. Charger Failed relay with voltage free changeover set of contacts wired to
terminals.
vii. Charger Failed indication.

f) The minimum requirement for the "Charger Failed" alarm shall be the detection of a.c.
supply and d.c. output failure. The relay shall not operate under a transient a.c. supply
failure condition.
g) An engine shut down solenoid shall be fitted, this shall be of the "energised to run type"
for operation from the engine control system battery. An emergency stop push button
shall be provided. Emergency air shut off flaps shall be incorporated at air intake to the
engine (at inlet of the charge air cooler). The shut–off flap shall be actuated manually
on pushing the emergency button or automatically in the event of governor failure. The
flap on closing interrupts the air feed to the cylinders and shuts down the engine. After
emergency shutdown, the flaps can only be re-opened manually for resuming the
operation. The shut-off flap shall have necessary limit switches to energise suitable
optical or acoustic alarms.
h) Stopping shall be attained by interrupting the shutdown solenoid circuit and this shall
also cancel any outstanding repeat start attempts.
18.10.3.3 Alternating Current Generators (Alternators)
General
a) Generators shall be brushless, single bearing salient pole, revolving field self-regulating
alternators of fabricated steel construction throughout, and shall comply fully with IEC
60034.
b) They shall have a dynamically balanced rotating field, salient pole construction with
heavy damper windings. The machine shall have an exciter and liberally rated silicon
diodes assembly with a self-contained excitation system with automatic voltage
regulator (AVR). It shall be screen protected and drip proof with a large terminal box
suitable for the outgoing cabling.
c) Automatic voltage regulators shall be of the solid state three-phase sensing type with
in-built protection against sustained over excitation. The voltage regulation shall be not
less than Grade VR2.21 to BS 4999: Part 140.
d) With the application of the maximum step applicable in the electrical system design at
any power factor between 0.2 and 0.8 lagging, the initial voltage shall not drop below
85 percent of the nominal value recovering to 94 percent within 1.5 seconds.
e) The generators shall be star connected.
f) The generators shall be capable of maintaining their continuous maximum rated output
when operating within ±5% rated voltage and at rated power factor.
g) The output waveform shall be sinusoidal, with THD less than 5%, and shall be entirely
suitable for operation of electronic equipment with a high percentage third harmonic
current of up to 80% of total current.
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h) All windings shall be tropicalized and suitably impregnated to withstand the site
ambient conditions.
Stator
a) The stator core shall consist of high permeability, low loss steel stamping, tightly
clamped and securely located within the machine casing.
b) The windings shall consist of electrolytic copper conductors insulated throughout with
class 'H' materials.
c) The windings shall be effectively braced to withstand the maximum forces arising from
any short circuit that may occur at the stator windings terminals. Any material that is
liable to shrink in service shall not be used for bracing, packing or wedging. The
ventilating circuit shall be designed to avoid hot-spots and to permit adequate cleaning
by a portable centrifugal blower.
d) Both ends of each stator windings shall be brought out to terminal positions on the
stator casing, the phase and terminal box being arranged for 3-phase and neutral
connection.
Rotor
a) The rotor shaft and hub shall be of forged steel preferably in one piece. The rotor poles
shall be constructed of steel laminations, keyed and securely fixed to the rotor hub and
fitted with interconnected damper windings to absorb the cyclic irregularity of engine.
b) The field winding shall consist of electrolytic copper conductors insulated throughout
with class 'H' materials. Rotor should be precision wet layer wound to ensure complete
encapsulation of rotor winding resulting in excellent environmental protection and
protection against centrifugal forces. Rotor should withstand 124% over speed.
Excitation system
a) The main exciter output shall be fed to their main rotor windings through a 3 phase, full
wave bridge rectifier. The diode bridge shall be protected against surge and voltage
transients caused, for example, by short-circuit or out of phase paralleling by a surge
arrestor. The automatic voltage regulator shall have following minimum features:
i. Three phase sensing for optimum voltage control with unbalanced three phase
loads.
ii. Volts-per-hertz regulation for optimum block load voltage and frequency
recovery.
iii. Steady state voltage accuracy better than 0.5 % for precise control and quick
recovery.
iv. Voltage regulation, 1% from no load to full load (maximum).
v. External gain adjustment for constant voltage output across the operating range.
vi. No moving parts should be there. All solid-state design for better reliability.
vii. Voltage adjustment range - 20% to 10%.
viii. Built in under voltage and under frequency protection for voltage regulator and
generator.
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ix. Paralleling capability.
x. Telephone Interference Factor (TIF) less than 50.
xi. EMI/RFI suppressions to commercial standards.

Waveform Distortion
a) The total harmonic distortion (THD) of the open circuit voltage wave-form shall be in
the order of 1%. Under three phase balanced linear conditions the (THD) shall be of
the order of 3%.
b) The output winding shall be 5/6-pitch design to optimize 3rd, 5th and 7th harmonics on
the voltage wave-form.
18.10.3.4 Remote Mounted Control Panel
a) Control panel shall be of a highly reliable design with protection against short circuit,
reverse battery polarity and overvoltage transient surges.
b) The generator shall have an electronic modular free standing control panel with solid-
state microprocessor based modules for engine control, AC metering and adequate
environment protection.
c) The panel should be equipped with self-diagnostic capability to help trouble shooting
for ease of maintenance.
d) Panel should have one engine control module to display engine operating information,
system checking diagnostics, and fault shutdown using 18 inch HMI display. The HMI
display shall have sequential display of operating hours, engine rpm, battery volts, oil
pressure and jacket water temperature. Any of these values shall be displayed by
means of a selector switch the controls shall be designed to provide the following
facilities:
i. Automatic starting and stopping of the engine.

ii. Manual starting and stopping of the engine.
iii. Simulated mains failure for testing the automatic starting and stopping of the
engine.
e) Subject to the approval of the DM/Engineer, the facilities specified below may be
modified to suit the manufacturer's standard control unit conditional on compliance with
the overall operating concept.
f) Control equipment shall be installed in a composite generator control panel which shall
be floor mounted in control room.
g) Indicating instruments shall be provided as follows:
i. Phase ammeters or ammeter with phase selector switch.

ii. Voltmeter with phase selector switch.
iii. Wattmeter.
iv. Frequency meter.
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h) Control switches shall be provided as follows:
i. Hand/Auto/Off.
ii. Auto Return On/Off.
iii. Key operated Simulate Mains Failure/Off.
iv. Engine heater(s) supply On/Off.
v. Generator anti-condensation heater supply On/Off.
vi. Push-buttons shall be provided as follows:-
vii. Engine Start/Stop.
viii. Engine Emergency Stop.
i) Hand regulating controls shall be provided as follows:
i. Engine speed.
ii. Generator voltage.
iii. Indicator lights shall be provided as follows:-
iv. Main supply available.
v. Standby supply available.
vi. Alarm annunciation shall be provided as follows:-
vii. Engine failed to start.
viii. Engine high cooling water temperature.
ix. Engine low lubricating oil pressure.
x. Engine over speed.
xi. Engine under speed.
xii. Generator voltage high.
xiii. Generator voltage low.
xiv. Generator circuit-breaker auto trip.
xv. Fire detection system operated.
xvi. Emergency stop operated.
xvii. Battery charger failed.
xviii. Bulk fuel tank overflow/leakage
xix. Daily service tank overflow/leakage.
xx. Daily service tank overflow/leakage.
xxi. Fuel transfer pump fault.

j) The control system shall initiate the automatic generating set start-up and shut-down
sequences as described below. The controls shall be designed to operate on an
"energise to run" and de-energise to stop" basis.
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k) With the engine control selection switch in the AUTO position, the control system shall
operate as follows:
i. On loss of main supply and after a preset adjustable time delay of 0-10
seconds, engine starting shall be initiated via a mains failure relay located in the
incomer unit of the associate switchboard. Concurrent with the starting of the
engine the inlet and outlet electrically operated air louvers shall be opened and
air intake fans shall be operated.
l) The engine cranking sequence shall comprise a maximum of three 10 second periods.
The control system shall provide facilities for adjusting both the number and duration of
the cranking sequence.
m) When the generating set reaches full speed and voltage, and after a preset adjustable
time delay of 0-5 seconds, a voltage-free relay contact shall close to initiate the closing
of the associated standby supply incomer breaker.
n) Should the main supply be restored before the closing of the standby supply incomer
breaker, the closing of the main supply incomer breaker shall be initiated and after
receiving a “normal mains supply incomer closed” signal and after a preset adjustable
time delay of 0-5 minutes the engine shall be shut-down.
o) On restoration of the main supply with the AUTO RETURN control switch in the ON
position and after a preset adjustable time delay of 0-5 minutes, opening of the standby
supply incomer breaker, closing of the main supply incomer breaker and engine
shutdown shall be automatically initiated. The shutdown procedure shall be in
accordance with the engine manufacturer's standard practice.
p) On restoration of the main supply with the AUTO RETURN control switch in the OFF
position the generating set shall continue to supply the load. The automatic shut-down
sequence shall be initiated by returning the switch to the ON position.
q) The facility shall permit the testing of the generating set automatic start-up sequence
under a simulated main supply failure condition. With the test facility switch in the
SIMULATE MAINS FAILURE position the automatic start-up sequence shall be
initiated. The engine shall be stopped by returning the switch to the OFF position.
r) The engine shall automatically stop and lock-out under the following conditions:-
i. Engine failed to start.

ii. Engine high cooling water temperature.
iii. Engine low lubricating oil pressure.
iv. Engine over speed.
v. Engine under speed.
vi. Generator voltage high.
vii. Generator voltage low.
viii. Generator circuit breaker auto trip.
ix. Fire detection system operated.
x. Emergency stop operated.
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xi. Daily service tank low level.

s) Alarm and lock-out systems shall be inhibited during normal starting and stopping
operations.
t) Restarting of the engine shall be prevented until the alarm has been reset.
u) The emergency stop shall operate in all control modes.
v) Voltage-free changeover contacts shall be provided for remote indications as follows:
i. Common group alarm for Generating Set Failed comprising each of the single
alarms causing engine lock-out.
ii. Generating set running.
iii. Generating set available for automatic mains failure operation.
w) The contacts shall be wired to a marshalling box.
x) Provision shall be made for the connection of an external emergency stop push-button
or switch. The associated terminals shall be fitted with a link.
y) A fire detection system shall be installed above the generating set. The system shall
comprise fusible links and tensioned operating wires and a Fire Push located adjacent
to each door entry to the Generator Room.
z) Link fusing or Fire Push operation shall initiate the operation of the engine fuel supply
fire valve, daily service tank jettison fire valve and switches for initiating engine lock-
out, remote alarm and fuel transfer pump stop.
18.10.3.5 Fuel Systems
a) The fuel system shall comprise an engine driven feed pumps with duplex filters, daily
service tank with supporting structure and bund, bulk fuel tanks and bund, fuel transfer
pumps and all interconnecting pipework including flexible engine connection pipe.
b) Daily service tanks shall be fitted with the following:
i. High, intermediate and low levels float switches for the control of a fuel oil
transfer pump and/or alarm initiation.
ii. A jettison connection fitted with fire valve. The connection shall be sized to
drain the contents of the tank in a period not exceeding 5 minutes.
iii. The bulk fuel tanks shall be provided with foam fire suppression system as a
minimum requirement.
c) The Local Authority and Fire Service shall be consulted, regarding the sitting of tanks
holding large quantities of fuel.
d) The capacity of daily service tanks shall be sufficient for eight hours full load operation
of the generating set. The Day Tank shall sit within a bund.
e) Galvanised steel shall not be used for any part of the fuel system.
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f) Bulk Fuel Tank(s) shall have a capacity sufficient for 3 days continuous running on full
load.
g) Bulk tank(s) shall be located at a lower level than the Day tank in order to permit
overflows from the Day tank to gravitate back to the Bulk Tank.
h) The Contractor shall provide adequate permanent access for fuel delivery vehicles.
i) Bulk tank(s) located under-ground. The under-ground containment for the bulk fuel tank
shall be suitably skirted to prevent ingress of rainwater. A level switch shall be installed
in the containment and be wired to a spillage alarm in the Engine Control Panel to
indicate leakage in the tank. Additional contacts shall be wired to terminals in the
Engine Control Panel for output to telemetry.
j) Bulk tanks shall be constructed in line with all relevant BS standards.
k) Tanks shall be suitably treated and coated. The interior shall be coated with oil at the
manufacturer’s works, to prevent corrosion occurring before being placed in service.
l) The Bulk fuel tank shall be fitted with a man way cover and shall have the following
facilities:
i. Filler connection.
ii. Fuel draw off connection, (piped to base of tank with foot valve for buried tanks).
iii. Tank Breather connection.
iv. Day tank overflow connection.
v. Fuel contents gauge, with output for remote indication.
vi. Pump up gauge.
vii. Overfill Alarm.
viii. Digital fuel capacity gauge, calibrated in litre

m) All fuel transfer pumps, for both day-tank and bulk-tank, shall have proper dry run
protection and pump control shall be with necessary float regulators suitable for fixing
inside fuel tanks and compliant to international safety regulations for identical
application.
n) A lockable outdoor Filling Cabinet, of stainless steel construction with a drip tray of not
less than 5 litre capacity, shall be provided. The fill pipe, overfill alarm, and a pump up
gauge, shall be housed within the enclosure.
o) Fuel transfer pumps shall be self-priming rotary-vane design and shall be provided as
duty/standby configuration. The pump shall be suitable for the duty taking into
consideration the location of the bulk tank(s). The pumps shall be located so as to
permit repair or replacement without removing other equipment. Diesel pump induction
motor shall be certified as ATEX/Ex Cat. EEx d IIB T3 and shall be suitable to be
installed within an ATEX Zone 1 area. If the system is not a flooded suction type (i.e.
where the Bulk Tank is below ground) then facilities shall be provided to prime the
pumps.
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p) All fuel pipe-work shall be manufactured from mild steel and shall be a pipe within a
pipe. The inner pipe carrying the fuel. The outer pipe being provided to carry the fuel
back to the Bulk Tank bund in the event of the inner pipe fracturing. A detector shall be
provided in the outer pipe of the return pipe-work, nearest the Bulk Tank, to initiate an
alarm in the event of the inner pipe leaking.
q) The pipe-work shall have a continual fall from the Day tank back to the Bulk tank. All
joints, in both the inner and outer pipe-work shall be welded. All pipe-work shall be
treated, externally to resist corrosion.
r) Pipe-work above ground and external to buildings shall be trace heated, and lagged, to
prevent waxing. Pipe-work laid in the ground shall be half lap covered in a non-woven
synthetic fibre fabric impregnated and coated with a neutral compound based on
saturated petroleum hydrocarbons and inert siliceous fillers.
s) The following pipe-work shall be provided:
i. Filler pipe-work from the Outdoor Filler Cabinet to the Bulk Tank.
ii. Suction pipe-work from the Bulk tank to the pump.
iii. Delivery pipe-work from the pump to the Day Tank.
iv. Overflow pipe-work from the Day Tank to the Bulk Tank.
v. Overflow pipe-work from the Day Tank Bund to the Bulk Tank.
vi. Engine feed and return pipes.
vii. Bulk tank and Day tank breather pipes.
viii. Day tanks shall be of welded steel construction.
t) The Day Tank shall be fitted with:
i. Semi rotary manual pump complete with filler pipe-work and isolating valve to
prevent run back or overflowing of fuel oil.
ii. Drain / draw off with pipe-work and valve.
iii. Breather.
iv. Inspection Plate.
v. Digital fuel capacity gauge, calibrated in litre, with Stop/start contacts for pump
control, High/High and Low/Low alarm contacts wired to the Engine Control
Panel for output to Telemetry.
vi. Fire Shut Off valve with contacts wired to the Engine Control Panel for output to
telemetry.
vii. Overflow to the bulk tank.
viii. Tee off connection with valve and hose connection on tank inlet to permit the
pumping through of dirty fuel prior to the first filling of the Day Tank.
ix. The bund shall be provided with:
x. Overflow to the Bulk Tank Bund
xi. Level switch wired to a spillage alarm in the Engine Control Panel.
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18.11 DIRECT CURRENT SUPPLY SYSTEM
a) This specification covers the design, manufacture, testing at works and supply of a
Direct Current Supply System complete with Distribution Section and Battery Discharge
Test Set.
b) The purpose of the unit is to supply a DC-Voltage to the specified essential services 24
hours a day, 365 days a year.
c) All rectifiers shall be subject to a load-duration test performed at rated voltage for a
period of not less than 48 hours prior to the execution of functional tests.
d) A battery discharge test shall be performed at the rated current of the DC supply unit
and the final battery voltage, after the specified time, shall be recorded.
18.11.2.1 General
a) The design of the Direct Current Supply System shall be based on achieving the
following minimum lifetimes.
i. 20 years for the rectifier and auxiliaries;

ii. 15 years for nickel cadmium battery cells.
b) Electrolyte type capacitors shall maintain their capacity within the tolerances for at least
10 years.
18.11.2.2 Safety and Reliability
a) The equipment shall be of a standard, well set and proven design which ensures
maximum safety to Personnel, maximum service reliability.
b) Design and construction shall be simple and provide good accessibility to components
and parts.
c) All equipment and parts shall be of modern design and of the highest industrial grade,
free from all defects.
d) Capacitors of the electrolyte type shall be non-toxic.
18.11.2.3 System Variations
The input voltage of the Direct Current Supply System, with transformer/rectifiers
disconnected, will be sinusoidal according to IEC 60146. The input voltage shall be
400V AC, 3 phase, 50 Hz, from a mains supply with system variations not exceeding
the following values:
Static ± 10 %
Dynamic + 16 % ; -20 %
Spikes 2 kV
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Dubai Municipality

Frequency ±5%
18.11.2.4 Arrangements
a) The DC Supply System shall be of the parallel redundant type and comprise of the
following items:
i. Two constant voltage, current-limiting rectifier

ii. Two battery banks (nickel cadmium)
iii. Auxiliary equipment
iv. Distribution section as integral part of the charger cubicle.
v. Battery Discharge Test Set.

b) The system shall have 2 x 100% charger 2 x 50% capacity battery.
c) The output of the rectifier shall either rapid (boost) charge the battery along with the
load or float charge the battery and simultaneously supply the power requirements of
the load. In the event of failure of the AC mains supply to the rectifier, the battery shall,
without interruption, immediately take over and supply the power requirements of the
load.
d) Each battery charger unit shall be suitable for operation in parallel with unsynchronized
supplies.
e) Interlocks between battery/battery chargers combination and the DC distribution board

shall be provided to prevent boost charging voltages from appearing on the dc
distribution system. The interlocks shall ensure the followings:
i. Only one battery charger can be selected to boost charge at any one time.
ii. Bus bars shall be interconnected prior to boost charging commencing
iii. Boost voltage shall not be applied to the dc distribution bus bar and system
18.11.3 Construction and Electrical Requirements
18.11.3.1 Accessibility and Enclosure
a) The unit shall have a complete metal enclosure of thickness at least 2 mm and shall be
self-supporting, suitable for floor mounting. The protection class of the unit shall be at
least IP42.
b) The enclosure shall be free standing sheet steel cabinets suitable for indoor operation.
The enclosure shall be arranged for front operation and maintenance.
c) Removable side (end) panels shall be provided. Rear access shall not be required.
Adequate ventilation shall be provided. The redundant equipment shall be in separate
cubicles to allow maintenance without interruption of supply.
d) Access hinged doors shall be lockable from a common key.
e) The design shall include measures to avoid condensation.
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f) Battery enclosure shall be provided with vent fan and ducting system up to outside of
battery room.
g) Adequate means shall be provided to ensure the safe removal of fuses. Fuses can only
be removed under no-load conditions. The fuses must be visible and easily removable
when the compartment doors are open.
18.11.3.2 Secondary Cables and Wiring
a) Auxiliary circuits shall be clearly grouped and be protected. All wires shall be at least
1.5 mm² of the PVC type and be able to withstand 2500 V impulse test. All wires shall
be connected to terminals individually and clearly identified at both ends by ferrules of
isolating material or plastic code markers in accordance with the wiring diagram(s).
b) Colour coding of secondary wiring shall be in accordance with IEC 60446. Wiring
between two terminals shall be continuous; joints or interconnections are not allowed.
c) To accommodate and support the secondary wiring, covered plastic channels,

insulated tubes or plastic strips shall be used.
d) Secondary wiring shall never be mounted direct to metal. The filling factor for channels
shall not exceed 70%. Where supporting of a wire is not feasible the wire or part of it
shall be as short as possible.
e) Terminal blocks shall be conveniently located for external connection. Terminal blocks
will be clearly marked for wiring. A wire label at both ends will identify each internal
interconnecting wire. Terminal blocks to be Klippon or equivalent.
f) For all wires and conductors individual terminals shall be provided unless terminals are
specially made for more than one conductor.
g) All circuits shall be protected by miniature circuit-breakers of the air-break type or

cartridge-type fuses.
h) Individual wires or cables, which may reasonably be expected to require disconnection

for the purpose of component testing or replacement, shall be identified at both ends by
means of ferrules of insulating material (slip-on-clips), marked in accordance with the
related wiring diagram.
i) Terminals shall be of non-loosening construction and of the wedge type, constructed in

such a way that direct contact between screw, bolt or nut and conductor is avoided.
j) Stranded conductors shall be provided with cable lugs for terminal connection.
k) Terminals carrying different voltages shall be logically grouped and separated. Barrier
plates shall be provided.
l) Furthermore sufficient spare terminals shall be provided for future purposes with a
minimum of 20 % of the installed terminals.
18.11.3.3 Anti-condensation heaters
a) Enclosures shall be equipped with anti-condensation heaters of sufficient capacity to

prevent the formation of condensation within the enclosure under the service conditions
and suitable for operation at 230 VAC.
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b) Thermostat controlled anti-condensation heaters shall be installed at the bottom of
each cubicle and shall be individually protected by miniature circuit breakers.
c) The main anti-condensation bus feeder breaker shall be provided with alarm contacts.
18.11.3.4 Marking
a) Unit shall be provided with name/rating plate of corrosion resistant material fixed to a
non-removable part. At least the following information shall be indelible marked in
English and Arabic language:
i. Year of manufacture;
ii. Name of manufacturer;
iii. Type and serial number of the unit;
iv. Nominal input voltage and current;
v. Nominal output current and voltage;
vi. IP class
vii. Type of battery/electrolyte
viii. Number of cells
ix. Ah capacity
x. Phase or pole marking of AC and DC supply terminals
b) Labels shall be colourless transparent plastic materials not less than 3 mm thick with
bevelled edges to half the thickness. Each shall be reverse engraved in Arabic and
English the engraving being filled white and the reverse side painted blue unless
otherwise detailed.
18.11.3.5 Battery Cells and Containers
a) The battery shall be of the nickel cadmium sealed type.
b) Battery cells shall be assembled in flame retardant, heat resistant, shock-absorbing

plastic containers with covers attached to form a permanent leak-proof seal. Covers
shall be sealed against creepage of electrolyte and shall be fitted with spray-proof vent
plugs.
c) Containers shall be marked on front side of each container.
d) Batteries shall be mounting in forced ventilated sheet steel enclosure. The enclosure
shall be made of electrolyte resistant material, designed to provide easy access to
each battery cell for maintenance or testing purpose.
e) Two polarities shall be insulated from earth.
f) Supplementary cells shall not be used as means of dc voltage control.
g) The battery shall be furnished complete with insulated inter-cell, inter-row and inter-tier
connections and hardware.
h) The battery connection to the DC distribution section shall be through an isolating

switch located in the section.
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i) To disconnect the battery at the source, a circuit breaker with shunt trip, rated for full
battery capacity, shall be installed at the battery cabinet.
j) The terminals shall be capable of carrying the battery current as well as withstanding
the effects of a short circuit that might occur at the battery.
k) The top tier of cells shall not be more than 1.5 meter above floor.
l) Vendor shall consider ageing factor and temperature correction factor based on
specified site condition while sizing the batteries.
18.11.3.6 Switching Devices
Switching (mechanical) shall be of the independent manually operated air-break type

for continuous duty. They shall as a minimum comply with utilisation category AC 23 for
use on the AC side and DC 23 for the use on the DC side in accordance with IEC
60947-3.
18.11.3.7 Earthing
a) A copper main earth bar shall be fitted along the whole width of the cubicle. This bar
shall be bonded to the enclosure of the unit. Within the cubicle an earthing bolt shall be
mounted M10.
b) A high resistance shall be connected between Positive and Negative poles of the
system and the center point of the resistance shall be earthed through an earth fault
relay, designed to indicate whether the earth fault exists on the Positive or Negative
pole of the system. The Value of resistance connected across the Poles shall be such
that in the event of a fault on either Pole the earth fault current does not exceed 10mA.
18.11.3.8 Finish
a) All structural work shall be adequately protected against corrosion. Painted structural
work shall be at least comprised:
i. One coat of primer;

ii. Two coats of oil-resistant finishing paint.
iii. Colour of finishing paint (subject to DM/Engineer approval)
18.11.3.9 Materials
a) The fuses shall be of the D-type and/or Hadkin knife-in type in accordance with IEC
60269-2. Fuse holders for quick acting fuses shall be marked "special thyristor fuse.
b) All Printed circuit cards shall be of plug-in-type, interlocked to prevent insertion in a

wrong slot. Each card shall have LED indication to indicate healthiness of the card.
c) All PCBs shall have test points which shall be easily identifiable and accessible for
testing. All printed circuit board shall be fully coated against corrosion confirming to
ANSI/ISA-S71.04 for class G3 Environment.
d) All power wiring shall be carried out with stranded insulated copper conductors
adequately sized for the required duty. Gland plate shall be of nonmagnetic material.
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18.11.3.10 DC Distribution Section
a) A separate section shall be provided for DC distribution system. Facilities shall be

provided for automatic disconnection of distribution before end of battery discharge.
Manual reclose facilities shall also be provided.
b) The distribution shall be unearthed and an earth fault detector relay shall be installed to
provide local and remote alarms. Protection shall be based upon detection of a low
frequency AC current circulation between DC network and earth. A front panel
mounted indicator shall permanently indicate the value of network insulation
impedance
c) The DC distribution section shall be rated on the basis of voltage and current ratings of
the charger.
d) Current-carrying components shall furthermore be capable of carrying their rated

current continuously at rated voltage and under specified service conditions without
exceeding the permissible temperature limits.
e) The MCBs shall be of two pole construction and shall be provided for the outgoing
feeders. Operating mechanism shall be quick make, quick break and trip free type. The
MCB's shall be provided with the following features:
i. Instantaneous tripping on short circuit.

ii. Common trip bar for simultaneous tripping of both poles.
iii. Mechanical position indicator.
iv. Auxiliary NO/NC contacts for remote indication of tripping.
18.11.4.1 General
a) The rated output of the rectifier shall be based on standard duty class 1 of IEC 60146.
The unit shall be suitable for continuous duty, operating under service conditions.
b) Battery chargers shall be fully automatic, silicon controlled rectifier type. Under normal
operating conditions both battery chargers will operate in parallel. In case of the failure
of one charger, the second will individually ensure the system duty. During switching
from one charger to another, the DC supply shall be uninterrupted.
c) In case of failure of incoming voltage or failure of both chargers, the battery will
continue to supply the load for 5 hour duration.
18.11.4.2 Battery Float-Charge Operation
a) The rated output current of the rectifier shall be the current corresponding to the
maximum load in KVA divided by the nominal DC system voltage, plus the current
required for the charging of battery from end cell voltage in 8 hours.
b) The rectifier steady-state DC output voltage variations shall be controlled to within plus
1% and minus 1% of the set value. This corresponds to the battery float-charge voltage
during load variations between zero and the rated output current of the DC supply unit
and during steady-state input voltage and frequency variations referred to in.
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c) During transient input voltage depressions up to 20% of nominal voltage, the rectifier
DC output voltage variations shall be controlled to a value that will at least prevent the
initiation of battery discharge.
d) Facilities for on-line adjustment of the set value of float-charge voltage shall be
provided. A suitable potentiometer shall be provided on panel front for this purpose.
e) The DC output current of the rectifier, when operating under constant current limiting
conditions, shall be controlled within plus 2% and minus 2% of the set value.
f) The rms value of the voltage ripple, with the battery connected, shall not exceed 3% of
the nominal DC system voltage.
18.11.4.3 Battery Rapid-Charge Operation
a) The "rapid"-charge cycle shall be according to a constant current/constant voltage

characteristic.
b) The duration of the "rapid"-charge operation shall be automatic and after the elapsed
time, will re-instate the rectifier output voltage to that corresponding to continuous float-
charge operation.
c) When operating under constant current-limiting conditions, the DC output current of the
rectifier shall be controlled to within plus 2% and minus 2% of the set value.
d) When operating under constant output voltage conditions, the voltage shall be
controlled to within plus 1% and minus 1% of the set value.
e) The applied set value of the rapid-charge voltage and the duration for which it is
applied to the battery shall restore the battery to 100% of its nominal ampere hour
capacity within 8-hour period.
f) Facilities shall be provided for on-line adjustment of the set of final voltage applied to
the battery, by a potentiometer provided at the front of the panel.
18.11.4.4 Battery Discharge Test
A switch shall be provided to isolate each battery bank whilst the charger and other
battery bank continue to supply the load to carryout battery bank discharge test. An
auxiliary contact shall be provided for local and remote indication of “battery isolated”
condition.
18.11.4.5 DC Supply Unit Output Voltage
The voltage at the output terminals of the DC supply unit shall be limited to within plus
10% and minus 10% of the nominal DC system.
18.11.4.6 Audible Noise Limitation
a) If not otherwise specified, the sound pressure level (ref 20 microPa) measured at one
meter distance from the equipment at any position, shall not exceed 70 dB(A) at any
load between zero and rated output of the unit. If tonal components are present, the
noise limit shall be taken 5 dB (A) more stringent.
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b) If the above values are unobtainable without the use of absorptive materials,
precautions shall be taken to limit their effect on cooling, dust deposits and fire
hazards, with minimal use of materials.
18.11.4.7 Radio Frequency Noise Limitation
The protection of radio frequency interference voltage shall not exceed the value of
suspension grade "N" as stated in VDE 0875.
18.11.5 Auxiliary Equipment
18.11.5.1 Indications and Alarms
a) The following indication equipment shall be provided on the cabinet door
i. AC "mains supply failure"

ii. Rectifier "charge failure"
iii. Rectifier "high DC float voltage".
iv. Alarm contact to main alarm system.
v. Rectifier "Low DC float voltage"
vi. Charger on boost
vii. Charger on Float
viii. Earth Fault
ix. Over temperature (shut down)
x. Overload
xi. Reverse polarity (tripping)
b) Indications shall be provided with in-built test facilities. Alarm indications shall have
manual reset facilities. They shall have a built-in memory to retain indication upon total
supply failure.
18.11.5.2 Measurements
a) The following measuring instruments shall be provided on the front of the panel of the
unit.
i. DC voltmeter measuring rectifier output voltage (with selection switch to

measure position to Negative, Positive to earth and Negative to earth Voltage).
ii. DC ammeter, with zero at mid-scale, measuring battery current
iii. DC ammeter measuring rectifier output current.
iv. AC Voltmeter measuring input voltage.
v. AC Ammeter measuring input current.
vi. Voltmeter for battery voltage.
vii. Percentage load indicator
b) The accuracy of the instruments shall be not less than that corresponding to class 1.5
of IEC 60051.
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18.11.5.3 Protection and Control
a) The following protective and control equipment shall be provided as a minimum

requirement:
i. Rectifier AC mains contactor with on/off control circuit switch and fuses
ii. Rectifier AC mains supply monitoring assembly
iii. Manually operated float-charge/rapid-charge selector switch mechanically
interlocked with the DC supply unit
iv. Output isolation switch
v. Manually operated DC supply unit output isolation switch
vi. Adjustable rapid-charge time control relay
vii. Rectifier DC output circuit fuses
viii. Battery circuit fuses.
ix. Auto/manual selector switch
x. Float/boost
xi. Input side filter to reduce harmonics on the mains side
xii. Potentiometer to set float and boost voltages in 'Auto' mode( * )
xiii. Potentiometer to vary float and boost voltage in 'Manual' mode( * )
* Range to be determined by VENDOR based on Battery requirements.
b) The AC mains supply monitor shall operate to open the rectifier AC mains supply
contactor in the event of AC supply voltage dips or supply unbalance that would if
impair the performance of the DC supply unit, and shall automatically re-close the
contactor on restoration of AC supply voltage.
c) Rectifier output and battery circuit fuses shall be in accordance with IEC publication
60269-2. The rating of rectifier output and battery circuit fuses shall be coordinated
such that the battery supply to the load is maintained in the event of rectifier bridge
short circuits.
d) The rectifier shall have the necessary equipment to ensure soft/slow starting upon
connection of the mains supply, to limit the in-rush current from the mains supply.
e) The DC supply unit shall incorporate necessary protection to protect the unit and its
components from excess current under all operating conditions.
18.11.5.4 Battery Discharge Test Set
a) An automatic, unattended battery discharge test set shall be provided for performing
discharge test on standby batteries. The unit shall be microprocessor controlled solid-
state electronic load bank based together with a non-volatile data-logging voltmeter.
The discharge current shall be continually monitored and the load bank automatically
adjusted so as to maintain the discharge current constant.
b) The charging state of the battery shall be checked by means of measuring method of
the voltage during discharge. The unit shall be design with MOSFET technology at 20
KHz and shall be Pulse Width Modulated type. High frequency electronic control shall
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be incorporated to smooth the DC current drawn from the battery without ripple.
Discharging time shall be adjustable for partial discharging. LCD display shall be
provided for operator interface.
c) The unit shall be supplied with parallel interface for PC / printer port and shall have RS
232 interface for communication with plant control system. All required software and a
rugged, field deployable notebook PC shall be provided with the unit for operation and
diagnostic purpose.
d) Battery load unit shall be added as an integral part of the system with selection facility
to discharge the battery bank at a constant current rate (C5 rating) and shall be
mounted in a separate compartment with sufficient ventilation arrangement, indication
for battery on float, on load and discharge mode to be provided.
18.12 UPS SYSTEM
a) This specification gives the minimum technical requirements for an AC Uninterrupted

Power Supply unit (AC-UPS). The purpose of the unit is to supply uninterrupted
400V/230V, 3phase with a constant frequency of 50 Hz to a specified load 24 hours a
day for 365 days a year. Battery backup shall be for 4 hours.
b) The basic AC-UPS system shall be composed but not limited to the following
components:
i. Rectifier/charger (dual)
ii. Battery banks;
iii. Inverter (dual, Parallel redundant)
iv. Static bypass switch.
v. Manual bypass switch
vi. Distribution section
c) Internal cooling of the unit shall be by natural or forced air ventilation. The unit shall be
capable of continuously delivering its rated output with any ventilation fan out of order
while the maximum temperature of the components shall not be exceeded.
d) The unit shall not incorporate cooling air filters that require periodic cleaning and/or
replacement.
e) When air inlets and outlets are protected by a screen, such a screen shall be of
corrosion resistant material.
f) The converters shall be loaded to its rated output, at 0.8 power factor lagging,
throughout a 48 hours test period. If an appropriated load is not available, the test shall
be carried out with a resistive load such the DC input current of the inverter is of the
rated value.
g) All functional tests shall be performed on the converters. The manufacturer test
protocol will be acceptable. The correct functioning of all measuring instruments,
alarms and indications, protections and (manual) controls shall be verified.
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18.12.2.1 General
a) The design of the AC-UPS System shall be based on achieving the following minimum
lifetimes.
i. 20 years for the rectifier and auxiliaries;

ii. 15 years for nickel cadmium battery cells.
b) Electrolyte type capacitors shall maintain their capacity within the tolerances for at least
10 years.
18.12.2.2 Safety and Reliability
a) The equipment shall be of a standard, well set and proven design which ensures
maximum safety to Personnel, maximum service reliability and economic operation for
an operational lifetime of at least 20 years.
b) Design and construction shall be simple and provide good accessibility to components
and parts.
c) All equipment and parts shall be brand new and unused, of current manufacturers, of
modern design and of the highest industrial grade, free from all defects that might
affect the performance of the unit.
d) Electrolyte type capacitors shall be of non-toxic and free from any PCB's.
18.12.2.3 System Variations
The input voltage of the AC-UPS, with rectifier disconnected, will be sinusoidal
according to IEC 60146. The input voltage is 400 Volt, 3phase, 50 Hz, which will not
exceed the following values:
Static ± 10 %
Dynamic + 16 % ; -20 %
Spikes 2 kV
Frequency ±5%
18.12.2.4 Arrangements
a) The equipment shall comprise but not limited to the following items:
i. 1 feeder selector switch

ii. 2 constant voltage, current limiting rectifiers
iii. 2 battery banks
iv. 2 inverters
v. 1 static bypass switch
vi. 1 manual bypass switch
vii. 2 transformers.
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viii. Distribution section as part of the charger cubicle.
ix. Auxiliary equipment
x. Microprocessor for overall operation and control

b) The AC UPS System shall have 2 x 150% charger, 2 x 150% capacity battery and 2 x
150% inverter.
18.12.2.5 Rectifier
a) The output of the rectifier shall supply the power requirement of the load via the
inverter and at the same time maintaining the battery in the float-mode.
b) If there is an AC-supply failure the battery will take over the power requirement of the
load via the inverter for not less than the specified time.
c) If the AC-supply is restored, the rectifier will then recharge the battery and at the same
time supply the power requirement of the load. The rate of recharging the battery shall
be sufficient to restore it to a capacity that is capable to fulfil the power requirement of
the load in case again an AC-supply failure may occur. The recharging has to take
place within 6 hours.
d) The inverter converts the input DC voltage into an AC output voltage. The output
voltage to the requirements is 400 V, 3phase, 50 Hz.
e) The dynamic output voltage variations shall not exceed ± 10 % of the rated output
voltage in case of an instantaneous load variation of 100 %. The steady state output
voltage variation shall not exceed ± 5 % of the rated output voltage in case of a load
variation of 100 %, the steady state output voltage shall be restored within 0.1 sec.
f) The waveform of the output voltage shall be sinusoidal according to IEC 60146 with a
relative harmonic content not exceeding 5% under linear load conditions and 10%
under non-linear load conditions.
g) The angular displacement of the 3 phases shall not exceed 120° ± 1% in case a
balanced linear load is applied and 120° ± 5% in case the load current in any two
phases differ more than 50%.
h) The variations in the output frequency shall not exceed the rated output frequency by ±
2%.
i) The inverter is of the pulse width modulation (PWM) type.
18.12.2.6 Static Transfer Switch
a) A no-break static transfer switch, programmable for sense and transfer time and return
transfer time delayed, shall be incorporated as part of the AC-UPS.
b) It will provide automatic bypass to the alternate supply system in case of inverter
malfunction or system overload. The total sense and switch transfer time shall not be
more than ¼ cycles.
c) When the load and inverter return to the normal operating range, the static transfer
switch shall automatically retransfer the load back to the inverter.
DM/SRPD Section 18 Electrical & Instrumentation Works Rev 00 June Page 100 of
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d) A continuity monitor shall be provided which will test that the switching devices in each
pole of the static switch control.
e) If the test fails it shall signal the control circuit to transfer the load to the alternate
position. If neither the inverters nor the alternate source are available, it shall
disconnect the load thereby further protecting the load from being burned up due to the
possible application of half wave AC.
f) The Contractor should ensure that the functioning of the switch shall not affect the
normal functioning of the control system.
18.12.2.7 Manual Bypass Switch
a) A manual bypass switch shall be provided as part of the AC-UPS.
b) It will be so arranged as to isolate the UPS from the load, permitting maintenance and
testing to proceed on the UPS, without disturbance to the load.
18.12.2.8 Feeder Selector Switch
A feeder selector switch shall be provided as part of the AC-UPS. It shall be so

arranged that in case of emergency a backup feeder can be selected as power supply
to the AC-UPS.
18.12.2.9 Specific Requirements

The specific requirements and details of the AC-UPS required are given on the datasheet(s)
and/or accompanying documents. In case of conflicting requirements between this general
specification and the specific requirements, the latter shall always rule.
18.12.3 Construction and Electrical Requirements
18.12.3.1 Accessibility and Enclosure
a) The unit shall have a complete metal enclosure (plate thickness at least cabinet 1.5
mm and door 2 mm) of sufficient mechanical strength and shall be self-supporting,
suitable for floor mounting.
b) The protection class of the unit shall be at least IP 43. The floor shall not be considered
as being part of the enclosure.
c) The maximum height shall not exceed 2.25 m and the maximum depth and door width
shall not exceed 0.8 m. The design shall include measures to avoid condensation as
much as possible.
d) Doors shall be equipped with locks and all components requiring maintenance shall be
easily accessible from the front.
e) The following features for personal and electrical safety shall be incorporated:
i. Cubicles, sections, sub-sections and compartments which have to be accessible

during operation, e.g. for fuse replacement shall contain no exposed live parts
under normal operational conditions in opened situation (IP 20 in opened
situation according to IEC 60529).
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ii. Adequate means shall be provided to ensure safe removal of fuses. Fuses can
only be removed under no-load conditions. The fuses must be visible and easily
removable when the compartment doors are open.
iii. Adequate protection in the form of vertical and horizontal screening between the
sections shall be provided to minimise the risk of accidental short circuit and to
limit their propagation, if occurring.
iv. The insulation shall be capable of providing adequate and lasting protection
under normal conditions and recognized over current and voltage.
v. The battery shall be installed in separate, enclosed, free-standing support
racks or stack assemblies.

18.12.3.2 Secondary Cables and Wiring
a) Secondary wiring shall preferably have black-coloured PVC insulation, and have a
cross-sectional area of at least 0.75 mm2 and shall be stranded. Wiring between
terminals shall have no joints.
b) Wire shall not be mounted direct to metal, but shall be kept in position by means of
insulated tubes or channels.
c) Individual wires or cables, which may reasonably be expected to require disconnection

for the purpose of component testing or replacement, shall be identified at both ends by
means of ferrules of insulating material (slip-on-clips), marked in accordance with the
related wiring diagram.
d) For all wires and conductors individual terminals shall be provided unless terminals are
specially made for more than one conductor.
e) Terminals shall be of non-loosening construction and of the wedge type, constructed in

such a way that direct contact between screw, bolt or nut and conductor is avoided.
f) Stranded conductors shall be provided with cable lugs for terminal connection.
g) Terminals carrying different voltages shall be logically grouped and separated. Barrier
plates shall be provided.
h) Furthermore sufficient spare terminals shall be provided for future purposes with a
minimum of 20 % of the installed terminals.
18.12.3.3 Marking
a) Unit shall be provided with name/rating plate of corrosion resistant material fixed to a
non-removable part. At least the following information shall be indelible marked in the
language as stated on the datasheet:
i. Year of manufacture;
ii. Name of manufacturer;
iii. Type and serial number of the unit;
iv. Nominal input voltage and current;
v. Nominal output current and voltage;
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vi. IP class according to IEC 60529.
vii. Type of battery/electrolyte
viii. Number of cells
ix. Ah capacity
x. Phase or pole marking of AC and DC supply terminals

b) The purchase order number shall be clearly marked on a nameplate made of corrosion
resistant material placed on the outside of the enclosure.
c) All other nameplates shall by 3 ply laminated phenolic and engraved through to the
black lamination. The edge of all name plates shall be bevelled at 45 degrees. These
name plates to be attached with nuts, bolts and washers. Self-tapping screws are not
be used.
d) Compartments and their components shall be provided with essential data such as tag
numbers and cable/core numbers.
e) Terminals shall be properly and clearly identified for easy identification by the operator.
f) The capacity of the battery shall be given based on a 10 hour discharge time (nickel
cadmium).
18.12.3.4 Battery Cells and Containers
a) The battery shall be of the nickel cadmium type with pocket plates in polypropylene
containers. Each unit or cell-block shall be only one cell.
b) The steel pocket plates inside the cell, containing the nickel or cadmium, shall be
welded to the collecting bar and the terminal posts. The separation between the plates
shall be of the open type with vertical plastic rods and free space between the plates.
c) The cell container shall be of translucent polypropylene so the electrolyte level can be
seen through the plastic wall. The different parts of the container shall be joined by a
heat-welding procedure. Gluing is not allowed, as the glue point will age faster that the
plastic.
d) The vents shall be of the flop-top type with flame arrester. Catalyst vents with
recombination shall not be allowed for reliability reasons.
e) The external connectors of the battery shall have plastic covers.
f) Terminal (pillar) seals shall be of a type that prevents the initiation of pillar corrosion.
g) Inter cells connections and terminals shall be insulated or otherwise provided with
protective covering to prevent inadvertent short circuit that might occur at the battery.
h) The battery voltage and capacity shall be such to fulfil the inverter input power
requirements when the inverter is delivering its rated kVA at a 0.8 power factor lagging.
i) The current ripple specified by the battery manufacturer shall not be exceeded during
at least the normal standby operating conditions.
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18.12.3.5 Switching Devices
Switching (mechanical) shall be of the independent manually operated air-break type

for continuous duty. They shall as a minimum comply with utilisation category AC 23 for
use on the AC side and DC 22 for the use on the DC side in accordance with IEC
60947-3.
18.12.3.6 Earthing
a) A copper main earth bar shall be fitted along the whole width of the cubicle. This bar
shall be bonded to the enclosure of the unit. Within the cubicle an earthing bolt shall be
mounted M10.
b) The DC system is free from earth; therefore an earth fault detection system must be
applied.
18.12.3.7 Finish
a) All structural work shall be adequately protected against corrosion. Painted structural
work shall be at least comprised:
i. One coat of primer;

ii. Two coats of oil-resistant finishing paint.
iii. Colour of finishing paint (subject to DM/Engineer approval)
18.12.4 Materials
18.12.4.1 Fuses
The fuses shall be of the D-type and/or Hadkin knife-in type in accordance with IEC
60269-2. Fuse holders for quick acting fuses shall be marked "special thyristor fuses".
18.12.4.2 Contactors
a) The contactors are manufacturers proposal and shall apply to the "Euro-norm mounting
standard" or comply with IEC 60947 and be rated for uninterrupted duty and
intermittent duty.
b) The utilisation category for DC contactors shall not be less than DC-3 and for AC
contactors not less than AC-3.
18.12.5 AC Distribution Sections
18.12.5.1 General
A separate section shall be provided in the battery charger cubicle for the transformers
and a 230V, single phase, 400V 3phase AC distribution system. Even under extreme
conditions of major short circuit or malfunction, there shall be no danger to persons in
18.12.5.2 Ratings
a) The AC distribution section shall be rated on the basis of voltage and current ratings of
the charger.
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b) Current-carrying components shall furthermore be capable of carrying their rated
current continuously at rated voltage and under specified service conditions without
exceeding the permissible temperature limits.
stresses resulting from prospective short-circuit currents without damage or injury of
personnel.
a) The distribution section shall comprise a busbar system having two incoming feeders,
two manual circuit breakers, and MCBs with earth fault protection for the outgoing
feeders.
b) The lay-out of the operational front and the location of the components of the assembly
shall be arranged in a logical and systematic sequence and standardized throughout.
c) Proper alphanumeric notation, shall be used for identification and marking of polarities
in conductors and terminals.
d) Interchangeable standardized components shall be used where feasible.
18.12.5.5 Three phase + Neutral
a) Busbars shall be of high conductivity electrolytic copper with joints by means of non-
corrosive high tensile steel bolts, nuts and washers, and secured against loosening.
Insulated busbars are preferred.
b) Compound or oil insulated busbar systems are not acceptable.
c) Insulators, including busbar supports, shall be non-hygroscopic and non-deteriorating.

The use of fibrous materials, linseed oil, varnish etc. is not acceptable.
18.12.6.1 General
The rated output of the converter shall be based on standard duty class 1 of IEC
60146. The unit shall be suitable for continuous duty, operating under service
conditions and the requirements specified on the datasheets.
18.12.6.2 Battery Float-Charge Operation
a) The rated output current of the rectifier shall be the current corresponding to the
maximum load in KVA as specified on the datasheets divided by the nominal DC
system voltage, plus the current required to charge the battery from the partially switch
off level discharged condition to 80 % capacity in 15 hours.
b) The rectifier steady state DC output voltage variations shall be controlled to within ± 1
% of the set value. This corresponds to the battery float charge voltage during load
variations between zero and the rated output current of the DC supply unit and during
steady state input voltage and frequency variations shall be as specified.
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c) During transient input voltage depressions up to 20 % of normal voltage, the rectifier
DC output voltage variations shall be controlled to a value that will at least prevent the
initiation of battery discharge.
d) Facilities for on-line adjustment of the set value of the float-charge voltage shall be
provided but only on the relevant control circuit card.
e) The DC output current of the rectifier, when operating under constant current limiting
conditions, shall be controlled within ± 2 % of the set value.
f) The rms value of the voltage ripple, with the battery connected, shall not exceed 5 % of
the nominal DC system voltage.
18.12.6.3 Battery Rapid-Charge Operation
a) The rectifier shall be rated and provided with a facility to restore the battery within a
period of 8 hours from the 80% capacity to 100 % nominal capacity. Which means the
battery can perform the discharge duty once again.
b) The rapid-charge cycle shall be according to a constant current/voltage characteristic.
c) The duration of the rapid-charge operation shall be automatic and after the elapsed
time, will re-instate the rectifier output voltage to that corresponding to continuously
float-charge operation.
d) When operating under constant current conditions, the DC output current of the rectifier
shall be controlled to within ± 2 % of the set value.
e) When operating under constant voltage conditions, the voltage shall be controlled to
within ± 1 % the set value.
f) The applied set value of the rapid-charge voltage and the duration for which it is
applied to the battery shall restore the battery to 100 % of its nominal ampere hour
capacity within the specified 8 hour period.
g) Facilities for on-line adjustment of the set value of the float-charge voltage shall be
provided on the relevant control circuit card.
18.12.6.4 Battery Discharge Operation
a) The battery voltage and capacity shall be such to supply a direct current corresponding
to the maximum load for a period as specified in the requisition while maintaining an
output voltage as specified within the permissible tolerances.
b) The battery discharge requirements shall be fulfilled the following conditions:
i. Under the prevailing climatic conditions including the minimum ambient

temperature specified.
ii. By a battery which is in a partially charged condition.
c) The battery capacity shall be selected such that fuses, protecting the connected loads,
and rated one quarter of the maximum output of the DC supply unit, have melted within
one millisecond after the occurrence of a short circuit.
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18.12.6.5 Audible Noise Limitation
a) If not otherwise specified, the sound pressure level (ref 20 microPa) measured at one
meter distance from the equipment at any position, shall not exceed 70 dB(A) at any
load between zero and rated output of the unit. If tonal components are present, the
noise limit shall be taken 5 dB (A) more stringent.
b) If the above values are unobtainable without the use of absorptive materials,
precautions shall be taken to limit their effect on cooling, dust deposits and fire
hazards, with minimal use of materials.
18.12.6.6 Radio Frequency Noise Limitation
The protection of radio frequency interference voltage shall not exceed the value of
suspension grade "N" as stated in VDE 0875.
18.12.7 Auxiliary Equipment
18.12.7.1 Status Indications
a) At least the following indications, in the form of led's/lcd's and or measuring

instruments, shall be provided on the front outside panel of the unit to enable
verification of the of the operational status of the UPS. The indications shall be
superimposed on a mimic diagram of the UPS to identify the relevant component or
circuit.
i. AC input supply available;

ii. Alternative/bypass supply available;
iii. Rectifier on;
iv. Inverter on;
v. Load on inverter;
vi. Load on bypass;
vii. Inverter and bypass synchronised;
viii. Battery on boost charge.
18.12.7.2 Measurements
a) Measurement instruments may have digital display.
b) The following measuring instruments shall be provided on the front of the panel of the
unit.
i. DC voltmeter;
ii. DC ammeter for battery charge and discharge current;
iii. AC output voltmeter inverter;
iv. AC output ammeter inverter;
v. AC output voltmeter;
vi. AC output ammeter;
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vii. Percentage load indicator

c) The accuracy of the instruments shall be not less than that corresponding to class 1.5
of IEC 60051.
18.12.7.3 Protection and Alarms
a) The status of the alarm and protection functions shall be visually verifiable by
appropriate indicators with first failure feature. Alarms associated with trip functions
shall be hand reset.
b) The following alarm and protection functions shall be provided as a minimum:
i. AC input phase under voltage;

ii. Rectifier failure;
iii. DC overvoltage;
iv. DC under voltage;
v. Charge failure/battery discharging;
vi. Battery disconnected;
vii. DC earth fault;
viii. Inverter failure;
ix. Inverter over current;
x. Inverter output voltage deviation;
xi. Inverter and static bypass not synchronized;
xii. Cubicle fan failure (when applied);
xiii. Cubicle/inverter stack over temperature;
xiv. AC distribution earth fault

c) The above mentioned alarm and protection contacts shall be wired to a terminal block
such as to provide one normally open and one normally closed potential free contact
for remote cabling to a common alarm. The operation of the common alarm shall have
an adjustable time delay with a range of not less than 4 seconds.
18.12.7.4 Controls
a) The following adjustment and control functions shall be provided:
i. Rectifier input isolation switch;

ii. Rectifier on/off control switch;
iii. Rapid charge initiation switch;
iv. Rapid charge duration timer;
v. DC output voltage adjustment;
vi. DC current limit adjustment;
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vii. Inverter on/off control switch;
viii. AC output voltage adjustment;
ix. Synchronising range adjustment for static bypass;
x. Load transfer initiation control switch for static bypass;
xi. Battery isolation switches (MCCB).
xii. Manual system bypass
18.13 FIELD MOUNTED COMPONENTS
a) Field mounted components shall be provided with all stainless steel supports and
sunshade. All out door panel’s control wires to be tin coated. All out door panel to be
gas tight / protected type.
b) Local isolators and control stations shall be mounted adjacent to the equipment
controlled, on a 1m high stainless steel stanchion.
c) All motors shall be provided with locally mounted emergency stop, start and stop
pushbutton and local/off/remote selector switch station.
d) All mains powered field mounted equipment, including all motors and actuators shall be
provided with local isolators.
e) Motor and actuator power tails shall be cabled through local isolators. Other LV cables
connected to the motor or actuator (e.g. motor heater tails, emergency stop
pushbuttons) shall be wired to the motor starter control circuit. 24Vdc signal and control
circuits shall be cabled through a separate, adjacent junction box.
f) Locally mounted junction/marshalling boxes shall be provided where a multicore or

multi pair cable is installed to serve more than one item of equipment or more than one
connection point to a single item of equipment.
g) All instrument cables shall be terminated in the field in a junction box adjacent to the
instrument location. The instrument signal shall be connected to the junction box via a
flexible cable suitable supported and with sufficient length to allow removal of the
sensor for maintenance purposes.
h) Outdoor mounted equipment/plant shall be provided with a stainless steel sunshade to

protect it from direct sunlight.
i) Local isolators and control stations shall be mounted adjacent to the equipment
controlled, either on the building structure or on a 1m high stanchion.
j) Unless specified elsewhere local isolators, pushbutton stations and junction boxes shall
be located at an accessible location and shall be fully corrosion resistant.
k) Where relevant, all field mounted equipment installed in Hazardous areas shall be
qualified by a test authority ATEX 94/9/EC or NEC (approval by FM) or the CEC
(approval by CSA). The contractor shall provide PEAZ report for the scope of work.
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18.13.2 Emergency Stop Pushbuttons
a) The emergency stop pushbutton station shall be suitable for hazardous area
installation if installed in such area.
b) Emergency stop pushbuttons mounted locally to equipment shall be red mushroom

head with yellow background, push to off, stay-put with turn to release, with single or
multiple contacts, as required.
c) The emergency stop pushbutton shall not be of the locked type with key release.
Emergency stop operation shall always latch out the motor control circuit. The motor
shall then only restart on operation of starter reset button
18.13.3 Isolators
a) The isolator assemble shall be suitable for hazardous area installation if installed in
such area.
b) The isolator including and above 100AMPs rating shall be provided in IP65 stainless
steel enclosure.
c) Locally mounted isolators shall be of the following type:
i. Either rotary switch to BS EN 60947-3 with red, turn 90o anticlockwise to off,
fault make load break, manually independent main contacts as required or
additional late make early break auxiliary contact as required.
ii. The local isolator shall be lockable in the OFF position only. The enclosure of
the isolator up to 63 AMPs shall be of aluminium die-cast and for the rating
above 63 AMPs shall be made of fabricated stainless steel sheet construction
complete with hinged front access doors.
18.13.4 Local Control Stations
a) The local control station assemble shall be suitable for hazardous area installation if
installed in such area.
b) Unless specified elsewhere local control stations shall be of heavy duty construction
having external fixing brackets and unless otherwise specified shall have a minimum
enclosure protection classification IP65.
c) Small control stations housing up to three control components shall be of die cast
aluminium construction complete with screw or bolt fixed front covers. Larger stations
shall be of fabricated sheet stainless steel construction complete with hinged front
access doors.
d) All mounted control equipment and internal components shall comply with that
specified for switchgear and control boards.
e) Control stations shall be provided with bottom cable entry, via removable gland plates.
f) An earthing terminal shall be provided.
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g) Pendant type local control stations for cranes, hoists, etc., shall be of moulded polymer
or equivalent heavy duty, flexible, high impact strength materials. The station shall be
connected by a long moulded-in cable strengthening sleeve, to minimise the possibility
of cable fracture at the bending point. The enclosure shall be self-coloured in safety
yellow.
h) Wall mounted local control stations shall be mounted not less than 10mm away from
the wall. Wall fixings shall be exterior to the enclosure.
18.13.5 Marshalling Panels and Junction Boxes
a) The marshalling panel assemble and junction box shall be suitable for hazardous area
installation if installed in such area.
b) The cable marshalling units shall compromise wall mounting boxes or floor mounting
panels according to size and function.
c) Marshalling panels shall be constructed of sheet stainless steel with ample space for
routing and terminating cables and cores.
d) Wall mounting marshalling boxes shall have front bolt or screw fixed cover plates.
e) Floor mounting marshalling panels shall have lockable front access doors.
f) Marshalling panel construction standards shall be in accordance with the general

standards specified for switchgear and control gear.
g) Junction boxes shall be constructed from polycarbonate or a similar material suitable

for the installed environment with opaque lid and housing.
h) Unless specified elsewhere enclosure classification shall be:
Outdoor mounting IP65.

Indoor mounting IP55.
i) All marshalling panels and junction boxes shall be arranged for bottom cable entry and
termination. Un-drilled cable glanding plates shall be provided in marshalling panels.
Gland plates on floor mounting marshalling panels shall be located not less than
300mm above floor level, shall permit cable glanding and termination from the panel
front and shall provide an effective vermin seal to the panel base.
j) Cable core termination assemblies shall be provided for all cable cores including
earthing cores and screens, and shall be arranged and grouped according to cable and
circuit functions. At least 20% spare terminals shall be provided overall and to each
terminal group.
k) Terminal assemblies shall be generously spaced to permit ease of cable termination,

the routing of cable cores from the cable gland plates, the fitting of core identification
ferrules and their subsequent reading, together with general direct access for
inspection and circuit test purposes.
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l) Terminal assemblies shall be located not less than 150mm from cable gland plates,
panel sides and cover plates.
m) Cable cores shall be installed between gland plates and terminations in wiring trunking
providing a cable to free space factor not exceeding 50 percent.
n) All marshalling panels and junction boxes shall be provided with an earthing
termination, together with front identification labels and internal labelling for the
assemblies and all auxiliary equipment.
o) All marshalling panels and junction boxes shall be provided with a label giving
identification tag number and function description.
18.13.6 GRP Kiosk
a) Wall thickness of the GRP kiosk shall be of 6 mm and at points of stress it shall be a
minimum of 9 mm. Ingress protection of the overall GRP kiosk shall be IP55. The GRP
kiosk shall be of half an hour fire rating and confirming to the terms specified in BS 476:
Part 7: 1997 class 2 / DIN 4102 class B2. External finish of the kiosk shall be plain
semi-gloss light grey gel coat finish to RAL 7035. All hardware shall be of grade 316
stainless steel. Hinges and door restrain for kiosks shall be of robust in design. Lock
and handle shall be heavy duty and approved by the Employer and all locks shall have
common keys. The GRP kiosk shall be fitted with the drawing pocket, full rain canopy,
lifting hooks, long life EPDM gasket and handle (3 point lock with dust cap).
b) If GRP kiosk is provided as an room to LV panel the following shall be considered:
i. The clear space between the front of the control panel and the kiosk shall not be
less than 1500 mm and minimum of 750 mm clear space on remaining three
sides the panel. The GRP kiosk shall be provided with stainless steel installation
skid.
ii. The kiosk shall be supplied with sufficient number of 36,000 BTU/hr floor
standing split air conditioner with drip trap, supports and drainpipe, 4 no. 36 W
limit switch operated fluorescent lights and hygrostat operated 2 no. tubular
heaters.
18.13.7 Labeling and Name Plates
a) A nameplate with the panel description shall be permanently attached to a prominent

position on the front door of the Marshalling Panels and Junction Boxes. An identical
nameplate shall be permanently attached inside the Marshalling Panels and Junction
Boxes. The nameplate shall be indelible, non-removable and with black lettering on
white background.
b) All warning or danger labels shall be indelible, non-removable with white lettering on
red background. The panel doors shall be fitted with a warning label stating "Isolate
before working on equipment". Where voltages exceed 110 V ac, warning labels
showing the voltage level shall be attached to the terminals, using nylon screws. The
label shall span all the terminals carrying the higher voltage.
c) All wiring shall be ferruled at each end, using slip-on-colour coded markers. All wiring
shall be uniquely identified with a number. The markings shall be as shown on the
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assembly wiring and circuit diagrams. Termination schedule shall be provided inside of
the Marshalling Panels and Junction Boxes.
d) The local control station and isolator shall be provided with labels indicating the
equipment description and asset/ plant tag code for which it is provided for.
e) Fixing screws of all nameplates, tags or inscriptions shall be non-corrosive type.
18.14 EARTHING
a) Unless otherwise specified, earthing shall conform in design, material, construction and
performance to the latest editions of the IEC/BS standards and in particular to the
following publications:
IEC 60364-5-52 Earthing Arrangements.

IEC 60364-5-54 Earthing arrangements
BS 6651 Lightning Protection Code
BS 7671 Wiring Regulations
BS 4444 Electrical Earth Monitoring
BS6739 Instrumentation Earthing
BS 7430:1998 Code of practice for earthing
b) Further to the international standard, earthing system shall in any case comply with the
local standards and/or regulations of DEWA, when these are higher, more stringent or
of special nature Design Considerations
18.14.2.1 General
a) The earthing in the distribution network and of HV and LV equipment should be TN-S
earthing system
b) The earth resistance of the HV protective earthing system shall be less than 25 Ω.The
star point of the LV windings of the distribution transformer shall be connected to one
or more earth rods with copper earthing conductor of no less than 70mm2.
c) The maximum earth resistance of the neutral will be less than 1 Ω.
d) At substations the HV earth and LV neutral earthing system shall be kept as far as
possible apart
18.14.2.2 Earthing and earthing systems
a) Provide a single, complete, integrated earthing system, including conductors, conduits

& cable trays, and connections, indicated and specified, and in accordance with the
relevant International, European and British standards on earthing.
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b) Include earthing of switchgear, substations, motor control canters, electric equipment
enclosures etc., substations, transformers, switch structures, etc.; earth grid systems
with earth rod and water pipe connections; structural steel.
c) Loop type, low impedance, earthing system interconnecting all components so at least
two earthing connections are provided for each major item of electrical equipment.
Ensure that severing of any single earthing conductor in this system does not remove
earthing protection on any major item.
18.14.2.3 Earth Electrodes
a) The earth electrode installation shall be provided to suit the site ground conditions,
which shall be determined by site survey.
b) Unless impracticable, Earthing electrodes shall consist of one or more solid copper or
stainless steel vertical rods of diameter not less than 20mm and length of not less than
1800mm.
c) Plate electrodes shall not be used.
d) Direct buried bare copper conductors shall be employed for interconnections between
electrodes.
e) Horizontal electrodes should be employed only where the use of vertical rods would
incur unacceptable drilling costs. Where copper is employed the electrodes should
consist of wide, flat strip with a minimum width of 50mm and a minimum thickness of
0.5mm, buried to a depth of not less than 500mm. A depth of 500mm is necessary to
provide adequate physical protection. (Improvement in the electrical effectiveness of
the earthing system gained by burying the conductors at a significantly greater depth is
likely to be small.)
f) To assist in lowering the earth resistance, Earth Enhancing Compound™ or a mixture

of Bentonite and Gypsum shall be used as a backfill.
g) The earth electrode installation shall be a system of interconnected driven rods.
h) The electrode system shall comprise the rod type incorporating solid copper rods. Rods
shall have hardened tips and driving caps to prevent damage during installation.
i) Couplings shall be manufactured from aluminium bronze and shall have completely
enclosed threads to prevent damage and corrosion.
j) Where multiple rods are installed, they should be separated by a distance of not less
than their driven length. PVC insulated multi-stranded cable, buried at a minimum
depth of 400 mm, and shall be used for the interconnection of rods. Each rod shall be
provided with a non-ferrous clamp for the connection of the earthing conductor.
k) The connections to rod or alternative design electrodes shall be made in a concrete or

other approved material inspection chamber set flush with the finished ground level.
The inspection chamber shall be permanently marked ELECTRICAL EARTH.
l) The resistance to earth of the earth electrode system shall not exceed a value of 1
ohm.
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18.14.2.4 Conductors
a) Earthing, circuit protective and equipotential bonding conductors shall be high

conductivity copper tape or 1000V grade PVC insulated multi-stranded cable. The
conductors shall be sized in accordance with the Reference Standard. PVC cable
insulation shall be green and yellow. Cable lengths shall be continuous.
b) Where aggressive atmosphere or ground conditions may be present, the copper tape
shall be PVC covered.
c) The earthing conductor interconnecting the main earth terminal and electrode shall be
PVC insulated copper tape or PVC insulated multi-stranded cable.
18.14.2.5 Main Earth Terminal
a) The main earth terminal shall be mounted in an accessible location and shall provide
facilities for connecting:-
i. The earthing conductor(s) between the earthing terminal and electrode(s).

ii. Circuit protection conductors between the earthing terminal and exposed
conductive parts.
iii. The main equipotential bonding conductors between the earthing terminal and
extraneous conductive parts.
iv. The system neutral earthing conductor (where specified).
b) Facilities (i) and (ii) shall be removable with a tool to permit measurement and testing.
c) The earthing terminal shall comprise a terminal block or busbar on an insulated frame
as appropriate. A label shall be provided inscribed MAIN EARTH TERMINAL.
a) The earthing installation shall be of robust construction and protected from mechanical
damage and corrosion.
b) The circuit protective conductors and equipotential bonding conductors shall be of the
radial, grid or ring form as dictated by the equipment layout. Joints in tape conductors
shall be tinned riveted and soldered, or brazed, or exothermically welded.
Non-corrosive flux shall be used for soldered joints. Compression type lugs shall be
provided for the termination of cables.
c) The conductors shall be secured to building structures, cable racks and trays using
proprietary fixings. Protective, earthing or bonding conductors extending between
buildings or to external equipment shall compromise PVC insulated cable direct buried
or installed in buried ducts.
d) The interconnection of conductors below ground to or forming part of the electrode

system shall be by means of exothermic welding or brazing.
18.14.2.7 Earthing of Extraneous Metalwork
a) All structural steelwork within the Site, including hand railing, ladders, walkways and
the like, shall be bonded to the electrical earthing system.
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b) An equipotential bond shall be provided to all metal pipework at the point of entry into a
building or chamber where electrical apparatus is installed. Electrical continuity across
all pipe joints within the structure shall be ensured. Where ever the pipework
incorporates a compression coupling (e.g. Viking Johnson coupling), a bond shall be
provided to any isolated section.
18.14.2.8 Instrumentation Earthing System (Clean Earth System)
a) An instrumentation earthing system shall be provided throughout in accordance with

the requirements of BS 6739 - Clause 10.7.5. The instrument earthing system shall be
isolated from the main electrical earthing system except at their point of connection,
which shall be at the main earth terminal in the relevant process area.
b) Instrumentation earth cables shall be segregated from other power and earth system
cables in order to reduce electrical interference on the instrument earthing system.
c) The instrument earthing system shall be used for the connection of any signal system
zero volt point and all communications and instrumentation cable screens. Cable
screens shall be earthed at one end only. Instrument cable armours shall not be used
as protective screens. Instrument cable armours shall be earthed to the electrical earth
system at one end only.
d) Avoidance of earth loops shall be paramount in the design of the instrument earthing
system.
e) Each instrumentation and control panel shall be provided with an: -
f) Electrical system earth bar bonded to the metalwork of the panel and providing earth
connections for all cable armours and power circuit protective conductors.
g) Instrumentation earth bar insulated from the panel metalwork for connection of signal
system zero volt connections and connection of all signal cable screens.
18.14.3 Equipment Earthing
a) Earth each piece of electrical equipment by means of an earthing conductor installed in

a cable way feeding that piece of equipment with copper wire sized in accordance with
the wiring regulations standards. Earthing conductors installed in conduit with insulated
conductors to be furnished with yellow/green, 600-volt insulation. Earth conductors are
in addition to and not to be considered as the neutral wire of the system.
b) Connect power transformer cases and neutrals to earthing system. Connect neutral
earth connection at transformer terminal. Provide two separate, independent,
diagonally opposite, connections for power transformers so removal of one connection
will not impair continuity of other.
c) Connect two separate earth connections from earth grid to earth bus of switchgear
assemblies, motor control centres and all outdoor substation equipment. Ensure that
each connection for item of equipment is from different section of earth grid.
d) Connect an earthing conductor between panelboard and earthing system. Where an

earthing bar is furnished with panelboard, connect earthing conductor to bar.
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e) Connect lightning arresters to earth system by suitable conductors. Where lightning
arresters are furnished with electrical equipment and earthing connections are not
inherently provided, ensure that suitable separate earthing conductor connects
lightning arresters with system earth.
f) Connect emergency generator neutral to earthing system by an earthing conductor of

size required by IEC standards, unless a larger size is indicated. Connect earthing
conductor to generator switchboard enclosure and generator neutral on generator side
of disconnect. Earth generator frame with two separate independent connections, so
removal of one connection will not impair continuity of other.
g) Street lighting poles shall be earthed in accordance with requirements of the relevant
IEC standards
h) Wire fences shall be earthed when used to enclose electrical equipment. Unless
otherwise indicated, provide minimal earthing by buried outside peripheral earth loop;
connections to each corner fence post and nearby earth rod; flexible connections to
each gate; and at least two connections to earthing system from approximately
opposite positions on fence.
18.14.4 Surge and Transient Protection
18.14.4.1 Power Circuits
Earthing systems for surge and transient protection of power circuits shall be designed
to conform to any requirements of the relevant electricity supply authority in addition to
the other Standards and References specified herein.
18.14.4.2 Telecom Lines
a) In new installations the earth terminal on the Main Distribution Frame (MDF) and Line
Isolation Module (LIM) Krone LSA-Plus back mount frames shall be connected to the
MEN earth bar in accordance with BS/IEC Standards.
b) In existing installations where a dedicated Telecom earth has been installed the MDF
or LIM Krone LSA-plus back mount frames shall be connected to the installation MEN
earth bar in accordance with BS/IEC standards requirements. If this is impracticable,
dedicated equipotential bonding of the telecommunications protective earth's to the
power supply protective earth shall be effected by connection(s) from the MDF link bar
and/or LIM to the MEN earth bar via a bonding terminal.
c) Bonding shall be affected using minimum 6mm2 green/yellow copper conductor. To

limit the effects of the conductor's self-inductance the bonding conductor shall be as
short and direct as possible.
d) Telecommunications Reference Conductors (TRC) shall not be used for protective

purposes.
18.15 CABLES
18.15.1 General
a) Power cable design shall be prepared and carried out using an appropriate electrical
system design package to the relevant IEC standard for electrical installation.
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b) The absence of specifications shall imply that the best engineering practices shall
prevail, utilizing first quality materials and workmanship.
c) The Contractor shall seek clarification from the DEWA/Engineer of any confusing or
conflicting information contained in this specification and the accompanying
documents.
d) In case of discrepancy between this specification and any of the applicable standards,
the following order of precedence shall apply:
i. Technical specification of DEWA

ii. Applicable standards
iii. Accepted alternative standards
e) The design and construction of electrical power and control cables shall be in
accordance with IEC standards.
f) All electrical power and control cables shall have coloured cores as follows and as
specified in IEC 60173
No. of cores Power Cables Control Cables

Single core red or black red or black
Two cores red and black red and black
Three cores red, yellow, blue red, yellow, blue
Four cores red, yellow, blue, black red, yellow, blue, black
Five cores red, yellow, blue, black, white numerical printed on
green black insulation

g) The black sheath is for the neutral and the other colours are for the phase conductors.
h) The type test certificates shall be certificated by an international testing institute such
as KEMA, CESI, etc. These certificates shall be supplied with the cables.
i) For multicore cables (i.e. above 4 cores) for control applications, the core numbers
shall be printed on each cable core for identification (i.e. nos. 1,2,3,4,5,6,7 upwards).
j) All cables shall be suitable for operation under the following conditions:
i. Directly buried in ground.

ii. Run in buried P.V.C., concrete or all steel ducts.
iii. Runs fastened to cable rack or tray in open air.
k) The cables shall be capable of continuous operation at highest system voltage as
specified with maximum conductor operating temperature of 90°C and maximum
temperature under fault conditions of not more than 250°C.
l) Manufacturer's test certificates shall be submitted to the Engineer for approval of the
material before commencing cable installation.
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m) Where a neutral conductor is required this conductor shall be in the form of a core of
the same section as the other cores.
n) The Contractor shall ensure that each cable is of sufficient rating for its normal and
fault conditions. To assess the rating and cross section required for each cable the
following factors shall be considered:-
i. Fault level.
ii. Conditions of ambient temperature relevant to method of laying.
iii. Voltage drop.
iv. Voltage drops in motor circuits due to starting.
v. Overcurrent settings of circuit breakers.
vi. Disposition of cabling whether in air, ducts or ground.
o) The Contractor shall submit details of the cable sizes for the Engineer's approval
before ordering. The Contractor shall be responsible for measuring the length of cable
required.
p) Each cable shall be supplied in a suitable length, continuous through its run. Through
joints will not be permitted without the written permission of the Engineer.
q) The overall sheath of the cables shall be coloured as follows:
Low voltage black

Protective conductors (earthing) green/yellow
Intrinsically safe blue
Instrument black
Communications black
18.15.2 XLPE PVC SWA PVC Cables
a) Low voltage (XLPE PVC SWA PVC) shall be manufactured in accordance with IEC
60502-1 specifications for the voltage range of 600/1000V and 1900/3300V systems.
b) Low Voltage Control and Auxiliary Cables (XLPE PVC SWA PVC) shall be
manufactured in accordance with IEC 60502-1 specifications for the voltage range of
600/1000V system.
c) Medium Voltage Cables (XLPE PVC SWA PVC) shall be manufactured in accordance
with IEC 60502-2 specifications for the following listed voltage grades - 3800/6600V,
6350/11000V, 8700/15000V, 12700/22000V and 19000/33000V systems.
d) Single core armoured cables shall be manufactured with aluminium wire armoured.
e) All such cables shall be terminated with mechanical glands in accordance with an
approved International Standard. The gland shall be of a type to provide adequate
mechanical support by locking on the armour, with outer seal, shroud and earth tag.
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18.15.3 PVC Insulated Cables
a) Single-core PVC insulated cables shall comply with an approved International Standard
and shall be 450V/750V grade.
b) Multi-core PVC insulated cables shall comply with an approved International Standard
and shall be 600V/1000V grade.
c) The cable used shall not be less than 1.5mm2 cross-sectional area.
18.15.4 PVC Insulated MICC Cables
a) PVC MICC insulated cables shall comply with an approved International Standard and
shall be 600V/1000V grade. The cable used shall not be less than 1.5mm² cross-
sectional area.
b) For fire alarms and associated uses they shall be coloured orange.
18.15.5 Instrumentation and Pilot Cables
a) Instrumentation cables used for analogue circuits (4-20mA) shall be of the polyethylene
or PVC insulated type rated voltage 300/500V complying with BS 5308: Part 1 Type 2
with individual and overall screens.
b) Screens shall be earthed at one end only to a suitable clean instrumentation earth.
The isolated end shall be tied back and insulated in a suitable sleeve.
18.15.6 Telephone Cables
a) Cables for use with telephone systems and speech band telemetry systems shall be of
the solid polyethylene insulated type rated voltage 110V ac/150V dc and petroleum
jelly filled complying with BS 3573 – specification for telecommunication distribution
cables. The minimum conductor diameter shall be 0.9mm. A minimum of 10 pairs
shall be provided.
b) Telephone cables for internal building office systems shall be to British

Telecommunications Ltd specification CW1308, and shall be installed in trunking or
other suitable protective containment system.
18.15.7 Optical Fiber Cables
18.15.7.1 General
a) The cable shall be supplied in sufficient length to allow for uninterrupted laying as far
as practicable. Splicing, connectors and repeater stations shall not be allowed except
specifically approved by the Engineer.
b) The fiber cores shall be marshalled into trunking inside panels. This trunking shall be
separate from the trunking used for copper cabling.
c) Fiber optic cabling shall be installed on separate cable trays to other site cabling.
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d) Each core shall be clearly labeled at the ST connector. The cabling shall be clearly
identified at 10m intervals, at each change in direction, at entry to buildings and at entry
to panels.
e) It is the Contractor’s responsibility to study the existing situation and requirements and
submit for approval detailed design drawings for the fibre optic system.
f) All products to be supplied shall meet the industry standards for communications
applications.
g) In engineering and selecting of fibre optic cable accessories, the guiding principle shall
be to provide complete, reliable and fail safe installations. Use shall be made of
exclusively new and modern material suitable for the intended purpose. The selection
of the cables shall be subject to approval. Samples and complete documentation of the
selected equipment shall be included in the submission.
h) The following list of standards indicate the requirements as minimum any other
standard not listed below or elsewhere in this tender documents shall be subject to
review and approve.
IEC-60793-1 Optical Fibres, Part 1 : Generic Specifications Including

Amendments
IEC-60793-2 Optical Fibres, Part 2 : Product Specification
IEC 60794-1 Optical Fibre Cables, Part 1 : Generic Specification
IEC 60794-2 Optical Fibre Cables, Part 2 : Indoor Cables
IEC 60794-3 Optical Fibre Cables, Part 3 : Outdoor Cables
IEC 60874-1 Connectors for Optical Fibres and Cables, Part 1 : Generic
Specification
IEC 61300 Fibre Optic Interconnecting Devices and Passive Components -
Basic Test and Measurement Procedures
IEC 60875 Fibre Optic Branching Devices
IEC 61073-1 Splices for Optical Fibre and Cables, Part 1 : Generic
Specification, Hardware and Accessories
IEC 60502 Extruded Solid Dielectric Insulated Power Cables for Rated
Voltage from 1kV up to 30 kV
IEC 60529 Degrees of Protection provided by enclosures
IEC 60885 Electrical Test Methods for Electric Cables
ITU-T G.652 International Telecommunication Union – Characteristics of a
Single-Mode Optical Fibre Cable
18.15.7.2 Technical Requirements (Fibre Optic Cable)
a) Fibre optic cables shall comprise quartz single-mode typically 10/125 micro-metre
optical fibres, contained in a jelly-filled loose tube configuration.
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b) These cables shall be armoured and designed for direct burial installation. These fibre
optic cables shall be capable of withstanding the anticipated harsh environment, the
predominance of water, and extreme temperatures as may be encountered in a desert
environment.
c) Fibre optic cables shall provide for a minimum 20 year life expectancy and meet the
industrial standard of operation under the temperature of 550C and humidity to 100%
without degradation to optical or mechanical performance.
d) Although the fibre optic cables shall be specified for direct burial, cable will be run in
duct banks or cable trays, whenever required.
Optical Fibre Transmission Requirements
Wavelength 1310 nm and 1550 nm

Maximum Data Rate 500 M-bit/sec over a distance of 2.0 Km or less at
1330 nm
Cutoff wavelength < 1260 nm
Attenuation No individual optical fibre shall 0.34dB/km at 1310
nm (typ) and 0.22dB/km at 1550 nm (typ)
Chromatic Dispersion < 3.5 ps/(nm.km) at 1310 nm (typ), < 18
ps/(nm.km) at 1550 nm (typ)
Polarisation mode dispersion < 0.6 ps/ (sqrt(km)
Optical Fibre Mechanical Provisions
Core diameter 10 µm (nominal)

Mode field dia at 1310/1550 9.2/10.4 + 0.3/0.5 µm
nm
Mode field eccentricity < 1.0 µm
Cladding diameter 125 µm (nominal), with no variation greater than 1
µm
Cladding elasticity Less than 1 percent
Proof test 100Kpsi (.69Gpa)
18.15.7.3 Cable Assembly Requirements
a) Fibre optic cable shall be a loose tube design and shall be dimensionally sized to
minimize local stresses and prevent micro-bend losses. The interior of each loose tube
shall be filled with a compound of suitable viscosity to dampen vibrations on the optical
fibres and to prevent the ingress and migration of water/moisture.
b) The fibre optic cable shall withstand water penetration when tested with a one meter
static head or equivalent continuous pressure applied at one end of a one meter length
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of filled cable for one hour. No water shall leak through the open cable end. Testing
shall be done according to the relevant standard.
c) The cable shall exhibit no flow (drip or leak) at 80 degrees C. The weight of any
compound that drips from the sample shall be less than 0.05 grams. A representative
sample of cable shall be tested in accordance with the relevant standard.
d) The cable shall withstand 25 impact cycles. The cable jacket shall not exhibit evidence
of cracking or splitting. The test shall be conducted in accordance with the relevant
standard.
e) Void areas around the loose tubes shall be filled with a moisture resistant compound or
other mechanical means to prevent moisture migration.
f) Fibre optic cables shall be fabricated of dielectric construction.
g) As a minimum, the cable shall be equipped with an outer polyethylene jacket.
h) The cables shall withstand a tensile load of 2700 N when tested in accordance with
FOTP-33, Test Condition II.
i) Without being under load, fibre optic cables shall be equipped for a minimum bend
radius of ten times the overall cable diameter.
j) Under load, fibre optic cables shall be equipped with a minimum crush resistance of no
less than 220 N/cm without damage to cable components or degradation to optical
performance.
k) The fibre optic cable shall be of minimum 24 cores.
18.15.7.4 Optical Fibre Environmental Splice Enclosures
a) Optical fibre environmental splice joint enclosures shall hermetically seal an internal
splice case. Each splice enclosure shall be re-enterable and wall mountable. The
interior splice case shall be equipped to mechanically accommodate single-mode
optical fibres connected by the fusion method. Splice case shall be equipped to
organize the splice trays and the required service loops of buffered incoming optical
fibres and outgoing 'pigtails' in such a way that allows each completed splice and
associated optical fibre to be maintained in an unstrained configuration.
b) The optical fibre splice enclosure assembly shall be capable of continued submersion
under water without degradation to the enclosure or optical fibre performance.
c) In general a splice (joint) enclosure shall be installed under the wall mounted fibre optic
distribution patch panels.
18.15.7.5 Fibre Optic Distribution Patch Panel
a) Fibre optic distribution panels shall be provided as required. The fibre optic distribution
panels shall be of a standard wall mounted sheet metal enclosure type.
b) Fibre optic distribution panels shall be equipped to secure optical fibre patch cables
and pigtails to prevent damage during all operation and maintenance functions.
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c) If no optical fibre splice enclosures are implemented, than the fibre optic distribution
panels shall be equipped with splice trays for storage and protection of fusion splice
connections of single-mode fibre optic cable and pigtails.
d) Each fibre optic distribution panel shall be fully equipped with 'SC' type bulkhead
connector sleeves. Unused sleeve ports shall be equipped with reusable caps to
prevent the intrusion of dust.
18.15.7.6 Connectorized Pigtails
a) All pigtails shall be factory SC-connectorized, and satisfy specified performance for
optical links.
b) All unused pigtails (including spares) shall be terminated with the connector to a
bulkhead connector sleeve, protected by a reusable cap on the opposite sleeve port, to
prevent the intrusion of foreign material or dust.
c) All necessary connectorized pigtails shall be provided in the lengths required.
18.15.7.7 Optical Test and Fusion Splicing Equipment
One automatic optical fibre fusion splicer, OTDR and light source/power meter test set
shall be provided as defined herein. Said optical equipment shall be utilized for the
performance of work pre-installation and installation work. All such optical equipment
shall be in fully operable condition without defects and shall be calibrated as defined by
the manufacturer’s recommendations.
18.15.7.8 OTDR Typical Requirements
a) A recording optical time domain reflectometer (OTDR) will be utilized to test for end-to-
end continuity and attenuation of each optical fibre. The OTDR must be equipped with
data storage, printer, help feature, compare trace features and OTDR software.
b) The data storage unit must include a built-in 3.5 double-sided, double-density DOS-
floppy disk drive capable of storing a minimum of 100 test traces.
c) Data traces saved to disk shall include the following labels:
i. Fibre Identification (ID) with a minimum of 10 characters

ii. Cable ID with a minimum of 10 characters
iii. OTDR location with a minimum of 20 characters
iv. Far End location with a minimum of 20 characters
v. Test Operator initials with a minimum of 3 characters
d) The printer shall preferably be an internal printer. The printer shall be able to print data
traces within 30 seconds or less. The machine settings used to repeat tests at a later
time shall include: index, range, wavelength, average time, pulse width and scale
settings. The test results (on printout) shall provide information including: loss,
distance, reflectance, date and time.
e) The requirements for the help feature consist of an internal, one-button access
process. The help options must be on-line and menu-driven with basic operating
instructions. The help feature shall provide step-by-step direction necessary to resolve
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any procedural conflicts encountered during normal operation of the OTDR. The help
feature must provide printable messages for immediate reference while performing
testing procedures.
f) The requirements for the compare trace feature include the ability to recall two
historical traces from a diskette and display them simultaneously for analysis and
printing. The compare trace must compute and display a single graph representing
any differences between two traces. The compare trace must be able to recall historical
traces from a diskette and perform the same tests on connected live fibres. The
compare trace shall perform a two point loss measurement test for any two particular
fibres in a comparison analysis. The losses between the two points on each fibre shall
be displayed, and the differences between the two readings clearly shown.
g) The OTDR must be equipped with software to support all of the above functions. The
software shall provide for printing of whole set of traces (batch print) with minimal
commands eliminating the time spent for printing traces individually. The software
must be compatible with various networks and printers which are driven by the latest
industry proven version of Windows. The software must provide the capability for a
global editing process of ID labels to be updated in one easy step, as well as allowing
personalized two-line headings on each test page.
Typical Functional Requirements:
dB Readout Resolution 0.01 db

Distance Range 0 km to 100 km
Refractive Index Range 1.400 to 1.700
Average Test Duration 2 min. (continuous)
Display screen 6 inch diagonal screen
Printer Output Integrated high speed graphics printer
Horizontal Scales 3 m to 100 km
Connector Types SC-compatible
Input Voltage (AC) 230V/127V, 47 to 63 Hz
18.16 DISTRIBUTION BOARDS
a) Distribution fuse-boards and miniature circuit breaker boards, herein referred to as

distribution boards, shall comply with IEC 61439-1.
b) Distribution board enclosures shall be fabricated from heavy gauge sheet steel with an
all-welded construction. Exterior edges and corners shall be rounded to give a smooth
overall appearance. Assembly bolts, screws or rivets shall not be visible from the front.
Doors shall be lockable.
c) Distribution boards shall have a minimum degree of protection IP31 to BS EN 60529

when located in clean and dry rooms. The protection classification for distribution
boards located in other indoor locations shall be IP54.
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d) Distribution boards shall be fitted with removable top and bottom undrilled gland plates,
each with a brass terminal stud.
e) Phase, neutral and earth busbars shall be provided, each clearly identified.
f) The phase busbars shall be fully insulated.
g) The neutral busbar shall have a terminal for each outgoing circuits.
h) The earth busbar shall be directly connected to the earth terminal without dependence
on the exposed conductive parts of the enclosure. The earth busbar shall have a
terminal for each outgoing circuit.
i) Each outgoing circuit including spare ways shall be controlled by a miniature circuit
breaker.
j) All circuits shall be protected with suitably rated circuit breakers.
k) Lighting panel/distribution board shall be protected by ELCB (for rating up to 100

Amps) and by ELR (for rating above 100 Amps) with 100 mA sensitivity.
l) Distribution boards supplying power sockets shall be protected by ELCB (for rating up
to 63 Amps) and by ELR (for rating above 63 Amps) with 30 mA sensitivity.
m) Lighting panel/ distribution board shall be protected by MCB for rating up to 100 Amps
and by MCCB for rating above 100 Amps.
n) Outgoing circuit terminations shall be shrouded and covers shall be fitted over all live
parts to prevent accidental contact and IP shall not be less than 2X. Incoming supply
cable gland shall be enclosed in an insulating housing which shall extend over the
cable insulation. Warning labels shall be fitted to all removable covers.
o) Unless otherwise specified, distribution boards shall be fitted with a switch

disconnectors complying with IEC 60947, Part 3 for isolation of the incoming supply.
For three phase distribution boards the switch disconnector shall be four poles. For
single phase a.c. and d.c. distribution boards the switch disconnector shall be two pole.
p) Outgoing circuits shall be clearly identified. Neutral and earth busbar terminals shall be
identified as their respective outgoing way. Embossed plastic and paper labels will not
be accepted.
q) A circuit identification chart in a clear and durable plastic wallet shall be mounted on
the inside of the door. All circuit information shall be typed or of a permanent typeface.
Hand written circuit cards shall not be provided at any stage of the project.
r) Distribution boards shall be fitted with an identification label reverse engraved in Arabic
and English the engraving being filled white and the reverse side painted blue unless
otherwise detailed. The label shall lay flat to the surface and shall be secured by non-
rusting screws.
s) Danger and warning labels shall comply with BS 5378, Part 1.
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18.17 LIGHTING AND SMALL POWER
18.17.1 General
a) The Contractor shall design, supply, install, test and commission complete lighting
system and power socket outlets for the pump stations and central control building.
b) Lighting shall be in accordance with the recommendations given in the CIBSE Code for
Interior Lighting 1994.
c) The Contractor shall carry out lighting calculation based on the final size of the rooms
and the lighting fitting provided by him such that the lighting illumination level as
specified are achieved for a maintenance factor of 0.8.
d) The whole lighting system shall be designed to provide adequate visual performance
and safety and shall be free from excessive glare, stroboscopic effects and flicker from
lamps. The system shall include provision for ease of erection, maintenance, cleaning
and lamp replacement.
e) Light fittings shall be surface mounted or flush type based on the type of ceiling.
f) All light fittings shall be of highest quality from reputed manufacturers and identical to
existing installations and subject to approval.
g) Lighting shall be designed to achieve working levels in these areas as follows:
Sr. Location Average Lux.

1 Corridor (as per requirement) 200
2 Office 400
3 Switchgear Room/Plant Room 500
5 Maintenance 300
6 Machine Room 300 to 350
7 Meeting Room 500
8 Roads 50
h) Industrial style metal halide lighting shall be used in all main plant areas. Lighting in
office, messing, laboratory and control room areas shall be of LED / compact
fluorescent type, compliant with the requirements for office environments and selected
for use with the equipment to be installed in that area.
i) To allow easy access for maintenance, luminaires shall, wherever possible, be

mounted at a maximum height of 2.7 m above floors or landings. Where the above
detailed maximum height cannot be achieved, e.g. within the plant area, the Contractor
should do a careful design to ensure access to these light fittings through the
maintenance platform of overhead travelling carne as far as possible.
j) Lighting shall be switched from switches or switching banks (in main equipment halls)
located adjacent to each entrance to the room or area. Where an area has more than
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one entrance, multi-way switching shall be utilised to allow operation of lighting circuits
from any entrance. Main process halls shall be provided with lighting on more than one
circuit to ensure that lighting cannot be de-energised with one switch operation or
circuit breaker trip.
k) Except as specifically approved by the Engineer, installation of exposed conduits,

mounting of lighting fixtures etc. shall be taken up only after all other services such as
piping, air ducting, cable tray/bus duct hangers, structural bracings etc. in a particular
area have been installed.
l) Small power installations shall be provided for the connection of portable appliances for
industrial use.
m) 230 Vac 13 A switched socket outlets to BS 1363 shall be surface mounted in MCC
rooms, office areas, control rooms and mess areas, spaced so that no point in the
room is more than 3m from a socket. All sockets shall be protected by a 30mA RCD.
n) Power socket outlets shall be rated at 16 A, 32 A, 63 A or 200 A and shall have 4 pole
connections and two earth connections.
o) The Contractor shall provide socket outlets in all oil filled transformers compounds for
the connection of a mobile oil purification plant. The socket outlets shall be located so
that the mobile oil purification plant can be positioned in front of each transformer bay
using a maximum cable length of 20 meters.
p) The Contractor shall supply and install welding socket outlets complete with plugs at
strategic points located on a nominal 30 meter grid so that all parts of the Plant can be
reached using a maximum cable length of 20 meters. The socket outlets shall be 400
V, 63A, three phase, neutral and earth to BS EN 60309. They shall incorporate an on-
load disconnector, MCB rated to suit the switch and a residual current circuit device
(RCCB) rated at 30 mA.
q) 110 V BS 4343 16 A socket outlets shall be provided in all equipment rooms, spaced
so that no point in the room in more than 10m from a socket.
r) All power outlet circuits shall be connected as ring mains. Where additional sockets
are added to a circuit, the ring shall be extended to incorporate the new outlet.
s) Locations of switches/receptacles shall be finalized by the Contractor in consultation

with Engineer.
t) Switches/receptacles which are to be wired on the same phase and to be located close
to each other shall be accommodated/housed in a common box.
u) Switches/receptacles wires on different phases shall be separated as per DEWA

requirements.
v) The luminaries shall comply with the following standard and directives:
Subject European Standard International

Standard
Luminaries General requirements and EN 60598-1
tests
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Luminaires – General types EN 60598 2-1 IEC 60598-2-1
Luminaires – Recessed EN 60598 2-2 IEC 60598-2-2
Luminaires – Street lighting EN 60598 2-3 IEC 60598-2-3
Luminaires – Flood lights EN 60598 2-5 IEC 60598-2-5
Luminaires – with transformer EN 60598-2-6 IEC 60598-2-6
Luminaires – Air handling EN 60598 2-19 IEC 60598-2-19
Luminaires – Emergency EN 60598 2-22 IEC 60598-2-22
Luminaires Track system EN 60570 IEC 60570
Photometric Measurements CIE 24/CIE 27
Photometry and data transfer EN 10302-1: 2004
Photometry for workplace luminaries EN 10302-2: 2004
Photometry for emergency luminaries EN 13032-3: 2007
EMC Emissions-Lighting EN 55015 CISPR 15
EMC Immunity-Lighting EN 61547 IEC 61547
Quality Systems EN ISO 9000 ISO 9000
Emergency Lighting EN 1838
Electronic transformers for lamps EN 61347-2-2 IEC 61347-2-2
Safety
Electronic transformers for lamps EN 61047 IEC 61047
Performance
Safety isolating transformers EN 60742 IEC 61558
Lighting Columns EN 40
Application - Standards and directives
Lighting of workplaces – indoor EN 12464-1: 2003
workplaces
Lighting of workplaces – outdoor EN 12464-2: 2007 CIE S 015/E:2005
workplaces
Light and lighting – Sports lighting EN 12193:1999
Emergency lighting EN 1838 CIE S 020/E:2007
Emergency lighting – testing and EN 50172: 2004
inspection
Road lighting practice EN 13201-1/4: 2004
Energy performance of buildings, lighting EN 15193: 2007
Radiation exposure limits EN 14255
Maintenance of indoor electric lighting CIE 97.2
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Lighting education CIE 99
Discomfort glare in interior lighting UGR CIE 117
Obtrusive light CIE 150
Maintenance of outdoor electric lighting CIE 154
18.17.2 General Purpose Luminaries
a) General purpose luminaries shall be of the LED / compact fluorescent, gas discharge
type.
b) General purpose fluorescent luminaries shall be manufactured from zinc-coated sheet

steel of minimum thickness 0.7mm with white epoxy polyester powder or equivalent
finish. Luminaries shall be fitted with a trough reflector or prismatic diffuser.
c) Unless specified elsewhere the Luminaries for installation in clean and dry area shall
have a minimum degree of protection IP20 (without a diffuser) and IP40 (with a
diffuser) to IEC 60529.
d) Luminaries for use in main equipment areas and in corrosive environments shall have
a glass reinforced plastic body with a prismatic acrylic or polycarbonate diffuser. The
degree of protection shall be IP65 to IEC 60529. Covers shall be sealed to the body
with a neoprene gasket and shall be secured using stainless steel fixing catches. The
catches shall be hinged to the body.
e) Fluorescent luminaries shall be of the electronic ballast, high frequency, quick-start

type.
18.17.3 Bulkhead Type Luminaries
a) Bulkhead luminaries shall be of the heavy duty type and shall have a die-cast
corrosion-resistant aluminium body and front frame with epoxy polyester powder or
equivalent finish, and prismatic cover. Covers fitted to luminaries located outdoors
shall be impact resistant polycarbonate. The cover shall be sealed to the body with a
silicon rubber gasket and shall be secured using stainless steel captive screws.
Retaining hinges shall be stainless steel.
b) Unless specified elsewhere the Bulkhead luminaries for indoor location shall have a
minimum degree of protection IP54 and for outdoor location IPW55 to BS EN 60529.
18.17.4 Floodlighting Luminaries
Floodlighting luminaries shall be of similar construction to the bulkhead luminaries

except they shall be fitted with a clear toughened glass panel. Floodlighting luminaries
shall be complete with high purity anodised aluminium reflector and galvanised steel
mounting bracket. Reflector characteristics shall be selected to suit the floodlight
application.
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18.17.5 Emergency Lighting
a) The emergency lighting shall be designed in accordance with the requirements of the
latest revisions of the British Standard 5266 Part 1 1988. Emergency lights shall be
automatically activated on loss of power supply to the appropriate area lighting circuit.
b) Emergency lighting fittings shall be of the non-maintained type with a 3 hour rating
following power failure to the lighting circuit.
c) A key operated test switch shall be provided adjacent to the lighting circuit main switch
for testing the operation of the emergency lighting circuits and fittings.
d) All exits and emergency exits shall have either ‘Exit’ or ‘Emergency Exit’ signs as
appropriate mounted directly over the exit. Areas where direct sight of the exit is
obscured, direction signs with the words ‘Exit’ or Emergency Exit’ and direction arrows
shall be suitable sited.
18.17.6 Luminaries for Hazardous Areas
a) Luminaries for location in Zone 0, Zone 1 and Zone 2 hazardous areas shall comply
with IEC 60079. The apparatus Group and Temperature Class shall be as specified.
b) Luminaries used should be correct for the environment they are used in. Environments
are classified using the ATEX system and luminaries should be adequate for the ATEX
classification of the environment
18.17.7 Handlamps
a) Hand lamps shall comply with BS 4533, Part 102 Class III, and shall be suitable for
230V operation. Hand lamps shall be complete with specified length of TRS flexible
cable, lamp and guard. Unless otherwise specified, the cable shall be terminated in a
plug complying with BS 4343.
b) When used with a portable supply transformer, the cable may be permanently
connected to the output terminals via a suitable compression gland.
c) Hand lamps shall be complete with a reeling drum or wall brackets or both for the neat
storage of the cable when not in use.
18.17.8 Lamps
a) Energy-saving compact fluorescent lamps shall have separate control gear and a
minimum rated average life of 8000 hours.
b) Compact Fluorescent lamps shall comply with IEC 60901and shall have caps of the bi-
pin type. Unless otherwise specified, lamps for installation in industrial areas shall
have a correlated colour temperature of 3500K (white appearance) and for other areas
shall have correlated colour temperature of 3000k (warm appearance). The minimum
rated average lamp life shall be 3000 hours.
c) LED lamp shall comply with IEC/PAS 62612.
d) Metal halide and High-pressure sodium vapour lamps shall comply with IEC 61167 and
IEC 60662.
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e) Tungsten filament lamps shall comply with IEC 60064 and IEC 60432 and shall a
minimum rated average life of 2000 hours. Tungsten lamps shall have reinforced
internal construction to provide increased resistance to filament breakage caused by
jolts and vibration. Lamps for special applications shall be as specified.
f) Tungsten lamps rated up to and including 150W shall be fitted with a bayonet type
lamp cap. For lamp wattage above 150W the lamp cap shall be of the Edison screw
type. Lamp caps shall comply with IEC 60061-1.
18.17.9 Wiring Devices
18.17.9.1 General
a) Switch plates, socket-outlet plates and similar items shall be having metal material or
as directed by the DM /Engineer.
b) Decorative finishes of metal plates shall comply with appropriate standards. The finish
and/or colour shall be standard throughout the installation unless otherwise indicated or
as directed by the DM /Engineer.
c) Switches shall comply with reference standards and be suitable for use on inductive
and resistive loads. They shall be single pole for 1-phase and neutral supply. Where
switches are mounted adjacent one to another, they shall be grouped in a single
enclosure and share a common switch plate.
d) Outdoor switches shall be provided with pilot lamps. This lamp shall be a 6 Watt neon
lamp with resistor and red coloured lens unless otherwise indicated.
e) 100% plugs shall be from the same manufacturer as that of the socket outlets. All types
of socket-outlets shall be handed over to the Client.
f) All Wiring Devices and other electrical equipment for use in potentially hazardous
atmospheres shall be selected as per the guidelines specified in BS 5345.
g) The electrical appliances such as electric water heaters, cookers, hot plates, washers,
dryers, window / split type air-conditioners and other household appliances shall
generally comply with BS 3456, BS 3676, BSEN 60335 and other applicable standards.
h) Residual current circuit breakers fitted to socket-outlets shall comply with BS EN

61008-1 and BS EN 612008-2 and shall have a tripping sensitivity of 30mA with an
operating time not exceeding 40mS at a residual current.
18.17.9.2 Bulk Switching Contactors
a) Bulk switching contactors for the control of lighting loads shall be of the
electromagnetic type complying with IEC 60947, Part 4. The contactors shall be rated
for uninterrupted duty and shall have an utilisation category compatible with type of
load being controlled.
b) Contactors shall be double pole for single phase a.c. and d.c. and four pole for three
phase loads.
c) Enclosure construction shall be as specified for distribution boards.
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18.17.9.3 Indoor Lighting Switches
a) Lighting switches for local isolation of electric supply to individual apparatus and / or
circuits shall comply with BS 3676 and of grid type.
b) Lighting switches for interior use shall be of heavy duty, AC, single or double pole,
minimum 10A or 20A with number of ways as needed and shall be mounted on
adjustable grid enclosed in metal box.
c) The switches shall be of the quick make, slow break type and shall be capable of
switching 100 % rated load. Switches installed for control of discharge lighting fixtures
shall have a current rating not less than twice the steady state continuous current of the
circuits.
d) Where switches are to be flush type they shall be supplied with overlapping cover
plates finished flush with the metal box.
18.17.9.4 Outdoor Lighting switches
a) All outdoor lighting switches shall have the characteristics as described above for
indoor lighting switches, but be complete with a gasket forming weather proof (splash /
dust proof) enclosures.
b) Outdoor weather proof switches shall comprise cast brass or epoxy coated cast iron or
copper free aluminium, gasket enclosure. These shall have minimum IP-65
classification and suitable for outdoor / wet locations as per BSEN 60529.
c) A suitable drain hole shall be provided for any condensate water.
18.17.9.5 13 Ampere Socket Outlets and Plugs
a) The single phase, 13 Amperes, 230 Volts switched socket outlets and plugs shall have
two-pole and earthing pins.
b) The switched socket outlets and plugs in domestic and commercial installations shall
comply with BS 1363 and local regulations. These shall comply with BS 196, BS 546,
BS 2757 and other codes of practice and standards as applicable.
c) The socket outlets shall be of the 3-pin type with switch, shuttered pattern, double pole,
flush / surface mounting with front plates as approved by the DM/ENGINEER. Socket
outlets shall be mounted on flush metal box of appropriate depth as required. Where
surface mounted socket outlets are required, they shall be similar to that of the flush
pattern, mounted on suitable adapter boxes.
d) Switched socket outlets provided in services and plant rooms shall be metal clad type,
surface or flush mounted as required.
e) Weatherproof socket outlets shall be provided for all outdoor and wet locations with
push-on cap retaining ring without switch and gasket to provide minimum IP-65
protection as per BSEN 60529.
f) All surface mounted socket outlets shall be provided with a 13 A unbreakable plug top
complete with fuse. Each twin socket shall be counted as two socket outlets.
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18.17.9.6 Cooker Connection Units
a) All domestic cooking appliances shall be controlled by cooker connection unit

complying with BS4177, local regulations and other codes of practice and standards
mentioned elsewhere in the Specifications and on the Drawings.
b) The cooker connection unit shall be separate from the appliance and within 2 meters of
the appliance.
c) The cooker connection unit shall be 2 pole for 1-phase and 4 pole for 3-phase
appliances with earthing terminal and connected to a separate final sub-circuit from the
distribution board.
d) All units shall be flush type with an overlapping front cover and fitted with a pilot neon
indicator.
e) Finishes shall be similar to other Wiring Devices approved.
f) Where surface mounted installations are required on site, a suitable adaptor box shall
be provided.
g) These connection units can also be utilized for other indoor fixed appliances such as
window / split type air-conditioners, washer, dryers, etc.
h) Use of cooker connection units incorporating a general purpose socket outlet shall be
avoided, to allow grouping of socket outlet circuits in separate 30 mA ELCB / RCCB
section.
18.17.9.7 Water Heater Connection Units
a) The water heater connection units shall be double pole type switches of appropriate
current ratings, complying with local regulations.
b) All units shall be fitted with pilot (neon) indicator light.
c) All water heater connection units shall be of flush type.
d) The final connection to the water heater shall be made from a flex outlet plate mounted
adjacent to the heater. The control switch for water heater installed outside the
bathroom / toilet.
e) The water heater shall be connected to a separate final sub-circuit from the distribution
board. Every heater circuit shall be protected by 30 mA ELCB / RCCB.
f) All such connection units and flex outlet plates installed within bathroom, toilets or other
wet areas shall be provided with minimum IP-54 protection as per BSEN 60529.
g) Where surface mounted installations are required, a suitable adaptor box shall be
provided.
h) These connection units and flex outlet plates with appropriate current ratings can also
be utilized for other indoor fixed appliances such as window / split type air-conditioners,
washers, dryers, etc. as per local regulations.
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18.17.9.8 Spur or Fused Connection Units
a) Spur or fused connection units shall be one complete unit combining a double pole
switch, fuse and a pilot light for confirmation that the unit is turned on.
b) The current and voltage rating of the spur or fused connection units shall be in
accordance with the power requirements of the equipment to be fed.
c) All surface mounted spur units shall be provided with purpose-made metal clad
mounting boxes.
d) In plant rooms and services rooms, spur units shall be of the surface mounted type.
18.17.9.9 Industrial Socket Outlets
a) Industrial socket outlets and plugs shall comply with BS 4343 / BS EN 60309 and shall
be with a switch integrally built-in with the outlet unit.
b) Industrial socket outlets shall have minimum IP-54 classification and IP-65
classification in all outdoor and wet locations as per BSEN 60529.
c) Single phase socket outlets shall be with two poles and earthing pin and three phase
socket outlets shall be with three poles, neutral and earthing pins.
d) The industrial socket outlets grounding pole shall make contact before the line poles
are engaged, when the plug is inserted into the socket.
e) The plug sleeve shall also make contact with the housing of socket outlet, before the
line and load poles make contact.
f) The industrial socket outlets shall be metal-clad, watertight and incorporate a spring-
return flap cover. The plug and socket shall be interlocked such that the unit cannot be
switched on until the matching plug is fully inserted, nor can the plug be withdrawn with
the switch closed.
g) Each industrial socket outlet shall be provided with plug from the same manufacturer
as that of the socket outlet.
18.17.9.10 Isolators and Switch Fuse Units
a) The isolators and switch fuse units for small power applications shall be of the double
pole or three poles, single throw type, complying with the requirements of local
regulations.
b) Finishes of all isolators and switch fuse units shall be either of white plastic for flush
mounted installations or rust proof metal for surface mounted installations or as
c) Isolators shall be used for the isolation of single phase and three phase fixed
equipment fed by an individual circuit.
d) All fuses in the switch fuse units shall be of HRC type.
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18.17.9.11 Explosion Proof Wiring Devices
All Wiring Devices such as switches, plugs, socket outlets, etc. in hazardous locations
shall be explosion proof in accordance with BS 5345 and BS 5501.
18.17.9.12 Outlets for Low Current Systems
a) The finish of cover / face plates of the outlets for all low current systems shall be of
similar style and finish to that specified for the associated lighting switches and socket
outlets shall be suitable for mounting recessed or surface as required.
b) Unless otherwise specified, telephone and data outlet plates shall be complete with a
terminal box suitable for termination of a 2 or 4 pair cable as minimum and a cable
clamp to secure the outgoing telephone handset connecting cable.
c) Unless otherwise specified, TV outlet plates shall be complete with one co-axial socket
outlet. Where twin outlets are required to provide both FM/Radio and TV signals, they
shall be complete with duplex network as necessary.
18.17.10 External Lighting on Buildings
Exterior light shall be provided all around the building and above all exit doors of the
building. Exterior light shall be controlled by combination of settable timer and
photocell.
18.17.11 Conduit
a) Contractor shall be responsible for any installations requiring concealed conduit on

walls/ceiling from lighting panels to light fittings, power socket, inspection/junction
boxes etc.
b) Conduit system shall be according to specified standards mentioned elsewhere in the

contract specification.
c) Conduits for lighting and small power when embedded into concrete or buried into
block works shall be of suitable rigid PVC pipe of 20mm dia. minimum size.
d) Minimum size of rigid conduits used for wiring shall be of 20 mm dia. in case of
exposed systems and 25 mm dia. in case of concealed/embedded systems.
e) For rigid metallic conduit saddles shall be used as means of support. Spacing between
saddles shall not to exceed 1m. In addition saddles shall be located on either end of
couplers/bends or similar fittings/accessories. In such cases the saddles shall be
located at a distance not exceeding 300 mm from the fitting/ accessories.
f) Separate conduits shall be used for wiring lighting circuits of different lighting
distribution systems such as normal, emergency etc. Also, wires for lighting & socket
outlets will be run in separate conduits.
g) Suitable pipe/conduit sleeves shall be used when wires are passed through walls/floors
and these shall be sealed properly.
h) The internal area of conduit shall be 2.5 times the total area of cables to be pulled
through it. A table is given below as a guideline.
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Max. No. of 450/750V Grade Single core
Nominal size PVC Insulated Flex, Wires
2.5 mm² 4 mm² 6 mm² 10 mm²
20 3 2 - -
25 5 3 2 3
32 8 6 5 5
40 - - 8 6
i) All necessary bends in the system including diversions shall be done by bending the
conduits or by inspection type bends/elbows etc. or by fixing cast iron inspection boxes.
18.17.12 Wiring and Cabling
a) Unless otherwise stated, the mode of wiring will be as follows:
i. 450/750V PVC insulated flexible single core wires in rigid steel conduits for
indoor lighting.
ii. Outdoor lighting cables shall be directly buried in ground at a minimum depth of
800mm and routed in the cable trenches. Cables crossing roads shall be laid in
concrete encased PVC pipes.
b) Where span of more than 1m occur between beams and supports, suitable size
galvanized steel sections shall be provided by the Contractor for fixing conduits,
cabling or fittings.
c) Stranded conductors having a nominal cross sectional area exceeding 6 mm² shall be
provided with soldered/crimped terminal lugs.
d) Size of wire shall be chosen to limit voltage drop to within 2.5%. Minimum area of
conductor shall be 2.5sq.mm copper, unless otherwise specified, density not to exceed
2.5A/sq.mm. Generally not more than 8 to 10 points shall be wired in one circuit. For
the purpose of calculating connected loads of various circuits a multiplying factor of
1.25 will be assumed to the rated lamp wattage for mercury vapour and fluorescent
lamp fixtures to take into account losses in the control gear. A loading of 100 watts and
500 watts will be assumed for single phase of 5 Amps and 15 Amps power sockets
respectively.
e) All types of wiring, concealed or unconcealed shall be capable of easy inspection.

Unconcealed wiring when run along walls shall be as near as possible to ceiling. In all
types of wiring, due consideration shall be given for neatness and good appearance.
f) Wiring shall be colour coded so as to enable easy identification of phase and neutral
conductors.
g) Each circuit live conductor shall be protected by circuit breaker in lighting

panel/distribution board. The wiring throughout the installation shall be such that there
is no break in neutral wire in the form of switch or fuse unit.
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h) Conductors not intended for connection to the same system and circuit or supply
different phases from the same supply, shall be kept apart throughout their entire run.
i) Wires belonging to different phases shall not be run in the same conduit. However,
more than one circuit, consisting of phase and neutral wires, of the same phases can
be run in the same conduit. For every phase wire a separate neutral wire shall be run.
j) Receptacles and lighting fittings in general shall be fed from separate circuits.
k) Each lighting circuit live conductor from a lighting panel/distribution board shall be
controlled by a single-pole switch.
l) For long conduit runs, inspection/pull boxes shall be provided at intervals not
exceeding 10m. Such facilities shall also be provided at conduit bends.
18.18 ROADWAY LIGHTING
18.18.1 General
a) All roadways within the pumping station area shall be lit by lighting columns
manufactured to BS 5649 and fitted with high pressure mercury vapour lanterns. The
lighting system shall be designed to minimise the effects of light pollution both beyond
the boundary of the central control building and pumping stations.
b) Around the works access road shall be column type lighting. All roads shall be provided
with lighting in accordance with BS5489 Part 10 Main Carriageway Grid.
c) Road lighting shall be switchable by selectable manual or automatic control operated

as follows:
i. Manual control – via on off switches on the control section door separated
appropriately into areas of the site.
ii. Automatic control - via photoelectric sensors with timer over-ride.
18.18.2 Columns
a) Roadway lighting columns shall be constructed and installed in accordance with BS

5649. The base compartment door/cover shall be fitted with a tamper proof fastening.
Columns, arm bracket and accessories shall be Hot Dip Galvanization, process by
immersing in molten Zinc in accordance with BE EN ISO 1461.
b) Columns shall be of the root type for installation in concrete foundation blocks and shall
incorporate bottom entry cable ducts. The columns shall be centrally hinged (if
specified elsewhere) to enable lowering of column to provide ground level maintenance
of the lanterns. All tools and equipment for lowering columns shall be provided.
c) Columns shall be complete with service cutout box, MCB and wiring between the MCB
and luminaries.
d) The service cutout shall be IP44 ingress protection, integral double entry cable
termination chamber with detachable front cover.
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18.18.3 Lanterns
All lanterns shall be of the high pressure sodium type fitted with high efficiency lamps
and complete with integral control gear. Luminaries shall be fully manufactured and
tested as per IEC 60598.
18.18.4 Roadway Lighting Controls
a) Roadway lighting shall be controlled via photocells either mounted on each lighting
column or via a centrally operated roadway lighting control panel utilising a minimum of
two externally mounted photocells.
b) The roadway lighting controls shall also be provided with a central override switch to
enable manual on/off control of roadway lighting circuits.
c) Time clock controllers shall be provided to operate a timed control sequence. The time
clock controllers shall be 7 day programmable. The time clock control shall operate to
allow the time clock to inhibit photocell control when roadway lighting is not required.
18.19 LIGHTNING PROTECTION
18.19.1 Building Lightning Protection
a) All major buildings and structures shall be provided with structural lightning protection
incorporating bronze finials and tapes as appropriate to the architectural qualities of the
building. The tapes shall be connected to series of earth rods installed at strategic
points at the base of the building.
b) All lightning protection shall be bonded to the buildings’ electrical earth system in
accordance with the IEC standard.
18.19.1.1 Design
The lightning protection installation shall be designed and installed in accordance with
IEC 62305 – ALL PARTS.
18.19.1.2 Materials
a) Materials used for the manufacture of the component parts of lightning protection
installations shall comply with IEC 62305.
b) Conductor material shall be bare or PVC covered copper or aluminium tape or solid
circular conductor. The colour of PVC covered conductors shall be agreed with the
DM/Engineer.
c) Careful attention shall be given to the selection of materials to minimise the risk of
corrosion.
18.19.1.3 Dimensions of Component Parts
a) The dimensions of component parts shall be not less than those specified in IEC
62305.
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b) Fittings shall be mechanically robust and shall have a high degree of resistance to
corrosion and erosion by the environment in which they are installed.
18.19.1.4 Metallic Building Fabric
Metallic building fabric used for air terminations shall be electrically continuous.
Comprehensive details of the methods to be used for ensuring electrical continuity and
making connections to structural steelwork and down conductors, shall be submitted
for the approval of the DM/Engineer.
18.19.1.5 Bonds and Clamps
a) Bonds shall be mechanically and electronically effective and shall be protected from
corrosion.
b) Bonds to structural steelwork, reinforcing bars and pipes shall be made using
proprietary clamps. The drilling of metallic building fabric to secure bonds shall not be
carried out without the approval.
c) When the reinforcement in concrete structures is used for down conductors, the metal
bar shall be interconnected, either by welding or by metal binding wire, to provide
definite electrical continuity. The interconnection shall be provided for both vertical to
vertical and horizontal to horizontal bars. The external conductor shall be connected to
the reinforcing bars via a proprietary non-ferrous built-in type bonding point. The
bonding points to be cast into the structure shall be provided by the Contractor together
with a drawing showing the required location.
18.19.1.6 Conductor Fixings
a) Conductors shall be fixed to the building structure using proprietary clips and holdfasts.
The fixings shall be purpose-made for the conductor type used and shall allow for
expansion.
b) Non-metallic clips shall be manufactured from high grade polypropylene. The material
shall be stabilised against degradation by sunlight and shall not become brittle at the
minimum temperature at the location where installed.
c) No welding or drilling of structural steelwork or drilling or cutting of the outside building

fabric for the attachment of fixings shall be carried out without the approval of the
Project Manager.
d) Fixings shall be securely attached to the building structure; mortar joints shall not be
used.
18.19.1.7 Joints
a) Joints in conductors shall be kept to a minimum and shall be mechanically and

electrically effective. Joints shall be clamped, riveted, bolted or welded. The overlap of
conductors shall not be less than 50mm.
b) Contact surfaces shall be thoroughly cleaned and coated with a suitable anti-corrosive
compound to inhibit oxidation. For bi-metallic joints a separate abrasive shall be used
to clean each metal.
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c) Bi-metallic connectors shall be used for joints between aluminium and copper
conductors.
d) Bi-metallic joints shall be made at test joints or in the conductor between the test joint
and the earth electrode.
18.19.1.8 Test Joints
a) A test joint shall be provided in each down conductor in a convenient position.
b) The connection between the test joint and earth electrode shall be PVC insulated
copper tape.
18.19.1.9 Earth Electrodes
a) Earth electrodes shall normally comprise solid copper rods. Rods shall have hardened
tips and driving caps to prevent damage during installation.
b) Couplings shall be manufactured from aluminium bronze and shall have completely
enclosed threads to prevent damage and corrosion.
c) Where soil conditions are very aggressive, solid copper earth rods shall be used.
d) Earth rods shall penetrate a minimum of one metre below ground water level. Due
attention shall be given to seasonal variation in ground water level.
e) Where multiple rods are installed, they should be separated by a distance of not less
than their driven length. Bare copper tape or multi-stranded cable, buried at a
minimum depth of 400mm and shall be used for the interconnection of rods.
f) Each rod shall be provided with non-ferrous clamp for the connection of the earthing
conductor. The connection shall be made in a concrete or other approved material
inspection chamber set flush with the finished ground level. The inspection chamber
shall be permanently marked LIGHTNING PROTECTION EARTH.
g) Where soil conditions make the use of rod type electrodes impractical or uneconomical,
a grid configuration shall be used. The grid shall comprise horizontally buried bare
copper tape or multi-stranded cable.
h) The resistance to earth of the earth electrode system shall be as stated in IEC 62305.
18.19.1.10 Bonding to Other Services
The lightning protection and electricity supply earth electrode systems shall be
interconnected in accordance with BS 7671.
18.19.1.11 Electronic Equipment Lightning Protection
a) All instrumentation and PLC/RTU systems shall be provided with local mains supply
surge/lighting protection devices installed in the ICA panels to protect equipment from
either excessive mains surges or lightning induced surges on the mains.
b) In addition, all incoming communications links from either radio or telecommunications

systems shall be fitted with lightning/surge arrestors to protect the connected
equipment.
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c) Where optical fibre cables are used for SCADA communications within the works there
shall be no requirement for installing lightning protection.
d) All lightning protection equipment shall be selected in accordance with IEC 62305.
18.20 TELEPHONE SYSTEM
e) The Telephone Junction box (TJB) shall be installed in pumping station. These
Telephone Junction box (TJB) shall be fed from Main Distribution Frame (MDF)
through required pair telephone cable. Each Telephone Junction box (TJB) shall feed
different numbers of telephone as per requirement. Telephone points shall be provided
in each room.
f) The system shall consist of local junction box, telephone wire and PVC conduits,
telephone socket. The product shall be from a manufacture having ISO-9000
certification.
g) The Contractor shall coordinate with Telecoms Company (Etisalat / Du) for the
estimate for complete telephone system except ducting, conduits and junction boxes.
The estimate of such works shall be agreed by DM and shall be paid through
provisional sum.
18.21 CABLE INSTALLATION
18.21.1 Cable Installation Requirements
a) The earthing conductor shall be of adequate cross sectional area and shall be a
separately run single core cable. The use of conduit, water or other service pipes in
any part of the earth continuity conductor is strictly prohibited.
b) The Contractor shall supply and install all necessary cable glands and sealing boxes
required to complete the installation.
c) The cores of each cable shall be taken direct to the terminals of the equipment to be
connected. Cable ends shall be sealed in suitable chambers bolted to terminal boxes.
d) The Contractor shall prepare drawings showing his precise requirements for cable
trench work detailing the width and depth of trenches and indicating the road crossing
cable ducts required. These drawings shall be prepared in consultation with the
Engineer and be approved before issue.
e) The cable route shall generally follow building outlines.
f) Cables with a conductor size of less than 2.5mm2 section shall not be used in the
installation.
g) All cables used shall bear the manufacturer's original guarantee and all cables shall be
delivered to Site in their original wrappings. The Contractor shall obtain the permission
of the Engineer before removing wrappings and commencing installation.
h) Each drum or coil of cable shall be accompanied by a certificate stating the

manufacturer’s name, rating of cable, result and date of tests.
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i) The Contractor shall ensure that no more than one phase will occur at switch lighting or
power outlets where these outlets are less than 2.5m apart unless guarded by a wall
partition or other barrier.
j) The scheme of wiring shall conform to the colour code requirements of an approved
International Standard.
k) A minimum tail length of 250mm shall be left on all cables at outlet positions for
connection of the apparatus fed by the outlet.
l) The bunching of small cables in large conduits will not be permitted.
m) The Contractor shall include for terminating each cable in excess of 30 amp current
carrying capacity in a pressure operated mechanically crimped leg terminal or terminal
socket.
n) All cables shall be delivered with cable ends effectively sealed. When a cable is cut
from a drum and is to be left for more than 12 hrs, both ends shall be immediately
sealed to prevent ingress of moisture.
o) Cable shall be sized in conjunction with electrical equipment operating characteristics

and should ensure the maximum circuit volt drops are not greater than:
i. Main feeder cables to and between system switchboards at rated circuit current
= 1%.
ii. Feeder circuits from control switchgear and panels to terminal equipment at
rated load current = 2%.
p) Unnecessary crossing of cables will not be accepted. Each cable shall be installed in
one continuous length, with no straight through joints being permitted, unless otherwise
agreed by the Engineer.
q) Cable sheaths shall not be damaged during installation. Should any part be damaged,
the cable shall be replaced.
r) At all exposed points where cables rise vertically through steel platforms or concrete
floors, the Contractor shall provide and position protective kerbing or sleeves made
from galvanized material extending 75mm above the finished floor level. Where single
core power cables are used, the sleeving shall be of a robust non-ferrous material.
s) At all points where cables rise into or against floor mounted equipment, the vertical
portion of the cable shall be securely cleated, to an adjacent purpose built supporting
frame, or frame mounted cable tray. Where vibration or expansion may occur
precautions shall be taken to protect the cable(s).
t) Spacing of clips, saddles and cleats shall be such to prevent sagging of the cables at
all times during their installed life.
u) Cables shall be segregated and run on trays. No cables shall be run on the bottom of
trenches without tray / ladder.
v) Where a number of cables are terminated to any particular item of equipment then
special care shall be taken to ensure that the cables finally approach the equipment
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from a common direction and are individually terminated in an orderly and symmetrical
fashion.
w) Cables installed around external structures shall be installed on cable tray with cable
tray cover. All cables shall be protected from exposure to direct sunlight.
x) Cable entry into underground chambers or building, e.g. flow meter chambers or
electrical/machine room shall be sealed with proprietary cable transit systems to
prevent ingress of ground water via the cable entry.
y) Every cable whether in or out of sight shall be neatly run vertically horizontally or
parallel to adjacent walls, beams or other structural members.
z) Bending of cables shall be in accordance with the manufacturer recommendation.
18.21.2 Cable Installation in Buildings or External Structures
a) Cable installed on external structures shall be supported with cable trays, ladders or
racking systems with cover.
b) All trays, ladders and racking shall have 20% spare width and loading capacity at
Contract completion.
c) Cables of up to 40 mm diameter may be fixed with cable ties or PVC coated aluminium
strip ties formed to shape on site. Where cable ties are used, fire support clips shall be
used on all cable runs spaced at 3 m intervals.
d) Cables above 40 mm diameter shall be fixed using correctly sized proprietary cleats.
The Contractor shall allow for the best quality components and must ensure adequate
supplies are available before commencing installation.
e) Trays, ladders and rack channels shall be fixed using galvanized steel or heavy duty
brackets. The bracket shall be proprietary type. Direct drilling or shot fired fixings shall
not be permitted.
f) Fixings to metalwork, where approved shall be by stainless steel machine screws, nuts
and washers (up to 4 mm diameter). Larger bolts may be zinc coated or stainless
steel. Self-tapping screws shall not be used.
g) MICC cables shall be fixed directly to concrete or other surfaces using PVC coated
copper clips. Trays shall only be used where more than six cables are run together.
18.21.3 Cables Buried Direct in the Ground
a) Cables laid underground shall have the following minimum cover below finished ground
level:
i. Up to and including 1000 V - 600mm.

ii. Above 1 000 V up to and including 33000V - 1000mm.
b) Before laying cables, the contractor shall bottom the trench with soft sand to a depth of
75mm. After laying, cables shall be covered with a further layer of soft sand to a depth
of 75mm and then protected with approved interlocking cable tiles extending at least
60mm over the outer edges of the cables. Finally, after completion of reinstatement of
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all work in the cable route areas, cable makers shall be erected. These shall be of an
approved type, indicating the number and depth of cables, and shall be positioned at
the beginning and end of a run, at all changes of direction and at intervals of not more
than 50 m.
c) Cables should not be pulled by hand, proper draw-wire attachment such as a cable-
sock or pulling eye shall be used. When cables are drawn into position, the operation
shall be facilitated by using a sufficient number of roller guides.
d) Any abnormal increase in draw-tension shall be investigated immediately and sufficient

operatives shall be stationed along the route length to ensure that the cable is running
smoothly.
e) Where cables pass through walls or under roads or hard-surfaced areas, they shall be
drawn into continuous PVC ducts surrounded in concrete and arranged in suitable
formation, with a minimum of one spare duct.
f) Cable laying shall only be undertaken in firm ground conditions.
g) The following minimum segregation between parallel laid power cables and an
analogue or digital signal cable, including a data highway (other than fibre optic) shall
be complied with: -
Voltage of adjacent cable Minimum distance to ICA cable

Less than 50V 0mm
Over 50V, up to and including 110V 100mm
Over 110V, up to and including 1000V 500mm
Over 1kV, up to and including 11kV 1000mm
Over 11kV 1500mm
h) The contractor shall survey the route where applicable and shall verify all relevant
information relating to existing and planned services.
18.21.4 Marking of Buried Cables and Joints
a) A warning tape shall be placed above individual or groups of cables and cable ducts.
The tape shall be laid at a depth of 30mm below the finished surface level. For groups
of cables or ducts where it is impractical to install individual tapes, a single tape shall
be installed above the each outer cable or duct.
b) Warning tapes shall be of polythene not less than 150mm wide and 0.1mm thick and
shall incorporate a metal foil or braid. They shall be yellow in colour and shall be
continuously marked “CAUTION ELECTRIC CABLE BELOW”, or similar, in black letter
not less than 30mm high.
c) The route of buried cables shall also be permanently identified by reinforced precast
concrete marker posts or blocks of an approved type with impressed characters "HV
CABLE” or "LV CABLE” as appropriate.
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d) The position of buried cable joints shall be permanently identified by reinforced precast
concrete marker posts or blocks of an approved type with impressed characters "HV
CABLE JOINT" or "LV CABLE JOINT" as appropriate.
e) Cable marker posts and blocks shall be located on the precise line of the cable at
regular intervals not exceeding 50m, at changes in direction and at points of entry in to
buildings. Marker blocks shall be installed flush with the finished ground level.
18.21.5 Installation in Cable Ducts
a) Cable ducts shall be manufactured from polyethylene. Unless otherwise specified duct
colours shall be as follows:-
i. Electric cables : Black.

ii. Telecommunication cables : Grey or white.
b) Proprietary couplings, bends and other accessories shall be used.
c) Cable ducts shall be installed and jointed in accordance with the instructions or
recommendations of the manufacturer.
d) Ducts installed under roads, hard standings and paved areas shall extend 1000mm
beyond the boundary.
e) Where site conditions require a surround of concrete, the thickness shall not be less
than 100mm.
f) After installation, all ducts shall be checked for alignment and the ends temporarily, but
effectively, sealed to minimise the risk of ingress of water, or other materials and
vermin.
g) On completion of cable installation ducts shall be sealed at all openings with a suitable
silicon foam sealant. The seal shall be cut back flush to the duct end. Where a gas
tight seal is required a block transit system shall be used.
h) A polypropylene draw rope with a 6kN breaking strain shall be installed in each duct.
Draw rope shall not pass through duct end seals.
i) Draw chambers shall be provided at changes in duct direction, at 30 meter intervals

along the duct run and at access points into buildings. The size and spacing of the
chambers shall be determined by cable minimum bending radii and permitted
maximum pulling forces. The total of all angles in a closed duct route shall not exceed
180o without passing through a draw chamber.
18.21.6 Cables in Concrete Trenches
a) Where the trench depth is less than 300mm, the cables may be laid on the bottom of
the concrete trench
b) Where the trench exceeds 300mm, the cable shall be supported with cable tray or
ladder with proper cable cleats
c) Electrical cables shall not be installed in trenches containing pipe-work conveying

flammable gases, liquids or sewage sludge.
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d) Concrete cable trenches shall be provided with suitable cover plates which shall be
installed flush with the floor/ground. All trench covers shall be bolted down to a
supporting sub-frame.
18.21.7 Cable Entry Seals through Ducts and Rectangular Cut-Outs - Cable
Transit Systems
a) General
i. Cable penetrations through external walls or ground slabs are to be conducted

through a mechanical cable and pipe sealing system to prevent any entry of
water, gas, dust, rodents and humidity.
ii. Temporary/ad-hoc/chemical seals like foam, mortar, bitumen, cement etc. are
STRICTLY not acceptable.
iii. The cables shall enter buildings either through circular duct sleeves or
rectangular cut out frames.
iv. The duct sleeves and rectangular frames populated with cables shall be sealed
using a mechanical compression based sealing system.
v. The seals shall have provision for future cable size modification or replacement
of cables.
vi. Cable transit systems shall be the compression type manufactured by Hawke
cable glands Ltd or Roxtec or equivalent.
b) Duct Sleeve and Sealing
i. Duct sleeve shall have a knock-out that ensures that the duct entry is
completely sealed off until a cable is routed.
ii. Duct sleeve shall be provided in the sizes 100mm, 150mm or 200mm.
iii. The duct sleeve shall have puddle flange.
iv. The duct sleeve shall be casted during initial(civil) stage.
v. The duct sleeve shall be of composite plastic, pp or stainless steel.
vi. Duct sleeve with cables shall be sealed with rubber based mechanical
compression seal.
vii. Rubber seals shall have Peel-able layers to adapt to a perfect/tight fit around
cables of varying diameters.
viii. All fittings shall be of AISI 316 grade steel.
ix. The duct seal system shall have minimum water tightness of up to 3m constant
water head.
x. The Duct sleeve shall be supplied as package along with the mechanical
compression seal.
c) Sealing of rectangular cable entries through walls and Cable trenches
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i. Cables entering buildings/structures through cable trenches and other
rectangular openings shall be sealed with a modular mechanical compression
based sealing system.
ii. A mechanical multi cable sealing system shall consist of a stainless steel 316
rectangular frame, sealing modules, stay plates and a compression wedge.
iii. The sealing modules shall have Peel-able layers to adapt to a perfect/tight fit
around cables of varying diameters.
iv. The cable population density and sizing of the multi cable sealing system shall
be decided according with manufacturer design.
v. The frame shall be either bolted with chemical anchor or pre casted into the
concrete.
vi. The frame shall be designed to use in both vertical and/or horizontal
combinations.
vii. The frame shall be supplied as a package along with Sealing Modules and
mechanical compression wedge.
18.21.8 Steel Conduit Systems
a) Steel conduit and fittings shall be of heavy gauge (class 4), screwed, solid drawn,
galvanized to BS EN ISO 1461.
b) Purpose made boxes shall be of robust construction and galvanized Screws etc. used
in boxes shall be zinc coated or of stainless steel with insulating sleeves and washers.
All boxes shall be fitted with a lid and rubber gasket.
c) Steel conduit shall form a continuous electrical enclosure throughout. Smooth bore
bushes and couplings shall be used with plain boxes or alternatively spouted boxes
may be used. The ends of tubing shall be cleaned with a reamer and exposed threads
shall be cleaned and painted with zinc paint.
d) Bushes shall be galvanized or of brass with insulating sleeves and washers.

Expansion couplings shall be fitted in surface installations at intervals as recommended
by the manufacturer.
18.21.9 Plastic Conduit Systems
a) PVC conduit shall not be used for surface installation.
b) Non-metallic conduit and fittings shall be to BS 4607: Part 1 and Part 3. Screws in
fittings shall be of stainless steel.
c) Non-metallic conduit joints into couplers slip type bends and spouted fittings shall be
made using silicone grease or a permanent solvent. Silicone grease shall be used for
expansion couplings.
d) Only fittings approved by the conduit makers shall be used. Jointing may be screwed
or by an adhesive as approved by the manufacturer. A continuous earth conductor
shall be provided through the conduit systems.
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e) Conduit shall not be less than 20 mm dia. Draw-in boxes or inspection fittings shall be
provided at every 2 right angled bends and in every 10 m of length of conduit.
f) Boxes to which lighting or other fittings are to be attached shall be fixed independently
of the conduit by non-ferrous screws in PVC plugs.
g) Conduit shall be adequately secured in chases and surface mounted conduit shall be
fixed with stand-off saddles providing a clearance of not less than 6 mm. The saddles
shall be fixed with non-ferrous or stainless steel screws in plastic or metal plugs, and
shall be provided at suitable intervals not exceeding two metres to form a robust
assembly.
h) Except for those installations located in areas classified as hazardous areas in

accordance with BS EN 60079-10., drain holes 4 mm in dia shall be provided at low
points of all conduit runs to allow condensate to escape.
i) Plastic conduit shall not be used in areas classified as hazardous areas in accordance
with BS EN 60079-10.
j) Flexible armoured conduit, PVC sheathed overall, shall be used to motors or other
units subject to vibration and elsewhere where specified. A through box shall be
provided at the joint between the rigid and flexible conduit, which shall be adequately
glanded at both ends. A separate earth conductor shall be provided in the flexible
conduit.
k) Where conduits are specified to be connected to apparatus or plant having a definite

movement, vibration or requiring adjustment in their position (e.g. motors, motorized
valves, insertion thermostats, dampers, pressure switch) flexible conduits and fittings of
metallic WT type to BS 731 shall be provided. Each end shall be provided with an
internally rifled split brass adaptor or sweated with solder into threaded brass sweating
glands and shall terminate in a suitable size brass double female adaptor box and fixed
motor type connector.
l) Earth continuity through flexible conduits shall be provided by a separate green/yellow

coloured PVC covered copper stranded earth-wire of appropriate size drawn into the
flexible conduit. The brass adaptors specified shall be drilled to enable the earth-wire to
be drawn out at each end when the earth wire shall be soldered to the brass adaptors
to alternatively positively connected to a substantial earth terminal. Where the flexible
is connected to plant (e.g. motors) the earth-wire shall be minimum 1.5 sq. mm. The
protective conductor shall be drawn into a flexible conduit and connected externally
and visibly to terminals on the two boxes.
m) Conduit smaller than 20mm size shall not be used.
18.21.10 Trunking Systems
a) Trunking shall be manufactured from hot-dip zinc coated steel or heavy duty plastic
complying with BS 4678: Parts 1 and 4.
b) When fitted, partitions shall be of the same material as the trunking. The gap between
the partitions and the trunking cover shall be a minimum to ensure the segregation of
circuits is maintained.
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c) Trunking shall be installed using factory made accessories. Site fabricated fittings will
not be accepted.
d) Blind ends of trunking runs for future extensions shall be fitted with removable covers.
e) Where trunking runs vertically, cables shall be supported at intervals not exceeding 5m.
The methods of support shall allow for future easy removal or addition of cables and
shall be subject to approval.
f) Non-flammable fire barriers shall be inserted where the trunking passes through walls
or floors. Conduit connections to trunking shall be made by flanged couplings and male
bushes.
g) Trunking shall be supported at intervals not greater than 2m horizontally or 2.5m

vertically.
18.21.11 Cable Trays and Ladder Racks
a) Cable tray shall be heavy duty hot dip galvanized steel, stainless steel or plastic with
return flanges.
b) Wherever possible, galvanized steel cable trays shall be installed in full lengths without
cutting. Cut edges shall be treated with approved zinc based paint.
c) Cable trays shall be installed using proprietary accessories and support systems. All
cables shall be firmly secured to the tray using approved purpose made fixings. Cable
tray shall be mounted not less than 25mm from the face of the structure.
d) Cable ladders shall be heavy duty hot dip galvanized steel, stainless steel or heavy
duty plastic.
e) Ladder trays shall be installed using proprietary accessories and support systems. All
cables shall be firmly secured to ladders using approved purpose made fixings.
18.21.12 Cable and Core Identification
a) All cables shall be permanently identified at each end and at entry and exit points of
ducts. Identification shall be by means of approved cable markers with semi-rigid black
PVC carrier strip, which shall be fixed axially by means of two PVC straps.
b) All cables shall have individual cores identified by means of suitable permanent ferrules
bearing the same number at both ends. Core identification shall occur at every point of
termination using an approved system of ferrule markers.
c) The size of the ferrule markers shall be such as to match the overall diameter of
conductor plus insulation. Numbering shall read away from the termination on all
cores.
18.21.13 Cable Glands
a) Cable glands shall comply with BS 6121 and unless otherwise specified, shall be
manufactured from brass. Glands for use with aluminium armoured cables shall have
zinc or nickel plated armour clamp and spigot.
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b) Cable gland and accessories should be selected to ensure that the product will
maintain the IP rating of the equipment and the integrity of the installation.
c) Cable gland should be tested and certified in accordance with IEC 60529.
d) Cable Glands should be classified as being equipment and should be marked with the
same or similar information as would be applicable for main apparatus.
e) Cable Glands for installation in hazardous area, should be certified to demonstrate

compliance with the EU ATEX Directive 94/9/EC or IEC Ex 02 Certification Scheme
and shall comply with either of the standards CENELEC or IEC standards IEC 60079.
f) Glands for armoured instrumentation cables shall be insulated from earthed metalwork
with facilities for shorting.
g) Glands for armoured cables shall be fitted with earth tags.
h) Cable glands for use outdoors shall have cable inner and outer sheath seals. Glands
for indoor use shall have a cable outer sheath seal.
i) Mineral insulated cables shall be terminated using proprietary termination kits

compromising moisture seal, insulating sleeving and gland. The type of seal shall be
compatible with the continuous operating temperature of the cable. The termination kit
and cable shall be of the same manufacturer.
j) Exposed cable glands shall be fitted with PVC shrouds.
18.22 Duct Banks and Draw Pits
18.22.1 General
a) The Contractor shall provide drawings clearly showing the locations and arrangements
of duct banks, draw pits and manholes.
b) The Contractor shall provide calculations clearly showing that the size and number of
ducts proposed are sufficient for the cable installation.
c) 25% spare ducts shall be provided, in additional to that needed for the installation,
between draw pits or not less than two spare ducts.
d) Power cables shall be installed in separate ducts from control and instrumentation
cables.
e) Ducts in cable draw pits shall be effectively sealed with water sealing material
approved by Engineer to avoid ingress of water into ducts in all cases.
18.22.2 Draw Pits
a) The duct system shall be designed to manage the cable segregation requirements as
specified elsewhere.
b) Draw pits shall be sufficiently sized to allow cables to be pulled through them and their
associated ducts without causing damage by exceeding the minimum bending radius of
a cable. Sharp changes of direction of cables at draw pits shall be avoided.
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c) The top section of each draw pit shall include 1000mm diameter or other approved size
and shape grooved opening for frame and cover. Each cover shall be marked in
compliance with the requirements of DM with stainless steel name plate and fixtures.
d) The assembly of manhole cover shall consist of outer cover, circular frame, gasket
rubber, inner cover, handles and bolt & nut for installation to circular block conforming
to ASTM F1143.
e) The material of outside cover and circular frame shall be made of carbon steel and
tensile strength shall be not less than 450 N/mm2. The centre of cover shall be
embedded with word ‘ELECTRIC’ or ‘TELEPHONE’ etc. as directed by DM/Engineer to
indicate the utility.
f) Details of concrete draw pit and manhole cover shall be provided in line with civil
requirements.
18.23 Scope of Instrumentation Control and Automation (ICA)
The scope of instrumentation works shall include the preparation of shop drawing,
related detail engineering (loop diagram, hook-up diagram and block diagram), supply,
and installation, testing, commissioning and setting to work a complete instrumentation
control and automation system for the plant/station.
18.23.1 Electrical Requirements for ICA
a) ICA equipment shall be designed to operate on one of the following power supplies
specified as follows:
i. Mains power supply of 230 V AC or 110 V AC at 50 Hz selectable by switch or

link.
ii. 24 V DC with reverse polarity protection built-in.
iii. Loop powered from a 4-20 mA current circuit in a regulated 24 V to 48 V DC
systems with reverse polarity protection built-in and operating as a two wire
device.
b) All preset parameters and user adjustments shall be retained for at least seven days
after disconnection or loss of power supply.
c) Equipment performance shall not be impaired by power supply variations within the
ranges:
i. -12% to +10% of voltage applied to the equipment.

ii. 45 Hz to 55 Hz supply frequency.
iii. ±1% of the regulated supply for loop powered devices.
d) System alarms shall not operate due to depression of the mains supply voltage by 25%
for up to 5 seconds or interruption of the supply for 0.5 second.
e) Equipment performance shall continue to meet the specified requirements when the
power supply waveform is distorted by up to 6% THD.
f) Mains borne transients of up to 1000 V peak at 1 Joule shall not damage the
equipment nor change the performance after such a transient.
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g) All circuit boards shall be of coated version to resist corrosion.
h) Adequate training of Dubai Municipality staff in operation & maintenance, control

system, software, etc. shall be provided by the contractor
18.23.2 Supply Isolation
ICA equipment circuits shall be fully isolated from power supplies by means of isolating
barriers having a resistance not less than 2 Mega-ohms, measured at 500 V DC, in
accordance with BS EN 61010-1.
18.23.3 Environmental Requirements
18.23.3.1 General
All equipment and equipment shall be selected in accordance with good engineering
practice to be suitable for the particular application.
18.23.3.2 Ambient Temperature
a) Equipment shall perform to the design specification within an ambient temperature of:
i. 0oC to +50oC within buildings

ii. 0oC to +55oC in exposed locations
18.23.3.3 Atmospheric Pressure
Equipment shall perform to the specified requirements when the local barometric
pressure varies by ±5% between 70 kPa and 106 kPa.
18.23.3.4 Construction and Materials
a) Electronic equipment shall be of modular construction. All modules are to be easily

accessible and readily removable, with an arrangement to prevent insertion in an
incorrect location.
b) All electronic boards of soft starters shall be conformal coating. Conformal coatings
shall be 1-2 mm. thick polymeric films that cover or encapsulate printed circuit

iii. UL746E
c) For potable water applications, sensors or other parts of the ICA system that are in
contact with the process medium or sample medium that may be introduced into the
process stream, shall comply with BS 6920 Part 1.
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18.23.3.5 Hazardous Atmosphere
All equipment intended for use in a potentially explosive atmosphere shall comply with
the requirements of BS EN 60079 and BS 5345 (IEC 60079) and shall be certified for
such use.
18.23.3.6 Humidity
ICA systems field equipment shall meet the specified performance when operated in
any atmosphere having a relative humidity within the range 5% to 95% including
condensation.
18.23.3.7 Interference, Magnetic Field and RF
a) Equipment shall be capable of meeting the specified requirements of performance

when subjected to a magnetic field of 400 A/m at 50 Hz applied in three mutually
perpendicular planes as defined in BS EN 60770-1 (IEC 770).
b) The equipment shall be screened to reduce or eliminate the effects of electrostatic

interference and radio frequency fields of strength:
i. 10 Vm-1 in the frequency range 20 MHz to 1 GHz.

ii. 1 Vm-1 in the frequency range 1 GHz to 2 GHz (BS 6667 (IEC 801)
augmented).
c) The Contractor shall install cabling and earthing provisions with due consideration to
segregation from power cables and other site services likely to produce interaction of
any kind. Items of equipment and methods of installation shall conform to the
requirements for Electromagnetic Compatibility (EMC), contained in European Union
Directive 89/336/EEC, BS EN 50081 and BS EN 50082.
18.23.3.8 Lightning Protection
a) Lightning surge diversion equipment shall be fitted for all incoming or outgoing local
Telephone Utility lines, private telecommunication lines, low power radio terminations
and data highways (excluding fiber optics).
b) The Contractor shall carry out a risk assessment in accordance with BS 6651 and take
appropriate steps to protect any other point of circuit access to the instrumentation and
control system, including power supplies and signal cables.
c) Lightning protection barriers shall be self-resetting, solid state, un-fused units bolted
directly to a lightning earth bar, all housed in a non-conductive enclosure. This
enclosure shall be mounted separately from other equipment and contain no other
components apart from lightning protection circuit items, it shall also be mounted close
to the earth connection point to ensure short, straight final connections.
d) The copper earth conductor shall have a minimum cross section of 16 mm2, a
maximum length of 10 meters and be routed to avoid other instrument circuits.
e) The lightning earth system shall be bonded to the main power system earthing in an
appropriate manner. Installation of all protective barriers and associated equipment
shall be strictly in accordance with the manufacturer’s recommendations.
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f) Where specified in the Particular Requirements, or where the risk assessment
indicates the necessity, lightning protection units shall be installed generally as follows:
i. To the power supply, close to the point of entry to ICA equipment enclosures.
ii. On 4-20 mA signal loops where the sensor or transmitter is installed in a
separate building from the Local Control Panel or microprocessor based
controller also where the sensor or transmitter is installed in an external
location, protection units shall be provided at the sensor or transmitter also at
the Local Control Panel or microprocessor based controller.
iii. On 4-20 mA signal loops installed entirely within buildings and having cable
lengths in excess of 100 meters or for all external circuits, protection units shall
be installed at the sensor or transmitter as well as at the Local Control Panel or
interface cubicle.
18.23.3.9 Mounting
Equipment performance shall be unaffected when mounted at an inclined angle of up

to 10o from the vertical in any direction.
18.23.3.10 Solar Radiation
The specified performance of any ICA system equipment shall be met when subjected
to incident solar radiation ranging from darkness to the maximum intensity likely at the
application location due to direct sunlight.
18.23.3.11 Sunshades
a) All instrumentation and enclosures containing electrical or electronic equipment shall

be shaded from direct radiation from the sun.
b) All sunshades are to be of stainless steel and shall be purpose designed and fabricated
to comply with relevant mechanical or civil specifications.
18.23.3.12 Vibration
Equipment shall continue to operate to the required performance and suffer no damage
when subjected to shock or vibration within the test limits detailed in BS EN 60770-1.
(IEC 60770).
18.23.4 Mode of Operation
a) Automatic motor control: - Automatic duty rotation of pumps shall be carried out, with
the facility for the Operator to override and edit the required duty sequence from the
PLC. Emergency stops shall be provided for all drives where there is a risk of injuries to
authorized users. Except when specifically described otherwise, all motors specified for
automatic operation shall be provided with HAND-OFF-AUTO (HOA) selector switches.
In HAND position, the motor shall be by-passed. In OFF position, the motor shall be
stopped. In AUTO position, the motor shall be dependent on the status of the output
contact of the control circuit, which may originate from local control logic or the PLC
commands will be initiated either by manually entered or software control routine
generated requests.
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b) Remote control: - When an item of equipment is selected as remote, using the LOCAL
REMOTE (L/R) switch, commands will be generated from the PLC / RTU commands
will be initiated either by manually entered or software control routine generated
requests.
c) Automatic Standby Operation: - Motors in multiple unit systems shall also be provided
with either a DUTY-STANDBY (D/S) selector switch for automatic motors with H/O/A
switches or START/STOP (S/S) switches for manually operated motors without H/O/A
switch.
i. The automatic control circuit shall control automatic motors with selectors on
AUTO and DUTY, those selected for AUTO and STANDBY shall operate only if
a DUTY motor fails to respond.
ii. The standby function shall be operated when the H/O/A selection for the
standby motor is in AUTO position. For manually operated motors with start-
stop (S/S) switches, motors selected for standby shall operate if a motor
selected for HAND fails to operate.
d) Lockout Stop Function: - Any lockout stop switch (LOS) associated with operating
equipment shall be utilized to stop the equipment on an emergency basis only and
shall not permit operation in any mode until the switch is physically reset. Whenever a
LOS switch is actuated, an alarm signal shall be transmitted to the PLC where the
stopped equipment shall be identified.
18.23.5 Signalling and control
18.23.5.1 Analogue Inputs
a) Analogue inputs shall be 4-20 mA continuous, linear signals capable of supporting

floating 250 ohms load impedance. To facilitate removal of circuit boards in current
loop circuits an external zener diode should be provided to avoid loop interruption.
b) Analogue to digital conversion should be at least 10 bit resolution having linearity within
±0.1% span or better.
18.23.5.2 Analogue Outputs
a) Analogue output range shall be 4-20 mA capable of driving into an impedance of 1000
ohms.
b) Digital to analogue conversion shall be at least 10 bit resolution having an accuracy of

c) The output shall be electrically isolated from other outputs and earth. It shall have an
insulation resistance of at least 1 Mega-ohm when tested for one minute at 500 V dc.
On multiple output units, system functionality shall be maintained when each output is
earthed in turn.
d) Output current shall not vary by more than 0.1% of span when load resistance is varied
from 0 to 1 000 ohms.
e) Peak to peak amplitude of internally generated ripple, noise or other unwanted

component appearing on the output signal, shall not exceed 0.1% of the selected
output span.
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18.23.5.3 Digital Inputs
a) All digital inputs shall be isolated, preferably by optical coupling, from other signals and
circuits.
b) Such inputs shall compromise volt free contacts wetted by 24 V DC at 5 to 25 mA

nominal current. Input filters should be provide where contact bounce may occur, such
debouncing may be carried out in either hardware or software.
18.23.5.4 Digital Outputs
All digital outputs shall be in the form of volt free contacts capable of switching on
inductive load of 0.1 A at 24 V DC and rated at 30 VA. Outputs shall be sustained, not
fleeting, arranged for fail safe operation (e.g. normally open to trip or signal alarm).
Wherever necessary, RC networks may be fitted to digital outputs when switching non-
resistive loads.
18.23.5.5 Interposing Relays
a) Any relays used to augment the I/O facilities shall be plug-in, of at least 11 pin design,
DIN rail mounting and fitted with transparent protective covers.
b) Clear identification of relay state and means of manual test operation shall also be
provided. Coil and contact suppression shall be provided.
18.23.6 Instrumentation and Control panels
18.23.6.1 Construction - General
a) ICA panels shall be of a wardrobe style construction, manufactured to the same

standards as that for switchgear and motor control centres and shall contain all
required components for the operation of the system.
a) The doors of the ICA panel shall be suitably braced in order to support all door
mounted components such as lamps, switches, HMI units.
b) The doors shall be lockable and shall be provided with handles on all doors which
operate a mechanism to secure the door at the top, centre and bottom to provide
ample securing of each door.
c) The panel shall be provided with a padlock stud to allow the panel doors to be
padlocked to prevent entry.
d) The panel shall be provided with an internally mounted, fully shrouded, mains supply
isolator not interlocked with the door which shall feed and include a distribution board
to provide sub-circuits to all relevant mains powered equipment/instrument located in or
fed from the panel.
e) Adequate space shall be allowed to enable external cables to enter the panel via the
gland plates and sweep into the internal panel cable containment systems in a neat
manner and without obstruction.
f) Separate trunking systems shall segregate 230Vac and 24Vdc circuits.
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g) Where intrinsically safe circuits are marshalled in the ICA panel, separate areas,
termination banks and wiring containment within the ICA panel shall be provided for
these circuits.
h) Terminal blocks shall be arranged such that both terminals and wiring ends are readily
accessible and have separate terminals provided for incoming and outgoing wires.
i) Each terminal shall be labelled to correspond with the diagram of connections and the
terminal identification label shall be attached to the fixed portion of the terminal blocks
only. Terminals for intrinsically safe circuits shall be coloured blue.
j) LV terminals which may be “live” when the equipment is isolated from the main supply
shall be adequately shielded from accidental contact and be clearly identified and
labelled accordingly.
k) Unless otherwise specified, not more than one conductor shall be connected to a
terminal. When more than one conductor needs to be connected together, the requisite
number of terminals shall be interconnected by means of permanent solid links, i.e.
conductor bars or combs.
l) Terminal blocks shall have separate terminals for internal and external connections.
External connections shall always be connected to the same side of the terminal
blocks.
m) Control circuit terminals shall be DIN rail mounting of the clamping plate type, Klippon
SAK 2.5 as minimum or similar manufacture and rated for continuous current
operation. Moulding material to be non-fracturing polyamide. Control terminal rails
shall be provided with 20% spare terminals within the panel.
n) Terminals connected to remote alarms, indications, conductivity electrodes and

analogue instrument circuits shall have a hinged disconnect test link (e.g. Klippon
SAKR or similar).
o) Pinch screws bearing directly onto the conductor shall not be used.
p) Barriers for segregation according to voltage shall be provided. For circuits of 110 V
and above, terminals shall be fully shrouded.
q) Main incoming supply cables shall be terminated on the main isolating switch and
shrouded. The shroud shall bear an appropriate warning label.
r) Terminals shall be provided for all outgoing connections and shall be located adjacent
to the cable gland. External connections shall not be made directly to terminals
forming an integral part of components.
s) All floor standing ICA panels shall be fitted with an internal anti condensation heater
and internal working light. The working light shall operate automatically from a door
mounted switch, switching the light on when the door is open.
18.23.6.2 Construction- End section of an MCC
a) Where ICA panels form the end section of an MCC the panel shall be constructed to
the same standard as that of the MCC and shall be manufactured as part of the overall
MCC assembly.
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b) Bus wiring from the MCC shall be provided between connections in the MCC and the
ICA section via a bus wiring system constructed as part of the assembly for control
cabling.
c) Suitably positioned terminals shall be provided in the ICA section for the termination of
all bus-wiring close to the wiring entry point into the panel in order to segregate bus
wiring from the main internal ICA panel wiring.
18.23.6.3 Construction - Stand Alone Control Panels
a) Standalone ICA panels shall be constructed in the same manner as MCC end section
panels, described above, but with single or double doors as appropriate to the design.
Standalone panels may be floor mounted, wall mounted or mounted on a proprietary
item of equipment.
b) These ICA panels shall be of constructed of steel not less than 1.5mm thick for wall
mounted panels and to the same standard as MCCs for floor mounted panels. Wall
mounted ICA panels shall not exceed 1.5m3 volume. Panels above this volume shall
be floor standing.
c) Wall mounted panels shall not be mounted directly to a wall, but shall be mounted on a
mounting frame providing a minimum of 50mm clearance between the wall and the rear
of the panel. Cable entry to wall mounted panels shall be from the bottom only.
18.23.6.4 Housings for Externally Mounted Instrumentation, Equipment and Control Panels
a) Instrument and control panels and other instrumentation equipment required to be

located outdoors shall be installed in stainless steel housings with protective sun
shade.
b) The housing shall be rigid and secure and shall have a minimum degree of protection
of IP 65 to BS EN 60529. Housings shall be mounted on a concrete base with
provision for cable access. A concrete or concrete slab hard standing of minimum
width 600mm shall be provided in front of the housing.
c) Large plain surfaces shall have adequate reinforcing to ensure rigidity. Doors shall be
complete with latching handles and locks. Door catches and locks shall latch onto
steel reinforced surfaces.
d) Box section steel shall be encapsulated into door edges and door frames. Door locks,
handles and hinges shall be of a high tensile strength, non-corroding alloy with
stainless steel pins and through fixing bolts. Doors shall be fitted with rigid self-locking
stays arranged to hold the door open at a minimum of 100 degrees and door stay
release.
e) Ground mounted small housings shall be installed on a concrete base as for large
housings. The base of the enclosure shall be sealed with a suitable silicone based
sealant to prevent water ingress.
f) Wall mounted housings shall be provided with external fixings and shall be a minimum
of 10mm from the mounting surface.
g) Threaded studs shall be incorporated into the structure of the housing for the mounting
of sub-frames or backing plates or boards, which shall be installed on all appropriate
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surfaces on which all internal equipment shall be installed. Fixing bolts through the
skin of the enclosure will not be accepted.
h) The front of externally - visible instruments and any window shall be of toughened
glass and shall not reduce the IP degree of protection of the housing.
i) Large housings shall be fitted with lighting, power socket outlet and anti-
condensation/anti-frost heater
18.23.7 Field Mounted instrumentation
18.23.7.1 Field Instrumentation Schedules
a) The Contractor shall provide a comprehensive and detailed list of all sensors and
instruments being provided for the control and monitoring of the whole station.
b) Typical information, which should be in a tabulated form for each item, shall include but
not be limited to:
i. Function;
ii. Manufacturer;
iii. Type/model;
iv. Technology employed;
v. Number of units;
vi. Display;
vii. Input;
viii. Output;
ix. Size/range;
x. Accuracy;
xi. Power supply;
xii. Enclosure IP;
xiii. Associated converter, etc;
xiv. Material;
xv. Other relevant parameters, e.g. dimensions, weight, pressure or temperature
limits, maximum separation distance between sensor and analyser, etc.
18.23.7.2 Requirements for Instrument Sensors and Transmitters
a) Sensors shall be accessible for safe inspection and removal for maintenance.
b) Electronics in Instruments shall be of corrosion resistant construction
c) All local Instruments shall be of corrosion resistant construction.
d) All Local Pressure and Temperature gauges shall be of durable corrosion resistant
construction.
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e) Sensors shall be mounted generally on the pipework or structure. Where impulse lines
are used, they shall be kept as short as possible.
f) Where the weight of a sensor is excessive for support via the pipe tapping, a separate
supporting bracket shall be provided. The supporting bracket shall not be attached to
the process pipeline.
g) Unless otherwise specified, the instrument transmitter shall be supplied integral with
the sensor in a common assembly. This shall only apply where the transmitter is
installed above the site flooding level. When the sensor is installed below flood level,
the transmitter shall be installed in a separate enclosure remote from the sensor above
the flood line.
h) When a transmitter is remote from the sensor it shall be fixed to a suitable frame
positioned 1.4 meters above ground or floor level. Where the instrument must be
located above 2 meters high a separate local indication shall be provided at 1.4 meters
above floor level.
i) Calibration sheets shall be supplied with each instrument showing that the instrument
has been tested and calibrated on a certified test rig or instrument. The sheets shall
show test results and confirm that the instrument is within the specified accuracy limit
across the whole of its range. Where a test instrument is used, a verification test
certificate shall be provided and reference to the certificate number shall be included
on the test sheet of the instrument under test.
j) Each instrument unit e.g. sensor and transmitter where mounted separately shall be
provided with a label giving tag number and function description.
k) Each 230V ac powered instrument transmitter shall be provided with a local

disconnector located not more than 5 meters from the transmitter.
l) Local disconnectors shall comply with BS EN 60947 and shall be padlockable in the off
position.
m) Signal output requirements for the transmitters and discrete signal devices shall be as
specified for signaling and control. The signals shall be cabled to the relevant MCC ICA
panel and cabling shall comply with the specification for cabling.
n) Where an instrument transmitter is integral to the sensor, a local terminal box shall be
provided and installed close to the transmitter for the connection of the signal cables to
the local instrument tails.
o) Process fluids which solidify or are highly viscous (e.g. sludges) at the lowest ambient
temperature shall be prevented from entering impulse pipes and instruments by the
use of diaphragm seals and capillary lines filled with a suitable inert, non-toxic liquid
which shall not evaporate under process conditions.
p) Before connecting any instrument to its associated impulse or air supply pipework, all
isolating valves shall be opened and the pipework blown through to clear any matter.
Each line shall be flow-tested for continuity, followed by a pressure test at 2 bar, or as
otherwise specified using clean dry air. Instruments and other ancillary equipment
shall be connected immediately after the successful completion of the pressure test, if
possible, and all open tube ends shall be sealed against the ingress of moisture.
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q) Transmitters/Indicators for measuring systems for tanks or other inaccessible areas
shall be installed at a convenient location at ground level on a support frame.
18.23.7.3 Indicating Instruments
a) Indicating instruments shall be flush mounting with semi-matt black bezels and non-
reflective dial glass. They shall conform to the requirements of BS 89 (IEC 51)/BS EN
60051 having an accuracy class index of 1.5.
b) Scaling shall be as recommended in BS 3693 Part I. Length of scale may be 90° or

240° as appropriate, with external zero adjustments and of dimensions not less than
DIN 72 mm x 72 mm.
c) All instruments shall be of similar appearance, preferably of the same type and
manufacture, with a clear indication of function. Where used for a local indication, the
indicator shall be mounted in a suitable enclosure locally to the instrument.
18.23.7.4 Recording Instruments
a) Recording instruments shall be flush mounted and comply with BS 90 (IEC 258),
having a measured quantity accuracy of class 1 and a time-keeping class of 0.05.
b) Clearly identified, graduated indicator scales of at least 100 mm length shall be

provided for each signal channel.
c) Each input channel shall be separate and fully isolated allowing individual zero and
span adjustments.
d) All instruments will be fully electronic with inbuilt data storage.
e) Front glass shall have anti-reflective properties, preferably contained within a semi-matt
black bezel.
f) All instruments shall be of similar appearance, preferably of the same type and
manufacture with a clear indication of function.
18.23.7.5 Analogue Outputs for Field Mounted Devices
a) The output range shall be 4-20 mA and capable of driving into an impedance of 1000
ohms.
b) The output shall be electrically isolated from other outputs and earth. It shall have an
insulation resistance of at least 1 Megohm when tested for one minute at 500 V DC.
earthed in turn.
c) Output current shall not vary by more than 0.1% of span when load resistance is varied
from 0 to 1 000 Ohms.
d) Peak to peak amplitude of internally generated ripple, noise or other unwanted

output span.
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18.23.7.6 Alarm and Control Outputs from Field Mounted Devices
a) Volt free changeover contacts shall be provided for alarm and control output purposes.
These shall be individually adjustable to operate at any point within the range of the
instrument. Operation at the selected set point shall not cause the analogue output
signal to deviate by more than 0.1% of span.
b) The dead band for set points shall be adjustable between 0.5% and 10% of span.
c) Output contacts shall be rated at 50 V dc, 3 A resistive and shall be sustained (i.e. not
fleeting).
d) If an instrument has some automatic operation (i.e. cleaning cycle) which requires it to
be periodically off-line, then a control interlock contact shall be provided to indicate to
the process control system that the instrument is temporarily out of action. The
process control system shall then “freeze” the analogue value last received until the
instrument is returned to normal operation.
18.23.7.7 Index of Protection for Instrument Enclosures
a) Enclosures and sensors shall be protected to BS EN 60529 as follows:
i. IP54 Indoors, clean locations.

ii. IP65 Indoors, dirty locations.
iii. IP67 Outdoors.
iv. IP68 to depth 5 meters where flooding may occur.
v. The degree of protection shall not be degraded during calibration and it shall
only be necessary to open the enclosure for the purpose of maintenance, fault
finding or repair.
vi. The degree of protection for all internal components shall not be less than IP2X.
18.23.7.8 Materials
a) Equipment housings and enclosures shall be constructed from materials which are
resistant to the effects of weather (outdoor applications) and from exposure to process
or sample media in solid, fluid, gaseous form or corrosive environment.
b) Instrument and sensor materials that are in contact with the process shall be suitable
for contact with that material (e.g. raw sewage, chemical) and shall be of an approved
material.
18.23.7.9 Security
Control, indication and adjustment facilities normally required by station operators shall
be brought to the front of the enclosure, made readily visible but protected against
unauthorized intervention which may affect the performance of the equipment or ICA
system.
18.23.7.10 Electrical Termination
a) Incoming and outgoing cables shall be identified and shall pass through glands fitted to
a properly designed gland plate or bushing and spaced so as to allow access to both
sides of the glands, without the use of special tools.
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b) All connections shall be properly identified both on the terminal and conductor by
indelible means. Sleeve type ferrules shall be used; open type clip-on ferrules are not
acceptable.
c) Separate terminal rails shall be provided for incoming and outgoing terminals.
18.23.7.11 Instrument Piping, Tubing and Fittings
a) Instrument piping shall be in accordance with the manufacturer's recommendations for

the specific applications. All connections from process systems to instruments other
than water quality sampling meters shall be made with 316 seamless stainless steel 15
mm O/D, minimum wall thickness 1.5 mm, with 308 stainless steel fittings to prevent
binding.
b) Sample water pipework and fittings for water quality sampling meters shall be sized
and selected to suit service conditions generally in the range 12-25 mm NB and shall
be in uPVC or 316 stainless steel as applicable.
c) Where a sample line cannot provide adequate sample volume or flow to the instrument
sensor in an acceptable process time, the system shall be pumped. The design of the
pumped system shall be in accordance with the mechanical and electrical specification.
d) Piping shall be neatly run and shall be clipped to walls, ceilings or other building
structures or shall be supported on galvanized mild steel tray. Piping routes shall be
chosen to avoid obstructing traffic or personnel movement through the station and to
avoid interference with accessibility for the removal of equipment. Where there is a
potential risk of mechanical damage to instrument piping, suitable mechanical
protection shall be provided.
e) Drain and vent facilities shall be provided at the lowest and highest points respectively
according to service. Drains and vents shall be plugged.
f) Tapping to main process pipework shall be provided with an isolating valve to enable
the isolation of the sample or impulse system from the process for maintenance.
Where an instrument is an insertion type, the assembly shall be retractable and
isolatable from the main process line for removal without shutting down the main
process line.
g) Pipework to pressure gauges, transmitters and switches shall each incorporate a

pulsation damper, instrument isolating valve and a connection via an isolating valve
and snap on connector suitable for connection of a portable test gauge or manometer.
h) Variable area meters shall have isolating valves upstream and downstream with, in the
case of liquid measurement, a drain valve between the upstream valve and the meter.
i) Pipe work shall be arranged to minimize the transmission of vibration and surges. Pipe
work to vessels shall contain a siphon, loop or condensate chamber and shall be
lagged.
j) All pipe work for fluids which may contain solid particles shall contain joints and bends
of the "cross" type for rodding through and shall contain valves and connections for
blowing down.
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18.23.7.12 Pressure Gauges/Indicators
a) Pressure gauges/indicators shall comply with BS EN 837-1 or equivalent and have

concentric scales and glycerin filled dials. There shall be over-range protection up to
1.5 times the maximum line pressure.
b) No plastic shall be used in their construction. Internal parts shall be made of stainless
steel or bronze.
c) The dial size shall be of minimum 150mm dia. Diaphragm isolator shall be provided on
all liquid, chemical and sludge lines.
d) Gauge graduations shall be such that the gauge is never used continuously beyond
60% of the maximum graduation.
e) Where compensation of more than 2% of the gauge span is required for the distance
between the instrument and the tapping point, the reading shall be adjusted and the
amount of compensation marked on the dial (i.e. calibrating for static head).
f) Where the gauge is mounted directly on the pressure tapping a Schaffer diaphragm
gauge may be used. Schaffer diaphragm gauges shall be fitted with 20 mm or greater
bore straight through isolating cocks.
g) Gauges shall be graduated in metres of water and bars gauge, together with vacuum
where appropriate. The accuracy of the system shall be 1.50% of range or 2.50m
bar.
h) Pressure gauges for use with sewage and sludge shall be Bourdon gauges. The
pressure transmission system shall be of the air-filled or oil-filled sealed type
incorporating stainless steel capillary tubing and diaphragm transmitter.
i) For the air-filled system, the diaphragm shall be mounted in clean-out housing. The
transmitter housing shall be mounted directly onto a 25 mm or greater bore straight
through isolating cock. The cock shall be mounted directly onto the pressure tapping.
j) The gauges shall not be connected to air release pipes or auxiliary suction pipes.
k) The gauges shall be fitted with a pressure snubber to dampen pressure pulsation.
l) The face shall have a warning label marked in red “IMPORTANT - TURN OFF WHEN
NOT IN USE” both in English and Arabic.
m) Before delivery, each gauge shall be tested in accordance with an approved

international standard and the test certificate sent the Engineer.
18.23.7.13 Pressure Switches
a) Pressure switches shall comply with BS EN 60957-5-1 (IEC 60947-5-1).
b) All pressure switches shall be 2 poles with snap action make-before-break changeover
features and a dead-band of not less than 5% of full scale.
c) All pressure switches shall be rated Class 3 and utilization category AC-11.
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d) The rated operational voltage (Ue) and the rated insulation voltage (Ui) shall not be
less than 265Va.c.
e) The rated operational current (Ie) shall be not less than 2 A with an electrical
endurance of not less than 0.3 million.
f) Where isolating transformers are not used, the rated fused short-circuit current shall be
not less than the short-circuit strength assigned to the control gear.
g) The contact elements shall be easily replaced. The enclosure shall be a die casting
with cable entry for glanding a 4-core cable.
h) All terminals shall be screw type suitable for 2.5 mm2 conductors and accessible from
the front.
i) Test certificates shall be made available on request for type tests and special tests
included in BS EN 60947-5-1.
18.23.7.14 Pressure Transducers
j) Transducers for pressure monitoring shall be suitable for the range and medium of the
application. Accuracy shall be better than ±1.5% of range.
k) All transducers shall be of adequate sensitivity over the working range and able to
withstand a 400% overpressure without damage. They shall be ruggedly designed,
waterproof to any pressure likely to be encountered for the particular application,
provided with a stainless steel enclosure having an isolation diaphragm and suitable for
either free wire suspension in the medium or threaded for external connection to a pipe
tapping.
l) Cable entry shall be either by an integral means of sealing or by 200 mm conduit entry
into a sealed and watertight housing with transducer venting facilities.
m) A transmitter shall be provided either integrally with the transducer or separately

mounted as appropriate to the application. It shall convert the transducer input signal
into a 4-20 mA output signal proportional to the pressure range. The transmitter shall
be provided with local (field) and remote (panel) mounted digital display. Independent
zero and span adjustments shall be provided together with a jack plug socket enabling
a test meter to be connected, without interruption of signal output loops, for test and
calibration purposes.
18.23.7.15 Differential Pressure Switches and Transducers
a) Pressure switches and transducers used for differential pressure duties shall be as
specified above and shall be provided with low and high pressure connecting ports.
These shall be clearly indicated with “low pressure” and “high pressure” on a
permanent part of the instrument.
b) Differential pressure switches and transducers shall be rated to withstand to total

system pressure.
c) Other requirements for differential pressure switches and transducers shall be as

above for atmospheric and transducers duties.
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18.23.7.16 Sight Glass Level indicators
a) Sight glass level indicators for measuring contents in pressurized vessels shall be
provided with a protective housing, borosilicate glass tube and isolating valves.
b) The indicator shall be suitably calibrated in volumetric S.I. units unless otherwise
specified.
c) The indicator shall be provided with flushing and drain points with valves and hose
connections. The valves shall be lockable on pressurized vessels.
d) Alternative magnetic level sight gauges may be used. These shall be manufactured
from 316 stainless steel and pressure rated to the rating of the vessel. Indications shall
be of the magnetically operated flip over type, providing a resolution of not more than
2% of the full scale measurement. The manufacturers proprietary level switches may
be used to provide alarms and controls for the vessel. Where these are used, suitable
proprietary fixings shall be used to secure the switches, fixed to preventing slippage.
18.23.7.17 Ultrasonic Level Transmitters
a) Non-contacting ultrasonic level instruments and transducers shall be of sufficient range

for the application with careful consideration given to the effects of beam width, any
solid objects which may impinge above the medium surface, also to the presence of
foam or other debris floating on the medium.
b) Accuracy shall be ± 0.25% of the measured distance, or better and resolution shall be
at least 1% or 2 mm, whichever is the greater.
c) Outputs shall consist of at least one 4-20 mA analogue and four SPDT relays. Relay
outputs shall be programmable for a number of functions, which shall include but not
be limited to:
i. Control;
ii. Set point alarm;
iii. Differential alarm;
iv. Loss of echo;
v. Rate of change.
d) A programmable, 4 digit LCD displays shall be provided to give a read-out in a range of
engineering units (e.g. Level or capacity in mm or liters) also alarm messages. Non-
volatile memory shall contain all set-points and display data etc., addressed by a
programming and calibration unit with keypad and security protection for access to
parameter change facilities.
e) It shall be possible to select fail safe modes as high, low or hold.
f) Transducers shall be corrosion resistant and unaffected by submersion in the medium.

Temperature compensation shall be provided where necessary.
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18.23.7.18 Conductivity Level Electrode Systems
a) Level control relays used in conjunction with conductivity probes immersed in the
medium shall employ alternating current probe circuits to avoid polarization. The probe
circuit voltage shall not exceed 25 V to earth.
b) Sensitivity shall be adjustable to suit the medium and together with a close switching
differential, provide means of avoiding hold-on due to the effects of foam or debris
which may cling to the probes. Switching differential shall be better than 5% of the
sensitivity setting.
c) It shall be possible to select the fail safe mode to either high or low conditions. At least
two SPDT relay outputs shall be provided to operate as high or low alarm outputs or for
control between two levels.
d) Electrodes shall be of a material which is suitable for the medium, mounted in

appropriate holders and may be fitted with intermediate steady brackets, all in
accordance with the manufacturer’s recommendations for the application.
e) Each electrode shall be firmly secured to avoid movement due to turbulence or flow.
Cable entry to the holder shall be via a standard screwed gland and shall be above top
liquid level. A separate return electrode shall be provided for each application.
f) All brackets and mounting or fixing materials shall be corrosion resistant.
g) To avoid repetitive alarms or rapid on/off equipment switching, the use of single
electrodes will only be accepted where external latching circuits are employed.
18.23.7.19 Buoyancy
a) Level switches of the buoyancy type shall comprise a switch with changeover action
enclosed in a non-corrodible material. A balance weight shall also be incorporated in
the switch to counteract the buoyancy effect of the specific gravity of the particular fluid.
The connecting cable shall be factory sealed to the switch.
b) Level switches shall be installed with a minimum of two metres of spare connecting
cable neatly coiled at a supporting bracket. The connecting cable fixing shall facilitate
any alteration in operating level within the limit of the spare cable.
c) Cables and switches shall be fixed to a weighted support chain.
d) An IP65 sealed ABS or aluminium die cast junction box shall be used to connect the
level switch to the site cables.
18.23.7.20 Electromagnetic Flowmeters
a) Flowmeters shall operate on the electromagnetic induction principle and shall consist of
a measuring sensor and measuring transmitter complying with BS EN ISO 6817. The
flowmetering system shall provide pulse and analogue current outputs proportional to
volume and rate of flow respectively.
b) Measuring sensors shall have a stainless steel metering tube and non-conductive,
abrasion-resistant lining to suit the fluid being metered.
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c) Measuring sensors shall be fitted with an anti-roll system to prevent damage during
storage and shall be flanged to BS 4504. The flanges shall be compatible with those
specified for the associated pipework.
d) Measuring sensors shall have factory-sealed power and signal cables. Unless
otherwise specified, the cable lengths shall be sufficient to permit termination external
to the chamber, either at a junction box or at the measuring transmitter.
e) Electronic converters shall be of IP 67 protection rating. Primary head and Transducer

shall be of durable and corrosion resistant construction.
f) Measuring sensors installed within a chamber shall have a degree of protection IP68
and shall be suitable for indefinite submersion under a head of water equal to the
chamber depth or 3 meters whichever is the greater.
g) Measuring sensors shall be installed on a steel cradle or concrete plinth with upstream
and downstream straight pipe lengths not less than those recommended by the
manufacturer. When fitted in lined non-metallic or internally-coated pipework,
measuring sensors shall have an earthing electrode or corrosion-resistant earthing
rings.
h) Measuring sensors shall be bonded by tinned copper braid links at each end to the
adjacent pipework to ensure a good connection between the body and the metered
liquid.
i) Measuring sensors installed in a cathodic protected pipeline shall have isolation and
bonding in accordance with the recommendations of the manufacturer.
j) The measuring transmitter supply voltage shall be 230Vac 50Hz unless otherwise
specified. The measuring transmitter shall provide a precise current input to the field
winding of the measuring sensor and shall convert the resultant signal from the
electrodes to analogue and pulse outputs in accordance with BS 5863. The signal
processing facilities of the converter shall ensure that the output signals are unaffected
by interfering voltages, stratified flow, changes in fluid electrical conductivity within the
limit stated, non-homogeneity of the fluid and the presence of ferrous particles. The
instrument zero shall be set at the manufacturer's premises and thereafter this zero
shall be maintained automatically without interruption of flow or output signals. The
zero and output signals shall be unaffected by partly-fouled electrodes.
k) The measuring transmitter shall have following features:
i. Pulsed d.c. field excitation.

ii. Scaled pulse output for integration counter drive.
iii. Capability of bi-directional measurement with differing forward and reverse
ranges and with local and remote indication of flow reversal.
iv. Contact operation at a programmable measured value.
v. Integral display of flow and integrated quantity.
vi. Galvanic isolation between each output circuit and between the electrode circuit
and output circuit.
vii. Output circuit isolation from earth within the instrument but suitable for earthing
at any point in the external circuit.
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viii. Key entry for basic parameters.
ix. Commissioning and rescaling to require no special programming knowledge.
x. Adjustable low flow cut-off.
xi. Self-diagnosis.
xii. Continuously adjustable velocity and flow range settings.
xiii. Terminals accommodated in a compartment separate from electronic
components.
xiv. Aluminium die cast enclosure
xv. Empty pipe detection signal
xvi. The following performance shall be available as a minimum:
True flow as % of full scale Maximum error

setting
50 to 100% ± 0.5 % of true value
Repeatability Not exceeding ± 0.2 of true value
l) Measuring transmitters shall be interchangeable with those of any other

electromagnetic flowmeter of the same design. Calibration checking shall require no
auxiliary test meter or simulator.
m) Equipment-mounted measuring transmitter enclosures shall have a degree of

protection of not less than IP 65. Measuring transmitters shall not be located in
flowmeter chambers or areas subject to flooding.
18.23.7.21 Variable Area Flowmeters (Rotameters)
a) Variable area flowmeters (rotameters) shall have a float moving vertically in a tapered
tube, the position of the float being proportional to the flow. The meter tube shall be
calibrated for the specific fluid in mass or flow units. The calibration conditions shall be
engraved on the tube.
b) The flowmeter shall have a glass or stainless steel tube according to the particular
application.
c) Metering tubes shall be removable for range change or cleaning without dismantling
the meter or removing it from the line. Metering tubes shall have ends of equal cross-
sectional area and if O ring seals are used, tube retainer springs shall be outside the
fluid stream. End fittings shall be capable of rotation to any angle.
d) Glass metering tubes shall be of borosilicate glass and shall be adequately shielded
with safety glass on the reading side and amply vented on sides, back and bottom.
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e) Variable area flowmeters shall be installed in locations free from vibration and with
sufficient clearance for the removal of the float. If used in conjunction with a flow
regulating valve, the valve and meter shall be close together, with the valve
downstream of the meter. Pipe work shall be supported, having regard to the weight of
the meter.
18.23.7.22 Flow Switches
a) Flow switches shall be of the calorimetric (thermal conductivity) type. Flow switches
shall provide a switched output on a volt-free changeover contact and shall monitor the
flow within a tolerance of ± 1% of actual flow.
b) The output shall be adjustable over the calibrated range of the sensor. Temperature
compensation shall prevent variation in the set-point value over varying process and
ambient temperatures.
c) Connections to pipes shall be via BSP threads appropriately sized tot he application.
The flow switches shall be protected to BS EN 60529, IP65.
d) Flow switch units shall be provided with adjustable damping to prevent spurious
operation due to operating surges in the process.
18.23.7.23 Flowmeter (Sensor) – Ultrasonic
a) The flowmeter shall operate with a single-head flow sensor mounted externally on
carbon steel, stainless steel, ductile iron, copper, FRP, PVC, GRP, ABS or cement
lined pipe.
b) Measure and indicate flow rates between 0.06 to 2.5 m/sec. in pipes from 150 – 1650
mm.
c) Shall respond to flow rates as low as 0.06 m/sec. on liquids with entrained particles or
gases of 100 microns or larger and minimum concentrations of 75 ppm.
d) The flow sensor shall be single-head, ultrasonic in stainless steel housing. It shall be
installed on the outside of a pipe without interrupting flow.
e) Shall include 6 m coaxial cable in a weatherproof and flexible armoured conduit.
f) Shall be capable of extending sensor cable up to 152 m, without adjustment, and with
no reduction in performance original strength.
g) Shall be transformer isolated and designed to meet intristic-safe requirements. Shall

be designed for maximum RFI rejection, and include automatic high voltage bleeds for
nearby lightning strikes.
h) The transmitter-indicator shall be housed in a watertight and dust tight NEMA4X

fibreglass enclosure with a gasketted shatter proof window, and suitable for wall
mounting.
i) Flowmeter electronics shall be designed to operate at temperatures to 55 deg. C

Electronic circuits are interchangeable with other flowmeters having the same model
number. The transmitter circuit and calibration frequency standard shall be crystal
controlled. The transmitter shall be powered by 100-160 VC 50/60 Hz requiring less
than 5 Watts.
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j) The transmitter shall include a built-in 3-key calibration system with operator selection
of parameters through visual prompts from a Menu calibration system.
k) The 4-20mA shall be flow proportional and isolated, with programmable zero and full
scale offsets. Maximum resistive load shall be 1000 ohms. It shall include automatic
high voltage bleeds for nearby lightning strikes.
l) Have a continuous 4-digit LCD display indicating flow in user-selected engineering

units. Have a 16-digit alphanumeric display indicating totalized flow, units of
calibration, and/or signal strength.
m) The transmitter shall contain electronic means to prevent cross talk from other in-
service flow meters from the same manufacturer.
n) Have 3-control relays rated 5 ampere SPDT. Relays shall be programmable for flow
proportional pulse output, or as flow rate alarms with separate ON/OFF set points.
o) Have a Cable Junction Box and up to 500 ft. (152m) extra transducer cable that shall
be dual coaxial RG174U for installation in metal conduit.
p) Have a dual head sensor; one head transmitting and the other receiving.
q) Have manufacturer’s recommended adjustable, stainless steel pipe clamps for sensor
mounting on specified pipe diameter.
r) Have power input of 180-260VAC 50/60 Hz, or 24VDC, or 12 VDC battery power.
s) Have a built-in 30 day strip chart recorder.
t) Have a built-in programmable data logger with RS-232C output. Have serial cable for
data transfer to a PC computer, and PC software for data analysis and reporting.
18.23.7.24 Insertion Magnetic Flowmeter
a) The existing pipes, which cannot be fitted with Ultrasonic type flowmeter, due to poor
acoustic conductivity, shall be fitted with insertion type magnetic flowmeter.
b) The magnetic probe flowmeter shall operate on the principle of Faraday’s Law,
generating a precise magnetic field in the tip of the probe to induce voltages into the
liquid.
c) The flowmeter shall be magnetic and provide for transmitting/totalizing /indicating flow
rate in full pipes.
d) The base transmitter shall drive the probe with pulsed DC coil excitation to ensure
stability at zero flow condition. The unit’s zero fluctuation shall not be greater than
.002% of full scale. The blind transmitter will utilize digital processing of the flow signal
and provide an isolated 4-20 mA signal into 600 Ohms and allow for field adjustments
to the full scale range and a calibration test function via a bank of DIP switches.
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e) The transmitter/indicator shall be housed in a NEMA 4X weather-tight enclosure with
LCD, digital indication and totalization and microprocessor keypad entry on enclosure
cover. Enclosure shall remain closed while entering data into the microprocessor. A
front enclosure lock by key or keypad code will lock out additional data entry. The
housing front shall be hinged to provide easy access to all controls and be suitable for
wall or pipe stand mounting.
Keypad functions must include:
Pipe I.D - 150 mm to 800 mm
Full Scale - Up to 6 m/sec
Total Flow - Factor 0 to 100,000/CT
Units - Cubic Metres/Sec
Calibration - Optional adjustment for field conditions
Damp - Optional response adjustment
Reset - Optional cycle for totalizer batching
Run/Ent - Run or entry mode
f) The sensing element circuitry shall be solid-state and transformer isolated. The
transmit circuit shall be cable length adjustable to permit matching of sensor cables for
up to 30 m in length.
g) The flowmeter electronics shall be designed to operate at temperatures between 0

degree C to 55 degree C. All electronic circuits are to be mil-spec coated with an anti-
fungus compound. The transmitter shall be powered by 220 VAC at 50/60 Hz requiring
less than 10 Watts. All field connections are via screw-type terminals only.
h) For ease of maintenance by plant personnel, an integral flow simulator for calibration
and test functions shall be provided via keypad entry on front cover.
i) A LED indicator on the front cover shall be provided to indicate abnormal back-flow
conditions or when the probe electrodes are dry.
j) An automatic, adjustable integrating circuit shall be provided to provide fast-tracking

with large flow changes and damping with small changes to ensure steady readings.
k) A transformer isolated analog output, proportional to the rate of flow, shall be provided
in terms of 4-20 mA DC with a maximum resistive load of 1000 Ohms. The electronics
shall permit selection of signal in 0-5 V DC span or 4-20 mA as desired. Diagnostic
L.E.D. indicator for fault, reverse flow, compensation, over range and transducer signal
condition shall be provided. The circuit shall permit signal dampening.
The transmit and receive circuitry shall be protected against transient voltages
generated due to spikes in voltage or by proximity to lightning strikes. The A.C line
shall be fuse protected using transient suppressing diodes rated at a minimum of 160
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volts. The 4-20 mA circuit shall be protected by transient diodes at a minimum of 80
Volts.
l) The flowmeter shall have a 4.5 digit, LCD display, 0-5 vdc reading directly in
metres/sec or cubic metres/sec or any other specified engineering units.
m) The optional totalizer shall be 10 digit electronic LCD type that will have the reset
circuit enabled per customer specification. The user replaceable alkaline batteries will
provide a standard life of 4 years.
18.23.7.25 Flow-Meter – Partially Filled Pipes
a) The system shall be designed to monitor liquid flow in partially full, closed pipe that is
suitable for the transmission of an ultrasonic signal. The system shall fully integrate
ultrasonic flow and level technology, and be packaged in a single transmitter with the
flow and level components produced by a single manufacturer. The system will
operate on all unpressurized, water based liquids or pressurized liquids with a
minimum level of 100 ppm of suspended particulate.
Transmitter
b) The transmitter enclosure shall be NEMA 4X weather-tight, to be suitable for wall or

pipe stand mounting in general purpose areas, and must include a hinge and
transparent window to allow for viewing the display. The maximum dimension of the
enclosure is 12” H x 10” W x 4” D.
The system shall be powered by 115 VAC +/- 10%, 50/60 Hz requiring less than 15
watts. All field connections are via screw type terminals only.
The system shall be powered by 12 or 24 VDC requiring 307 A/Hr. All field
connections are via screw type terminals only.
Instantaneous indication of flow rate and total flow shall read in 1/s via a backlit, dual
line LCD display with 20 characters .25” high and a resolution of .01 engineering unit.
The transmitter shall provide an output, optically isolated 4-20 mA DC signal into 600
ohms maximum.
The Flow meter electronics shall be designed to operate at ambient temperatures

between 40 to 55 deg. C when equipped with enclosure heater. All electronic circuits
will be mill-spec coated with an anti-fungus compound and are to be interchangeable
with other units having the same model interchangeable with other units having the
same model number. The transmit and receive circuitry shall have high voltage
transient protection for proximity lightning strikes. The power supply shall be fuse
protected and use transient suppressing diodes rated at a minimum of 160 volts. The
4-20 mA circuit shall be protected by transient suppressing diodes rated at a minimum
of 80 volts.
Flow calculations are performed by a microprocessor which reviews the flow and level
data stream, calculates the instaneous volumetric flow, the total volumetric flow, and
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drives the 4-20 mA DC output. The microprocessor shall enable the following 8
functions to be performed in the field via keypad entry.
A) Selection of pipe size from 100 to 1500 mm

B) Select totalizer multiplier – XI, X10, X100, X1000, and X10000
C) Reset totalizer
D) Adjust dampening
E) Adjust calibration
F) Adjust full scale output
G) Select to read out GPS/Sec,GPM/M,GPM/day
H) Test
The test unit shall also include LED diagnostic indicators for:
a) Power on
b) Flow/Velocity
c) Level
d) Fault
e) Velocity
f) Signal strength
The sensing element circuitry shall be solid state and transformer isolated. The
receiver circuit shall be multiple high-Q staged for maximum RFI rejection. The
transmit circuit shall be cable length adjustable to permit maximum transmit power to
sensor cable up to 15 m in length.
The system performance shall be as follows:
Flow Accuracy - +/- 3.0% Full Scale
Level Accuracy - better than +/- 1.%
Rangeability - 10:1 or greater
Repeatability - better than +/- 0.5% under flow
Linearity - better than +/- 0.5% under flow
The sensors shall provide for non-invasive measurement of both liquid flow and
level in closed conduits. Installation must be achieved without interrupting flow in
the line. Wetted sensors in contact with the liquid will not be accepted. The PFP
system shall be designed to operate on pipe materials that allow for efficient
transmission of ultrasonic signals which would include most metal and plastic
piping.
The sensors shall be epoxy encapsulated with a metal housing and include 6.0 m of
RG62 cable in non-metallic conduit and fittings suitable for accidental or incidental
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submersion to depths not to exceed 3.5 m. Sensing elements shall be
interchangeable without recuperation of the measuring circuit.
The sensors must be secured to the bottom of a horizontal pipe utilizing a stainless
steel strap and a RTV silicone for acoustic coupling. The sensor profile shall not
exceed 5 cm from the pipe wall to facilitate installation.
The velocity measurement shall be made utilizing the Doppler effect and the
sensitivity of the system shall be able to detect flow velocities from 0.3 to 3 m/s.
The level measurement shall be made utilizing a ultrasonic pulsed echo from the
liquid interface and the sensitivity of the system shall be able to detect liquid levels
as low as 1 cm to a full pipe condition.
The sensors shall be designed to operate continuously over a temperature range of

0 to 55 deg. C.
18.23.7.26 Temperature Measurement
a) Unless otherwise specified, platinum resistance elements shall be used for applications
up to 200oC and chrome-alumel thermocouples for spans exceeding 200oC. Accuracy
shall not be less than ±1%.
b) Each temperature sensor, unless otherwise specified, shall have a stainless steel
pocket and extension assembly, non-corrodible metal sheath and waterproof terminal
head. Pockets for steam, oil and pressurized water lines shall be welded; pockets for
other duties shall be screwed.
c) The sensor assembly shall be designed to permit removal of the temperature element
without twisting the leads.
d) Platinum resistance thermometers shall comply with BS 1041 and BS EN 60751 and
shall have fundamental intervals of not less than 38.5 ohms. Each element shall be
artificially aged during manufacture. Terminal heads and amplifiers shall be designed
for four-wire connections between head and amplifier.
e) Platinum resistance elements shall be fully encapsulated in ceramic, elements and high
temperature resistant lead wires shall be hermetically sealed. The associated
resistance-to-current converters shall have zero and span adjustments and input-
output circuit isolation.
f) Thermocouples shall be of the mineral insulated type and, unless otherwise specified,
shall be of the chromel-alumel (nickel chromium v nickel-aluminium) type. Wires shall
not be smaller than 1.0 mm² and shall comply with BS 1041 and BS 4937.
18.23.7.27 pH Monitoring
a) The equipment supplied shall comply with the requirements of BS 1647.
b) Sensors shall be rugged in design and incorporate temperature compensation and an

integral pre-amplifier. They shall measure with a minimum accuracy and repeatability of
0.1pH and 0.05pH respectively.
c) The equipment shall be suitable for use at the specified separation distance between
sensor and transmitter/analyzer.
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d) Sensors shall be suitable for the application and include an automatic self-cleaning
system where fouling is likely.
e) Retractable line insertion sensors to be supplied unless otherwise specified.
f) Analyzer/transmitter units shall incorporate controls for calibration, zero and span
together with controls for adjustment also readout of measured value and other settings
or parameters.
g) Interconnecting cables between sensor and analyser shall be readily detachable and
complete with international standard connectors.
18.23.8 PLC's and Microprocessor Equipment
18.23.8.1 General
a) All telemetry, micro-processor and PLC equipment and similar solid state equipment,
status inputs and outputs shall be isolated by opto-isolators or an approved alternative
and analogue inputs shall be as differential circuits. Individual noise filtering shall be
provided as necessary for each application. Series mode rejection and over-ranging
protection shall be fully adequate.
b) Where applicable components shall be mounted on high grade flame retardant printed
circuit boards which shall comply with the relevant parts) of BS 4584, have gold plated
edge connections, be equipped with test points to facilitate checking of major functions
and have mechanical keying to prevent accidental insertion of an incorrect card.
c) The equipment shall accept status inputs from site and panel mounted volt free
contacts and 4-20 mA analogue signals from site and panel mounted transmitters.
Analogue inputs shall be scanned into a 10 bit binary analogue to digital converter with
buffered inputs.
d) Status outputs shall be suitably rated for switching filament indicator lamps, connecting
into alarm systems, operating hardwire control circuits or other switching functions in
accordance with the requirements of the application Clauses.
e) Analogue outputs shall be 4-20mA suitable for driving control circuits, indicating
meters, recorders and integrators. The overall accuracy of transmitted analogue
signals shall be within ±0.5% of FSD over the operating temperature range of 0°C to
55oC.
f) The power supply unit shall be suitable for operation on a supply having a voltage
variation ±10% and a frequency variation of ±2%. The power supply unit shall have an
isolated output and incorporate protection against voltage spikes on the mains supply,
over-voltage and short circuit.
g) The equipment shall be maintained in operation during a period of mains failure, either
drawing power from the main instrumentation and control battery/charger system or
from a separate UPS system, as appropriate.
h) Each system unit shall include spare installed capacity of not less than 25% of each
type of input and output module, together with a minimum of 25% spare system logic
capacity.
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i) All systems and equipment shall include diagnostic and automatic self-test routines
with volt-free contacts to initiate an alarm in the event of malfunction.
j) As far as possible all computers, micro-processors, plc's and similar system elements
provided throughout the whole system shall operate with similar protocol/language so
as to provide a compatible system with all peripherals, programs, program
development units, file management routines, data storage facilities and similar
facilities being common to all elements.
k) All equipment shall be fully programmed in accordance with the requirements of the
application Clauses. All programs, in the form of flow diagrams or logic circuits shall be
submitted to the Engineer for approval not less than 6 weeks before the equipment is
to be inspected.
l) In all cases the facility shall be provided for modifying the program, altering set points
and adjusting time settings white the equipment is "on line". There shall be a
permanently connected means of accessing set points and timer settings.
m) All equipment associated with an operator interface shall utilize a high level, engineer
orientated language to permit programming, editing and similar functions by engineers
and operators.
n) The contractor shall provide all required hardware, software and software modification
at existing central control / master station and liaise / coordinate with the concerned
Dubai Municipality departments for timely completion of the interface and configuration
of station to existing central control / master station.
o) The PLC / RTU controllers shall be selected to meet the performance requirements of
the system.
p) All electronic boards shall be coated version against corrosion and shall have gold-
coated connecting pins for long life.
q) The processor memory shall be sized such that its utilization for the application does
not exceed 50% of its capacity.
r) The PLC / RTU controller shall include for all communications ports for connection to
the site wide field network and for connection to any required slave racks or remote I/O
racks. Other communications networks may be serviced via separate rack mounted
network cards.
s) The PLC / RTU controller rack shall be back plate mounted such that the cards can be
visible from the front of the ICA panel.
t) All rack configurations/set up shall be consistent across the station. Rack mounted
cards shall be grouped such that common card types are located in adjacent slots in a
rack and that card grouping is consistent in all installations across the station.
u) All rack slots shall be clearly labelled with the card type (DI, DO, AI, or AO), the logical
rack and the logical slot numbers.
v) Dual redundant (hot standby) controller and power supply unit should be provided to
avoid all the units going out of service when the PLC controller is faulty.
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18.23.8.2 Modularity
a) The PLC /RTU controllers are of modular construction with individual modules being
readily removable without disturbing wiring or other modules.
b) The range of modules shall include, but not be limited to:
i. Power supply unit.

ii. Central processor unit.
iii. Analogue inputs with differential isolation.
iv. Analogue outputs with differential isolation.
v. Digital inputs with opto-isolation.
vi. Digital outputs with opto-isolation and buffer relays according to design.
vii. Communications.
viii. Watchdog relay via a hardware bus monitor card and panel indication.
c) Each module shall be equipped with status LEDs indicating I/O states and fault
conditions for diagnostic facilities.
d) Modules shall be installed such that they are accessible and easily removed with
means of protection against insertion into an incorrect location and against reverse
polarity of inputs or power supply.
18.23.8.3 Power Supply Requirements
a) The PLC / RTU controller main power supply shall operate at 230Vac and shall be
rated such that it is capable of powering the full card complement of the installed rack
system. In order to ensure the requirement the rating calculation shall include all
installed cards plus the requirements of the largest load module in the specific PLC /
RTU range installed in each of the remaining spare slots.
b) Volatile memory shall be provided with a dedicated, on-board battery back-up,

providing memory retention for 6 months.
c) All input/output systems shall be powered at 24Vdc, using the ICA panel power supply.
Exceptions to this shall be analogue 4-20mA input signals powered from the
instrument/signal transmitters and actuated valve control circuits, which shall be
powered from the actuator.
18.23.8.4 Maintenance Power Supply
Within each PLC / RTU controller enclosure, the Contractor shall provide a 230V, 13A,
BS 1363, twin switched socket outlet, protected by a 30mA RCD, for the connection of
test and diagnostic equipment.
18.23.8.5 Communications
a) Each PLC / RTU controller shall be provided with at least two communications ports for
the following purposes as required by the specific system design:
i. Serial RS232 connection to a Local HMI terminal.
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ii. Ethernet network connection
b) The Contractor shall provide details of all protocols employed and be responsible for
verifying the compatibility and performance of all communications interfaces.
Universally accepted protocols shall be used wherever possible.
18.23.8.6 Watchdog
a) A watchdog relay shall be included to monitor the controller in a fail safe mode. When
the watchdog circuit trips, all control outputs from the controller shall be disconnected,
the alarm condition signaled and fall back modes of operation instigated.
b) Watchdog operation shall be electrically signaled and visually indicated. The unit shall
continuously monitor power supply and control system status, operating upon failure or
abnormal conditions.
18.23.8.7 I/O Configuration
a) I/O shall be configured such that failure of a single card (or rack in large multiple rack
systems) does not cause total station shut-down. Duty and standby equipment I/O
shall not be connected to the same card (or rack on large multi-rack systems).
b) I/O shall be configured and installed in logically grouped and repeated patterns.
c) Single equipment devices shall have their inputs and outputs on adjacent cards in the
same rack with this pattern repeated for other equipment units.
d) Where on-board isolation of I/O is not available, external signal isolation shall be
provided.
e) A minimum of 25% spare capacity of each type of I/O shall be provided, wired down to
terminals. This number of spare I/O shall be considered as minimum and maintained
as such by the Contractor until completion of the Contract.
f) Terminals shall be grouped to reflect the I/O card functions and groups.
g) Provision shall be made for easy disconnection of the equipment signals enabling
modules to be removed or test units to be connected in a fast, simple manner, without
disturbing the field wiring. This arrangement shall be consistent for all controllers
across the station.
a) Analogue inputs shall be configured to accept 4-20mA continuous, linear signals and
shall exhibit an input impedance of less than 250 Ohms. To facilitate removal of circuit
boards in current loop circuits an external zener diode shall be provided on each
channel to avoid loop interruption.
b) Analogue to digital conversion shall be at least 10 bit resolution having linearity within
±1% and overall accuracy of ±0.1% span or better.
c) All analogue inputs shall be provided with “out of range” flags monitored by the control
system. “out of range” flags shall be provided with adjustable tolerances of ±1mA of the
nominal zero or full-scale values of the input signal in order to allow for hysteresis in
the analogue measuring circuit.
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a) The analogue output modules shall be configured for 4-20 mA and capable of driving
into an impedance of 1000 Ohms.
b) Digital to analogue conversion shall be at least 10 bit resolution having an accuracy of

c) The output shall be electrically isolated from other outputs and earth. It shall have an
insulation resistance of at least 1 Mega-ohm when tested for one minute at 500 V DC.
earthed in turn.
d) Output current shall not vary by more than 0.1% of span when load resistance is varied
from 0 to 1 000 Ohms.
e) Peak to peak amplitude of internally generated ripple, noise or other unwanted

output span.
18.23.8.10 Digital Inputs
a) All digital inputs shall be optically isolated from other signals, circuits and input
channels.
b) Such inputs shall comprise volt free contacts wetted by 24 V DC at 5 to 25 mA nominal

current. Input filters shall be provided where contact bounce may occur; such
debouncing may be carried out in either hardware or software.
a) Digital outputs shall be in the form of volt free contacts capable of switching an
inductive load 2A at 24Vdc or 2A at 230Vac. Outputs shall be sustained, not fleeting,
arranged for fail safe operation (e.g. normally open to trip or signal alarm).
b) RC networks shall be fitted to digital outputs when switching non-resistive loads.
c) Surge Suppression diodes shall be fitted to all relays operated from digital output
circuits.
18.23.9 Control system Application Software
18.23.9.1 Software Design
a) Software shall be designed, developed and tested in accordance with BS EN 61131-3

(IEC 1131-3), utilizing standard function blocks for all common applications.
b) All software shall be properly structured, developed to strict quality control standards
(BS 5750 Part 13) (BS EN 29000-3) (ISO 9000-3) and written to allow non-expert
personnel to be able to read, understand, maintain and modify.
c) Software shall be designed and implemented in a structured and modular fashion to

reflect the hardware divisions and equipment groupings. Program structure and use of
standard modules shall be consistent in all controllers across the site. A file allocation
list shall be developed and submitted for the approval of the Project Manager prior to
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commencement of software development. This file allocation shall be consistent in all
controllers across the station.
d) Module types shall be dedicated to sensors, loops, equipment items and automatic
sequences as required by the application.
e) Software shall be structured in a hierarchical layered manner.
f) Transactions such as inter-unit communication, alarm generation, manual input points,

shall all be produced in a similar and easily recognized fashion.
g) The installed software shall enable the system to carry out a range of functions which
include, but shall not be limited to:
i. Status and alarm monitoring of equipment and sensors.

ii. Data acquisition of analogue values.
iii. Transmission of monitored and logged data to other systems.
iv. Sequence control of the equipment.
v. Closed loop process controls.
vi. Fail safe actions in the event of failure of power supply, circuitry, instruments,
sensors, communications or process equipment items.
vii. Controlled start-up or shut-down of station under all circumstances.
h) Data tables shall be structured in contiguous blocks to facilitate block transfers to other
controllers or systems at variable scan rates. A structured list of data tables shall be
agreed prior to commencement of software development. This list shall be used in all
controllers across the station.
i) The system shall be configured with password security features to prevent

unauthorized access to set up files, program files and data tables.
j) Application software shall have safe power on and power off sequences to ensure that
equipment is in safe state at all times. On power up, the controller shall operate an
initialization sequence to ensure that all applications start up from a known position.
However, all current control system set points and settings shall be retained on loss of
power to ensure that the process continues in the same manner as prior to the loss of
power.
k) Set points, software derived alarm settings, process control and PID control
parameters etc. shall not be embedded in the controller application code or software
modules. These settings shall be adjusted via suitably security protected local HMI to
enable changes to station control or alarms operating values to be made without
changing the application code.
l) Individual field controllers shall continue to operate independently of the main system
when communications are lost with the network. Where the controller relies on remote
data, it shall revert to a set of look up tables for that function. The look up tables shall
operate over a selectable 24 hour or 7 day period and the values shall be determined
during commissioning of the controller.
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18.23.9.2 Software Documentation and Quality Control
a) The Contractor shall operate a quality control system for controlling all software design,
development, installation and commissioning.
b) This system shall incorporate the control of the following documents at various project
stages:
i. Operating and control philosophy.

ii. Functional design specification.
iii. Software development/installation version control system.
iv. Commissioning data/test schedules and plan.
c) The software version control system shall ensure that all versions of software installed
in PLC / RTU in the station are left at a known state of completion. The system shall
record:
i. Software name and version installed.

ii. Date of installation.
iii. Set-up parameters.
iv. A changes mode to software and date of change.
v. Results of tests on software changes.
d) Once the station is under commission or operation, the Contractor shall operate a
permit to work system to ensure that all software changes are carried out under a safe
manner of working.
e) Back up versions of all software shall be made at appropriate Contract stages. In

particular, during commissioning, software shall be backed up at the end of each
commissioning session. Previously loaded versions of the code shall be kept on the
same backup media in order that the equipment under commission can be restored to
its previously known state should recent changes during commissioning prove
problematic to the equipment.
f) HMI software version control shall be matched to that of the controllers. This is to
ensure that incompatible versions of HMI software are not retained in the HMI unit
when controller software is upgraded. In the case where no changes are necessary to
the HMI software when its associated controller software is upgraded, then the HMI
software version number shall be upgraded anyway to maintain a match with that of the
controller software.
g) The Project Manager shall have the right to audit the Contractor’s software control
system at anytime to ensure that the requirements of the specification are being met.
All non-compliances shall be rectified immediately.
h) Software documentation shall be produced in accordance with the "Guidelines on the

Documentation of Software in Industrial Computer Systems", published by the
Institution of Electrical (ISBN 086341 0464).
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i) All software license or registration requirements shall be forwarded to the DM. Sole
rights to all software systems, specially developed for the control system, shall become
the property of the DM after Take-Over of the equipment.
18.23.10 Local Operator Panels
18.23.10.1 Human Machine Interface Units (HMIs)
a) The Contractor shall provide an HMI with a key pad and flat screen, as manufactured
by Proface or equivalent. Touch-screen interfaces are preferred.
b) Operation of the unit, access to controller data, parameter and data editing or other
functions, shall not require software language programming skills but shall be executed
via selection from screen menus.
c) Facilities and displays shall include:
i. A minimum of three levels of password protection for access:

Level 1 shall permit operator access for monitoring, alarm acceptance and
equipment duty selection etc
Level 2 shall permit supervisor access for changing operating parameters
(e.g. Pump start/stop levels, time intervals) and forcing controller outputs to
start/stop equipment, open/close valves etc. in remote manual mode
Level 3 shall permit engineer access for changing critical control parameters
such as PID loop settings and software modifications
ii. Overview menu
iii. Alarm list for the last 64 (approximate number) alarms, displayed with date and
time on a rolling log, together with operator’s alarm handling facilities.
iv. Event log for the last 20 (approximate number) events or operator changes etc,
displayed with date and time on a rolling log.
v. Set point display list with editing.
vi. Current value of analogues with editing.
vii. Display of equipment status and alarms.
viii. Display of control programs with edit facility for PID loop parameters etc.
ix. Operator control commands, or changes to data or parameters, to be on a
select and execute basis with abort/cancel option.
x. Live mimic displays and trending facilities.
18.23.11 Remote Telemetry Units (RTU's)
18.23.11.1 General
a) The remote telemetry units shall be of modular constriction and housed in wall or floor
mounting cabinets dust and damp proof to IP 54 if not provided as a part of ICA panel.
The cabinets shall house the local UPS or battery backup supply and marshalling
terminal section for interfacing and connection with the Dubai Municipality existing
master station, communications links and field equipment. Where transducer remote
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electronic equipment is provided e.g. ultrasonic level measuring devices may be
incorporated within the remote telemetry unit cabinet. Cabinet and panel arrangements
shall be submitted for approval by the Engineer.
b) Supply, modification and configuration of the existing control / master station at Dubai
Municipality facility including all required hardware and software shall be the contractor
responsibility / scope of the work all stations modified / constructed under this contract.
c) Each motor control centre will be equipped with an RTU and PLC based controller with
communications link to the in site data highway.
d) Intelligent remote telemetry units (RTU) with measurement, control and

communications capability are to be provided at the pumping stations on the network.
These will utilize the local Etisalat PSTN and GSM network for communications with
the master station.
e) Each pumping station is to be provided with its own self-contained control system. The
control system is to monitor the level of sewage in each of the pumping stations wet
well sumps and start/stop pumps as .the levels rise and fall. Continuous level
measurement is to be provided by hydrostatic level measuring system. Back up level
sensors of the float switch type will be provided for control/operation levels of pumps
and high level alarms and low level trips (to prevent dry running of the pumps). The
float switches shall be provided complete with stilling tube.
18.23.11.2 Future Expansion
a) Sufficient plug in modules shall be provided and wired to terminals ready to accept
future signals of up to 25% or a minimum of one module, for each remote telemetry
unit.
b) Each RTU shall be able to accept at least two more I/0 modules of each type without
requiring replacement of the original equipment.
18.23.11.3 Hardware
a) Each controller shall be mounted in an IP 54 enclosure and constructed to allow easy

replacement and maintenance modules.
b) Particular attention shall be given to the ability of the remote telemetry unit and its
enclosure to withstand the harsh environment prevailing in Dubai, U.A.E.
c) The remote telemetry units shall be intelligent devices that can collect data, generate
alarms, perform process and control functions.
d) The remote telemetry units shall be able to receive analogue and digital inputs from the
field, perform processing and alarm checking, perform the algorithms control and
output to pumps, valves and other actuators.
e) Each remote telemetry unit shall be sized for controlling the required input/outputs and
future expansion.
f) The program and data held within the memory shall remain intact and error free if all
external power is removed from the remote telemetry unit for a minimum period of two
weeks.
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g) The Contractor shall supply UPS and/or batteries for each RTU with sufficient capacity
to maintain full power to the RTU for 4 hr after a power failure. The UPS system shall
be integral to the RTU. The batteries shall be of a sealed maintenance free type.
h) All field connections shall be made in terminal blocks located for easy access. They
shall be clearly marked and identified. Terminals carrying voltages in excess of 24 V
shall be fully shrouded. All terminals shall be of the flip up isolator type with test points.
i) A hand held programmer, shall be provided for local display of signals, programming
and fault diagnosis.
j) The remote telemetry units shall be capable of being equipped with RS 232/485 links
for interconnection to standalone control systems and standard station packages.
k) The connection to other devises will use modules ASCII or remote telemetry units
protocols as standard, however details of other protocols available are to be included
within the tender. Each remote telemetry unit shall support peer to peer
communications, either directly or via the Master Station System.
l) LED's indicating status of input and output digital signals shall be provided on the
input/output modules.
m) RTU shall be configured such that a single RTU module failure will not interrupt or
degrade station monitoring and control functions. RTU failure shall be alerted to the
operator at the highest alarm priority.
n) Surge protection shall be provided in accordance with the latest IEC requirements.
18.23.11.4 Remote Telemetry Unit Software
a) The RTU shall be capable of processing locally input station information before
transmitting it to the master station.
b) The software programs shall be written such that they facilitate easy alterations and
additions. Structured programming techniques shall be followed and accompanied by
flow diagrams. The programs should be extensively annotated and be self-
documenting. The system shall be supplied with programs that use a high level
language for the operator’s works stations.
c) Total internal scan time interval for all inputs and outputs in an RTU shall not exceed 1
second.
d) The RTU shall operate on a report by exception basis.
e) The RTU shall have sophisticated in built control facilities to permit control loop
configuration using simple building blocks. These blocks shall sequence control, three
term control and other control routine components as required. The RTU shall be
capable of routine signal processing including integration, summation, subtraction and
totalisation of one or more inputs. Control loops shall incorporate deviation and rate of
change alarms, bump-less transfer facility, set point and output high and low limits.
f) The RTU shall be capable of executing sequential control logic. Programming of

sequential control shall be by means of high level function block language or ladder
diagram format as part of an integrated package.
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g) The RTU shall have standalone capability able to continue monitoring station and
executing control loops if the communication link to the master station fails. In the event
of such a failure the RTU shall log all alarms and required analogues until the entire
tool memory is filled. When the communication link is restored the RTU will
automatically upload the logged data to the data archiving system.
h) The RTU shall have a watchdog function and full self-diagnostics capable of detecting
and reporting faults to the master station and displayed locally.
i) The Contractor shall program the RTU fully under this Contract. It shall be possible to
modify the programs remotely by downloading from the master station.
j) It shall be possible to initial current data retrieval on demand, from the master station,
leaving the original RTU data contents intact for routine up-loading.
18.23.11.5 Communication Standards
a) Transmission of data shall conform to a recognized Consultative Committee for

International Telephone and Telegraph (CCITT) standard. The data transfer system
shall be self-monitoring such that any equipment or line failure shall be displayed at
both ends.
b) The protocol used shall safeguard against false data transmission, allow for error
detection, recovery, failure detection and initiate switchover the redundant data
highway. A diagnostic routine shall be included to monitor the highway performance.
Data protocol and diagnostics shall be fully documented.
c) Within the confines of the pump station site a hard wired serial communications link
shall be utilized.
18.23.11.6 Inputs/Outputs
a) All process I/O and station interface boards shall comply with the requirement to
accommodate a minimum of 1.5mm2 cross-section conductor. Terminals shall be of
the test disconnect type to permit ease of signal isolation and loop monitoring for
commissioning and maintenance purposes.
b) Hot removal of I/0 modules shall be possible without special tools.
c) Digital inputs shall meet the following requirements:
i. All digital inputs shall be optically isolated.

ii. All alarm and state indication shall be from dry contacts. Filter circuits and
software de-bounce techniques shall be provided.
d) Contact operation shall be fail safe as follows:
i. Alarms: in the healthy condition the contacts shall be closed with the relay coil
energized: in the alarm condition the contacts shall be opened with the relay
energized.
ii. States: contacts shall be open with relay coil de-energized in the off condition,
and closed in the on condition.
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iii. Two bit digital e.g. valve position: One contact shall close when the valve is in
one state and a second contact shall close when the valve is in the opposite
state.
Independently configured channels shall be in the range 4-20 mA, 1-5 V, d c, 0-1 V d
c., 0.5 V d c. All analogues cables shall be screened and segregated from other cables.
A clear earth shall be provided for signal which shall be separate from the system main
earth. Input impedance shall be greater than 1 M for voltage inputs. ADC conversion at
ten times per second shall be 12 bit, system accuracy+ 0.2% of span.
All digital outputs shall be optically isolated and matched to the new and existing
station requirements.
In general all analogue outputs shall be 4-20 mA or 1-5 V d c., selectable and drive a
maximum loop impedance of 60 for current outputs and 2000 for voltage outputs. The
signal earth shall be separate from the system main earth. DAC conversion shall be of
12 bit, system accuracy + 0.2% of span.
18.23.11.10 Power Supply
a) The power supplies shall conform the following:
i. Shall be comprised of standard available units

ii. Shall have adequate input / output fuse protection
iii. Shall have short circuit protection and current limiting facilities
iv. Shall be de-rated to allow for future expansion to improve the reliability and help
increase the mean line between of the units. With all the expansion described in
this specification, the loading on the power supplies shall not exceed 70% of
their total capacity.
v. The module failure shall be indicated at the remote telemetry unit and Master
Station.
vi. The failed module shall be removed without disconnecting system power or
affecting control.
18.24 VENDOR LIST
a) Tenderer to select the equipment from the list of recommended vendor list given in the
table below and they shall select only one manufacturer or supplier from the list below
and mention in the tender proposal.
b) It is Tenderer’s responsibility to ensure that the offered make / supplier fully comply
c) Tenderer may propose for any equipment item(s) where vendor name are not specified
or not included in the recommended vendor list in the table below. Such proposal will
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be subjected to Engineer clarifications during tender clarifications and tender
evaluation. All the necessary information required by Engineer will be requested and it
shall be submitted by Tenderer immediately to the Engineer for tender assessment.
18.24.1 List of Approved Manufacturer / Supplier
Local Agent / Dealers /

Sr. Material Manufacturer Make
Assembler
1 Medium voltage Merlin Gerin UK Schneider electric -
switchboard Dubai
ABB Europe ABB – Dubai
Bloudan Control
Systems - Dubai
Bin Ghalib - Dubai
Siemens Germany Scientechnic - Dubai
2 RMU Merlin Gerin UK Schneider electric /
Haris Al Afaq - Dubai
ABB Europe ABB - Dubai
Siemens Germany Scientechnic - Dubai
Lucy UK Haris Al Afaq
Alstom France
3 Transformer Emirates UAE Dubai
Transformer
Federal UAE Federal transformer -
transformer Abu Dhabi
Tesar Italy / UAE Tesar
Schneider Europe Schneider electric
electric
Fuji Electric Japan Fuji Electric - Dubai
4 LV Boards, ABB Europe Bloudan Control
SMDBs, DBs, Systems - Dubai
Siemens Germany
MCCs, ICA Panel, Arabian Gulf Switchgear
Enclosures, Eaton USA - Sharjah
Isolator Panel,
Schneider UK Bin Ghalib - Dubai
Capacitor panel
electric Cimac - Dubai
Elsteel Denmark
Logstrup Denmark
5 Medium voltage Ducab/BICC UAE Ducab - Dubai
cable
Ptvoksel Indonesia Khalid & Khalid Abbas -
Dubai
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Assembler
Riyadh cable Saudi Saudi Modern Cable
Co. - Dubai
6 Medium Voltage Rockwell Canada / Rockwell Automation -
Soft starter / VFD Automation – Poland UAE
Allen Bradly
IGEL Electrical Germany
Siemens Germany /
USA
Schneider Europe
Electric
7 LV BICC/Ducab UK/UAE Ducab - Dubai
power/control/auxil
Draka Netherland
iary Cables
Pirelli Italy
Riyadh cable Saudi Saudi Modern Cable
Co. - Dubai
Oman Cable Oman
8 Fiber optic cable BICC UK
Coring UK
Cavial
General
Photonics
Oman Fiber Oman
Optic Co.
S.A.O.G
9 Signal/data cables Belden UK Belden - Dubai
Siemens Europe Scientechnic - Dubai
10 Fire resistant BICC pyrotenaz UK
(MICC) Cables
AEI UK
Top cable Spain Top cable - Dubai
11 Flexible Cables / Eupen Belgium UK
Heat Resistant
BICC UK
Pirelli UK
12 Wires Ducab UAE Ducab - Dubai
13 DC supply unit & Jovyatlas Germany Igent - Dubai
UPS
American power USA American power
conversion conversion corp.
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Assembler
corp.
ABB Germany ABB - Dubai

GE USA GE Middle East /
Bloudan Control
Systems-Dubai
Infosec France Bloudan Control
Systems-Dubai
Siemens Germany Scintechnic - Dubai
14 Actuators Rotork UK Universal Technical LLC
AUMA Germany AUMA - Dubai
15 PLC / RTU Rockwell US Rockwell Automation -
Automation – Dubai
ControlLogix-XT
(1756 series)
Siemens - Germany Siemens - Dubai
SIPLUS RIC
Siemens – Germany Siemens - Dubai
SIMATIC
SIPLUS
RUT - Australia
Kingfisher
ABB Europe ABB - Dubai
Beckoff Germany Beckoff - Dubai
16 Gas Detectors Drager / Germany
Leopold Siegrist
GmbH
General USA Autochim systems
monitors Middle East
MSA USA MSA Middle East
Det-tronics USA Telectron - Abu Dhabi
17 Portable fire Leeds UK Dafoos - Dubai
extinguishers
Kidde USA Telectron - Abu Dhabi
Angus USA Telectron - Abu Dhabi
Moyne UK Dafoos - Dubai
18 Fire Alarm System Simplex USA SIBCA electronics -
Dubai
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Assembler
Notifier USA Telectron/DCL - Dubai
Siemens Germany Siemens - Dubai
19 Nitrogen fire Nohmi Basai Japan Corodex - Dubai
extinguishing
system
20 FM200 fire Hygood UK Dafoos - Dubai
extinguishing
Pyrochem USA Dafoos - Dubai
system
Kidde USA Telectron - Abu Dhabi
21 Deluge fire Fireguard USA Dafoos - Dubai
extinguishing
Angus USA Dafoos/Telectron -
system
Dubai
Kidde USA Dafoos/Telectron -
Dubai
Nohmi Basai Japan Corodex - Dubai
22 CCTV Yicon UK SIBCA electronics -
Dubai
Schneider USA Schneider Electric
Electric - Pelco
Siemens Germany Siemens - Dubai
23 Security gate Newgate UK SIBCA electronics -
Dubai
Federal APD USA Jos Hanson - Dubai
24 Chiller Unit Carrier USA UTS Carrier - Dubai
York USA Jonson Control - Dubai
Mitsubishi Daiya Japan ETA
Trane USA Wabco
25 Package/Split Carrier USA UTS Carrier - Dubai
package Unit
York USA York - dubai
Trane USA Juma Al Majid
26 AHU Carrier USA UTS Carrier - Dubai
York USA York - dubai
Trane USA Juma Al Majid
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Assembler
27 Industrial fan Vent Axia UK Rapid cool - Dubai
Soler & Palau Spain ACE Technical Services
Penn USA Energy International
28 Wall extract fan Xpelair UK Al Awazi Al Gargash
Soler & Palau Spain ACE Technical Services
Ventaxia UK
Penn USA
29 Fire dampers Trox UK Al Amana Trading Ets. -
Abu Dhabi
Rustin ATAI - Abu Dhabi
CIACO Kuwait
Advanced Air J.M Gulf Gen. Trdg. Est.
- Dubai
Pottorff Energy International -
Sharjah
30 Grilles & Diffusers Air Master Air Master Equipment -
Ajman
KMC Qatar
CIACO Kuwait
Beta Beta Trading - Dubai
Airton Airton - Dubai
31 Silencers Anemostat USA
KMC Qatar
CIACO Kuwait
Titus UK
Trox UK
32 Thermal Insulation Arabian
Fibreglass
Kimmco Kuwait Remco
Izocam Fawaz
33 Switch & Sockets MK UK SMKA - Dubai
Crabtree UK BMTC - Dubai
34 PVC Pipes and EGA Tube UK BMTC - Dubai
Fittings and PVC
Marshall Tufflex UK AL Hathboor - Dubai
Trunking
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Assembler
35 G.I.Boxex MK UK SMKA - Dubai
Barton UK Al Hathboor - Dubai
36 Galvanized Steel Barton UK SMKA - Dubai
Conduits
Kopex UK Al Hathboor - Dubai
Walsall UK
37 Cable Tray and Davis UK Engineering Int. - Dubai
Trunking
Walsall UK Al Hathboor - Dubai
Swift UK Marwan Elec. - Dubai
38 Isolator and Moeller Germany Juma AL Majid - Dubai
Industrial switched
Tolmaga France Tolmaga - Dubai
socket
Stromsburg Sweden Juma AL Majid - Dubai
CEAG Germany CEAG Middle East -
Dubai
39 Cable Sleeves/ Hepworth UAE Hepworth - Dubai
Ducts
Gulf Eternit UAE Gulf Eternit - Dubai
Terrain UAE Faraidoni - Dubai
40 Flexible Conduits Adaptaflex UK Electronic - Dubai
Metallic / PVC
Kopex UK Al Hathboor - Dubai
Coated Metallic
Barton UK
41 Lighting Protection WJ Furse UK BMTC - Dubai
and Earthing
AN Wallis UK Al Hathboor - Dubai
System
42 Electrical Grade Boddington UK
Rubber Mat Electrical
Martins Rubber UK Bloudan Control
Systems-Dubai
43 Cable Glands and BICC (Bicon) UK
Terminations
CMP UK
44 Zinc Rich Cold Galvafroid UK
Galvanized paint Zinga
45 Street Light Pole Galva Coat Abu Dhabi Galva Coat - Abu Dhabi
Al Babtain Saudi Al Babtain -Saudia
Arabia Arabia
Omaga Saudi Omaga -Saudia Arabia
Arabia
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Assembler
Jaffney Saudi Al Ghandhi
Arabia
46 Light Fittings Zumtobel Austria Debbas
Holophane USA Telectron - Dubai
Thorn England Thorn - Dubai
47 Industrial & Abtech UK Bloudan Control
hazardous area Systems-Dubai
enclosure/junction
Stahlin USA
box
WAGO Germany
Klippon UK
48 Chargers Saft Nife France Saft Nife Middle East
Ltd
Hoppecke Germany Hoppecke - Sharjah
Chloride UK Site Technology - Abu
Dhabi
Varta Germany
49 Battery Saft Nife France Saft Nife Middle East
Ltd
Alcad UK Site Technology - Abu
Dhabi
Hoppecke Germany Hoppecke - Sharjah
Exide UK Telectron - Dubai
Prosonic USA Tibo - Dubai
Varta Germany
50 Standby Diesel MTU Germany Generator Technologies
Generators - FZE - Sharjah
Engine Caterpiller USA Caterpiller - Dubai
Wartsila France Wartsila - Dubai
51 Alternators Stamford UK
Leroy Somer France
AVK Germany
52 Electric motor ABB Europe
Siemens Germany
53 Process Endress & Germany E&H - Dubai
Instruments – Hauser
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Assembler
 Level ABB Europe ABB -Dubai
 Flow Siemens Germany Siemens - Dubai
 Pressure
Yokogawa Japan Yokogawa Engineering -
 Analytical Dubai
54 Pressure / Wika Germany Wika Middle East -
Temperature Ins. Dubai
Endress & Germany E&H - Dubai
Hauser
Delta UK
Emerson / Europe
Condor / Tival /
Fanal

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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 19
MECHANICAL WORKS
DM/SRPD Section 19 Mechanical Works Rev 00 June 2016 Page i of 1

Dubai Municipality
DM/SRPD Section 19 Mechanical Works Rev 00 June 2016 Page i of iv

Dubai Municipality
SECTION 19 – MECHANICAL WORKS
CONTENTS
19 MECHANICAL WORKS ....................................................................................... 1
19.1 METAL AND PLASTIC MATERIALS ................................................................... 1
19.1.1 Aluminium Alloy .............................................................................................. 1
19.1.2 Steel ................................................................................................................ 1
19.1.3 Stainless Steel ................................................................................................ 1
19.1.4 Reinforced Thermosetting Plastics ................................................................. 1
19.2 METAL AND PLASTIC PREFABRICATED ITEMS ............................................. 5
19.2.1 Ladders and Safety Hoops ............................................................................. 5
19.2.2 Open Mesh and Chequered Plate Flooring .................................................... 6
19.2.3 Stainless Steel Open Mesh Flooring............................................................... 6
19.2.4 Aluminium Guard railing.................................................................................. 7
19.2.5 Stainless Steel Guard railing........................................................................... 7
19.3 FINISH ................................................................................................................... 7
19.4 MATERIALS ......................................................................................................... 7
19.5 SETTING OF MACHINERY .................................................................................. 7
19.6 VALVES ................................................................................................................ 8
19.6.1 General ........................................................................................................... 8
19.6.2 Non-Return Valves.......................................................................................... 9
19.6.3 Gate Valves for Sewage and Related Fluids ................................................ 11
19.6.4 Air Valves ...................................................................................................... 11
19.6.5 Back Pressure Valves ................................................................................... 13
19.6.6 Flap Valves ................................................................................................... 13
19.7 PENSTOCKS ...................................................................................................... 18
19.7.1 General ......................................................................................................... 18
19.7.2 Stainless Steel Penstocks............................................................................. 19
19.7.3 Plastic Penstocks .......................................................................................... 20
19.7.4 Actuators ....................................................................................................... 21
19.8 PRESSURE AND COMPOUND GAUGE FOR SEWAGE .................................. 21
19.9 MECHANICALLY CLEANED BAR SCREEN (GENERAL FOR
SEWERAGE AND DRAINAGE APPLICATION)................................................................... 22
19.9.1 Description .................................................................................................... 22
19.9.2 Performance and Design Requirements ....................................................... 22
19.9.3 Coarse Screen Design Specifications ........................................................... 23
19.9.4 Controls and Instrumentation ........................................................................ 25
19.9.5 Spares........................................................................................................... 27
19.9.6 Installation and Testing ................................................................................. 27
19.10 SCREENS AND SCREENINGS HANDLING EQUIPMENT FOR
SEWAGE PUMPING STATION ............................................................................................ 28
DM/SRPD Section 19 Mechanical Works Rev 00 June 2016 Page ii of iv

Dubai Municipality
19.10.1 Materials ....................................................................................................... 28

19.10.2 Item Description ............................................................................................ 28
19.10.3 Washpactor Performance Guarantee ........................................................... 29
19.10.4 Shop Tests .................................................................................................... 29
19.10.5 Spare Parts ................................................................................................... 30
19.10.6 Installation ..................................................................................................... 30
19.10.7 Field Performance Tests ............................................................................... 30
19.10.8 General requirements for all screening and compaction equipments ........... 30
19.11 BAR SCREEN AND SCREENINGS HANDLING EQUIPMENT FOR
DRAINAGE PUMPING STATION ......................................................................................... 31
19.11.1 General ......................................................................................................... 31
19.11.2 Materials ....................................................................................................... 31
19.11.3 Description .................................................................................................... 32
19.11.4 Operation for Automatic Raking Machine ..................................................... 34
19.11.5 Unit Control Panel ......................................................................................... 34
19.11.6 Shop Tests .................................................................................................... 35
19.11.7 Spare Parts ................................................................................................... 35
19.11.8 Field Performance Tests ............................................................................... 35
19.11.9 General requirement for all screening and compaction equipment .............. 36
19.12 PUMPS ................................................................................................................ 36
19.12.1 Pump Performance ....................................................................................... 36
19.12.2 Pump Casing ................................................................................................ 37
19.12.3 Casing Wear Rings ....................................................................................... 38
19.12.4 Bearings ........................................................................................................ 38
19.12.5 Sealing .......................................................................................................... 39
19.12.6 Pump Shaft ................................................................................................... 41
19.12.7 Centrifugal Sewage Pumps .......................................................................... 41
19.12.8 Horizontal Mounting ...................................................................................... 43
19.12.9 Vertical Mounting .......................................................................................... 44
19.12.10 Couplings .................................................................................................... 45
19.12.11 Installation .................................................................................................. 46
19.12.12 Sump Pumps / Drain Pumps ...................................................................... 46
19.12.13 General Requirements................................................................................ 46
19.12.14 Submersible Pumps ................................................................................... 47
19.12.15 Axial Propeller Pumps ................................................................................ 50
19.13 ODOUR CONTROL EQUIPMENT ...................................................................... 53
19.13.1 General ......................................................................................................... 53
19.13.2 Ventilation and Odour Treatment .................................................................. 53
19.13.3 Materials ....................................................................................................... 55
19.13.4 Enclosures and Covers ................................................................................. 55
19.13.5 Ductwork (Incorporating Dampers) ............................................................... 56
19.13.6 Carbon Deodoriser Units .............................................................................. 59
19.13.7 Bio filter Units ................................................................................................ 60
19.13.8 Chemical Absorption Units ............................................................................ 61
19.13.9 Two-Stage Odour Control System ................................................................ 69
19.13.10 Hoses ......................................................................................................... 72
19.13.11 Drench Showers ......................................................................................... 72
19.13.12 General requirements for odour control units for main sewage pumping
stations ....................................................................................................... 73
DM/SRPD Section 19 Mechanical Works Rev 00 June 2016 Page iii of iv

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19.14 VENTILATION .................................................................................................... 73

19.14.1 Wall Mounted Air Conditioning Units ............................................................ 73
19.14.2 Centralised Air Conditioning Systems ........................................................... 74
19.14.3 Split Unit Air Conditioners ............................................................................. 75
19.15 CENTRIFUGAL FANS (AIR BLOWERS) ........................................................... 75
19.15.1 General Construction .................................................................................... 76
19.16 LIFTING EQUIPMENT ........................................................................................ 76
19.16.1 Electrically Operated Traversing Cranes ...................................................... 76
19.16.2 Manually Operated Lifting Equipment ........................................................... 78
19.16.3 Lifting Frames ............................................................................................... 79
19.16.4 Lifting Davits ................................................................................................. 79
19.17 GAS DETECTORS ............................................................................................. 79
19.17.1 Portable Gas Detectors: General ................................................................. 79
19.17.2 Portable Gas Detector .................................................................................. 80
19.18 SURGE SUPRESSION & CONTROL ................................................................. 80
19.18.1 General ......................................................................................................... 80
19.18.2 Intersection of Welds .................................................................................... 81
19.18.3 Vessel Geometry .......................................................................................... 82
19.18.4 Sight Glasses ................................................................................................ 82
19.18.5 Inspection Port .............................................................................................. 82
19.18.6 Main Access Flange...................................................................................... 82
19.18.7 Safety Relief Valves & Pressure Gauge ....................................................... 83
19.18.8 Bolting & Gaskets ......................................................................................... 83
19.18.9 Radiographic Testing .................................................................................... 83
19.18.10 Welding ....................................................................................................... 83
19.18.11 Marking of Vessels ..................................................................................... 83
19.18.12 Compressors .............................................................................................. 84
19.18.13 Automatic Air Volume Control System........................................................ 84
19.19 SUPPORTS AND FIXINGS................................................................................. 85
19.20 SUPPORT FOR PIPEWORK AND VALVES ...................................................... 85
19.21 SUPPORTS AND ANCHORS ............................................................................. 85
19.21.1 Process Piping .............................................................................................. 85
19.21.2 Building Services Piping ............................................................................... 88
19.21.3 Execution ...................................................................................................... 92
19.22 VENDOR LIST .................................................................................................... 96
DM/SRPD Section 19 Mechanical Works Rev 00 June 2016 Page iv of iv

Dubai Municipality
19 MECHANICAL WORKS
19.1 METAL AND PLASTIC MATERIALS
19.1.1 Aluminium Alloy
Aluminium alloys shall be selected as having properties appropriate to the duty of the
unit, the method of fabrication and the environmental conditions.
The materials shall be manufactured in accordance with an approved International

Standard and shall be anodised when specified.
Alternative alloys may be proposed by the Tenderer if the manufacturer considers its
properties more appropriate to the application, the environmental or the physical
conditions prevailing.
19.1.2 Steel
Steelwork shall be manufactured / fabricated in accordance with an approved
international standard. Where specified or detailed steel work shall be hot dipped
galvanised in accordance with an approved International Standard at the place of
manufacture / fabrication.
19.1.3 Stainless Steel

Stainless steel shall have the following composition with mechanical properties to the
appropriate approved standard.
Table 19-1 Required Properties for Stainless Steel

Element Percentage Chemical Composition
Welded Fabrication Cold Fabrication
% minimum % maximum % minimum % maximum
Carbon - 0.03 - 0.07
Silicon 0.20 1.00 0.20 1.00
Manganese 0.50 2.00 0.50 2.00
Nickel 11.00 14.00 10.00 13.00
Chromium 16.50 18.50 16.50 18.50
Molybdenum 2.25 3.00 2.25 3.00
Sulphur - 0.03 - 0.03
Phosphorous - 0.045 - 0.045
Alternative, higher grade, stainless steel may be proposed by the Tenderer if the
manufacturer considers its properties more appropriate to the environmental or
physical conditions.
19.1.4 Reinforced Thermosetting Plastics

Reinforced plastic shall be as follows unless otherwise agreed in writing by the
Engineer.
DM/SRPD Section 19 Mechanical Works Rev 00 June Page 1 of 98
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1) Manufacturing Standards
The specification for design, materials, construction, inspection and testing of plant
manufactured from reinforced plastics shall conform to the appropriate sections of the
approved standard.
2) Resins
a) Isophthalic, Terephthalic, Bisphenol and Vinyl Ester resins may be specified
and they shall comply with the approved standard. The resins used shall
have a minimum strain to failure of cured cast resin of 2%.
b) Pigments or fire retardant resins (or fillers) shall only be used when specified
or ordered in writing.
c) Additives shall not be included in the resins unless they are required for
viscosity control.
d) Due attention must be paid to preclude the possibility of air inhibition
occurring on the laminate surfaces. The inclusion of paraffin wax, etc., must
be in accordance with resin suppliers’ recommendations.
e) Where protection against Ultra Violet light degradation is required, a
translucent UV inhibitor shall be included in the outer layers of the laminate.
3) Curing
Curing systems shall be in accordance with the Resin Manufacturer's
recommendations. The manufacturer of the laminate shall demonstrate that the
laminate has been adequately cured prior to its acceptance at the laminator's works.
4) Reinforcement
a) 'E' type glass chopped strand mat reinforcement shall be to the approved
standard and shall be to a maximum unit weight of 600 gm/m².
b) 'E' type glass woven roving fabrics shall be to the approved standard and
shall be to a maximum unit weight of 800 gm/m².
c) 'C' type glass veil (or synthetic fabric veil, where use is agreed by the
Engineer), shall be used to reinforce all surface sealing resin layers on
laminates.
d) Use of 'ECR' Corrosion Resistant glass will be permitted.
5) Structural Design
a) The laminate shall be designed to withstand all the loadings normally carried
by the laminates.
b) Under the worst combination of loading conditions, a maximum strain of
0.2% shall be permitted in the laminate.
c) A minimum laminate thickness of 6 mm shall be maintained for all GRP
laminates including the facings over or under stiffener sections.
d) Stiffener sections may be used to increase the rigidity of a structure. The
minimum glass reinforcement content shall be 1.2 kg/m² in these areas.
Depending upon the application, stiffener sections may be manufactured
from the following materials :
i. Polyurethane Foam
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Dubai Municipality
ii. Marine Plywood

iii. Other material agreed in writing
Stiffener sections shall not be made from steel or metal sections unless written
consent has been previously obtained. Where stiffening sections are employed they
shall not be construed as adding to the strength of the section to which they are
added. Plywood stiffeners shall not be acceptable for access ladders.
6) Moulds
Moulds shall be of adequate rigidity to retain dimensional stability and permit a high
level of laminate consolidation. The mould surfaces shall be of a quality which will
ensure the surface finish of the product.
7) Fabrication Methods
Manufacture shall be by approved mechanical methods wherever possible. Items
produced by hand lay-up processes will only be permitted if a suitable mechanically
manufactured product is not available. If deposition of resin by gun is used, this must
be carried out by airless spray technique.
a) Unreinforced gel coats shall have a maximum thickness of 0.5 mm.

Unreinforced flow (top) coats shall be fully brushed out to remove resin rich
areas. The flow coat shall not exceed 0.3 mm in thickness.
b) Surface veil or synthetic fabric reinforced layers shall consist of
approximately 90% resin by weight. The thickness of this reinforced layer
shall not exceed 0.5 mm.
c) Chopped strand mat layers shall have a resin content of between 65% and
75% by weight.
d) Woven roving glass fabric layers shall have a resin content of between 40%
and 60% by weight.
e) Where edges of laminates are cut or exposed these shall be sealed with a
continuous layer of fully cured resin.
f) Bisphenol or vinyl ester protective layers to isophthalic / terephthalic
laminates, shall be applied with a 'C' type glass veil (or synthetic fabric veil)
reinforcement after hardening of the substrata. When this has sufficiently
cured to prevent movement, a continuous flow (top) coat of bisphenol or vinyl
ester resin shall be applied and fully cured. In such cases it is anticipated
that an appropriate paraffin wax additive will be required to prevent air
inhibition of the surface.
8) Samples
a) A sample measuring 1 metre square and typical of each different laminate
proposed shall be submitted for approval together with a detailed descriptive
specification at least 4 weeks prior to the commencement of manufacture.
b) Production samples measuring 300 mm square and typical of each different
section of laminate shall be submitted to the Engineer's duly authorised
Inspecting Engineer throughout the period of manufacture for the purpose of
testing.
c) Samples of liquid and cast resin together with reinforcements and surfacing
veils (or fabrics) required to manufacture the samples indicated in (b) above
shall also be made available to the Engineer.
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Dubai Municipality
d) Failure to provide any of the samples designated in (a), (b) and (c) above
shall be construed as representing a delay in completion of the Contract
under the terms and conditions contained therein.
9) Tolerances for Moulded GRP
Table 19-2 Thickness Tolerances for Moulded GRP

Nominal thickness Moulding from Moulding from Matched metal
(mm) open mould. closed mould mouldings
(mm) (mm) (mm)
Up to but not p 0.50  0.20  0.18
including 1.5
1.5 to but not  0.75  0.30  0.20
including 3.0
3.0 to but not  1.10  0.50  0.30
including 6.0
6.0 to but not  1.50  0.75  0.40
including 12.0
12.0 to but not  2.00  1.40  0.50
including 25.0
25.0 and over  3.00  1.90  0.65
10) Quality Control and Testing
a) The following tests for inspection and quality control shall be carried out:-
i. The laminate shall be fully cured and shall show full resistance to a
commercial acetone sensitivity test.
ii. The laminate shall give Barcol Hardness of at least 90% of the resin
manufacturer's recommendations. The measurement of hardness by
means of a Barcol Impresser shall be carried out in accordance with the
approved standard.
b) Resin burn off tests shall be performed on cut-outs, where no such cut-outs
exists the Engineer reserves the right to have 50 mm diameter cut-outs for
checks to be made on local glass reinforcement content. The tests shall be
conducted in accordance with the approved standard and the result shall
define glass content.
c) The following strengths of the laminate shall be determined in accordance

with the approved standard.
i. Ultimate tensile unit strength
ii. Flexural strength
iii. Lap shear strength
iv. Shear and Peel strength of bond between thermoplastic linings and
laminate shall be at least 95% of the minimum value specified by the
laminate manufacturer.
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Dubai Municipality
d) Where a laminate has been designed to take bolts in the makeup of the
structure tests for bolt bearing strength shall be performed. Bolt bearing
strength tests shall be performed in accordance with the approved standard.
e) Where a laminate is to be used in conjunction with electrical control
equipment all or part of the following additional tests may be called up which
shall be carried out in accordance with the approved standard.
i.
ii. Electrical strength of sheet parallel to the plane of the sheet.
iii. Electrical strength of sheet normal to the plane of the sheet.
iv. Electrical strength of casting laminating resin system.
v. Insulation resistance of laminated sheet using IEC taper pins.
f) Additional tests may be called up at the discretion of the Engineer.

g) Certificates of Inspection and Testing
i. Test Certificate shall be obtained from the resin supplier for the heat
distortion temperature of resin and the unreinforced resin extension to
failure.
ii. Test Certificates shall be obtained from the glass reinforcement
manufacturer for each grade and type of glass employed in the fabrication
of the laminate.
All the tests referenced in (a) to (f) above shall be witnessed by the Engineer or his
Representative unless waived in writing by the Engineer.
11) Trial Election

A sufficient proportion of the fabricated sections of the structure must be trial
assembled to demonstrate the correctness of fit of the various sections.
19.2 METAL AND PLASTIC PREFABRICATED ITEMS

19.2.1 Ladders and Safety Hoops
Ladders and safety hoops shall be manufactured from either stainless steel or
approved glass reinforced plastic, as specified in the contract documentation.
The materials of ladders and safety hoops shall be in accordance with an approved
international standard.
Stringers of stainless steel ladders shall be 65 mm by 12 mm and spaced 375 mm

apart. The rungs shall be 25 mm dia. reduced to 20 mm dia. at the ends and welded
on both sides of the hole in the stringer and shall have an approved antiskid surface.
Rungs shall be spaced at 225 mm centres. The ladders shall be provided with fixing
brackets or the ends of the stringers shall be turned over to form fixings. The fixings
shall be drilled for 16 mm diameter bolts. Spacing between fixing brackets shall not
exceed 1200 mm.
Stainless steel safety hoops shall be of circular pattern fabricated from 50 mm by 10

mm flats and shall be provided at centres not greater than 900 mm and distance from
floor to safety hoop shall not exceed 2500mm. Fixing shall be by 12 mm dia.
countersunk screws with washers and nuts, the screws being inserted from the inside
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Dubai Municipality
of the ladder stringers. Vertical straps for safety hoops shall be 5 in numbers of 50
mm x 10 mm S.S flats to an approved International Standard fixed to safety hoops
with M12 countersunk screws inserted from inner side of the hoop.
Dimensional details of GRP ladder shall be similar to stainless steel ladder.
All fixing brackets, screws, bolts and nuts, etc. shall be SS grade 316 S16.
Ladders shall be fixed to the structure using Resin Anchors S.S Grade 316, size
M12 minimum.
All ladders shall have proper hand holds.
19.2.2 Open Mesh and Chequered Plate Flooring

Open mesh and chequer plate flooring shall be of mild steel, aluminium or reinforced
plastic.
Bearing bars for metal flooring to be serrated to form an antiskid surface.

Alternatively, twisted cross bars may be welded on top bearing bars to achieve the
required antiskid property. Reinforced plastic flooring shall have a similar non slip
tread surface.
Bearing bars shall be designed to achieve a loading capacity of 500 kg / m2

minimum.
Deflection under a concentrated load of 100kg shall not exceed span/200 for metal
flooring and span/100 for reinforced plastic flooring.
Unless a higher grade of protection is detailed, all mild steel flooring shall be hot dip
galvanized after fabrication.
All anchor bolts used for fixing the frame for flooring to structure shall be S.S 316
resin anchors
19.2.3 Stainless Steel Open Mesh Flooring

Open type flooring shall be of stainless steel grade 316L complying with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985 and BS4592: Pt 1 2006),
Suitable for a super imposed loading of 5kN/m.sq. The flooring shall be rectangular
pattern type constructed from main span bars designed to suit the loading and made
up of suitable size panels for ease of handling and complete with welded on nosing
bars. The mass of any individual panel shall not exceed 40kg. Where floor panels are
supported on structural members, adjustable type fixing clips or shot fired fixings shall
be provided with a minimum of 2 clips per panel, securing each corner with 2
additional clips for end panel covers. Where floor panels are contained within angle
curbing, fixing clips are not required. Where angle curbing is provided, this shall
complete with bent flat lugs welded on for grouting into the surrounding concrete at
maximum 900mm centres and at a maximum of 150mm from each end or corner.
Flooring shall be of such depth to ensure that deflection does not exceed span/200 or
10mm whichever is lesser when fully loaded. Support beams of grade 316 stainless
steel shall be provided, including all cleats and fixing bolts to facilitate easy removal
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Dubai Municipality
where necessary. Fixing clips shall be stainless steel grade 316 material. Where cut
outs are required in flooring around pipe work or other obstructions, a continuous
nosing bar shall be fully welded to all load bearing bars around the cut out. The
clearance around the obstruction shall not exceed 30mm.
Flooring shall be untreated mill finish (welds as laid), pickled clean or electro-polished.
19.2.4 Aluminium Guard railing

Unless otherwise specified or ordered, aluminium guard railing shall be constructed
with tubular rails fixed to double ball pattern solid forged standards. Both rails and
standards shall have a minimum outside diameter of 38 mm.
The rails and standards shall be of aluminium alloy anodised after fabrication. The
standards shall be fitted with base plates approximately 150 mm x 65 mm x 16 mm
thick.
Heights of rails, overall dimensions and details of the bases for the standards, fixing
bolts and any other special requirements relating to the guard railing are shown on
the drawings.
19.2.5 Stainless Steel Guard railing

Tubular handrails and standards shall be constructed of schedule 40, stainless steel
tubes of 32 mm nominal internal diameter. The ball on the standards shall be of
adequate size to accommodate the rails which shall be fixed by grub screws or by
approved fixings.
Height of rails, overall dimensions and details of the bases for the standards, fixing
bolts and any other special requirements relating to the guard railing shall be as
All guard railings shall have approved toe plates, 6 mm thick and 150 mm wide, or
to an approved size at the base of standard, irrespective of the material of railing .
Toe plates shall be fixed to the standards with suitable clamps. Standards shall not
be drilled for fixing toe plates.
19.3 FINISH
All covers flanges and joints shall be properly faced, bored, fitted, fixed, hollowed
moulded or chamfered as the case may be according to the best approved practice.
All working parts of the plant and other apparatus shall in like manner be well and
accurately fitted, finished, fixed and adjusted.
19.4 MATERIALS
All materials incorporated in the works shall be the most suitable for the duty
concerned and shall be new and of first class commercial quality, free from
imperfection and selected for long life and minimum maintenance.
19.5 SETTING OF MACHINERY

The machinery shall be mounted on flat steel packing of thickness selected to take up
variations in level of the concrete foundations.
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The packing shall be bedded by chipping or grinding of the concrete surface.
Packing shims of approved material and of the appropriate thickness shall be located
adjacent to each holding down bolt. The number of shims shall not exceed three at
each location.
The machinery shall be aligned, levelled and pulled down by the nuts of the holding
down bolts with a spanner of normal length. No grout shall be applied until the
machinery has been run and checked by the Engineer for stability and vibration.
Where specified an approved high performance non shrink grout shall be poured to
bed the equipment.
19.6 VALVES
19.6.1 General
Valves and penstocks shall be capable of withstanding corrosion in the ambient
conditions.
Nylon or other thermoplastic materials liable to attack shall not be used where
hydrogen sulphide is likely to be present.
All valve waterways shall be coated internally with a solvent free epoxy or polyester
lining of 100% solid content to be applied at the place of manufacture. The lining
shall be of 300 micron nominal thickness and holiday free.
All valves and penstocks will normally be witness tested at works.
Unless otherwise specified all valves and penstocks shall be anti-clockwise opening
and the maximum effort required, applied at the circumference of the hand wheel to
operate the valves against the maximum unbalanced head shall not exceed 55kg.
Valves, 400 mm and above in nominal diameter shall have a suitable gear box
All hand wheels shall have the words “open" and “close" in Arabic and English with
arrows indicating the direction of rotation cast on and shall be coated in plastic, nylon
or other approved materials in order to withstand the ambient conditions.
Unless otherwise specified or agreed spindles and extension spindles shall be of

stainless steel Grade 316 S16.
Extension spindles, where required, shall be connected by suitable muff type

couplings manufactured from stainless steel grade 315S16. The muff couplings shall
be supplied drilled with nuts and bolts for connection to the spindles.
A clear polycarbonate tube shall be securely fitted to protect the thread of rising
spindles for penstocks.
The nuts shall be of gunmetal or synthetic material and mating surfaces of gates and
bodies shall be of gunmetal, copper alloy or approved synthetic material.
All construction bolts, nuts and washers shall be in S.S grade 316.
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Dubai Municipality
Valve bonnet shall be fixed to valve body with bolts and nuts; fixing bonnet with bolts
screwed into drilled and tapped holes in valve body not acceptable.
All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.
All valves shall have the following embossed in casting:

a) Manufacturer’s badge
b) Type of casting/ material code
c) Nominal diameter
d) Pressure rating /Flange drilling
e) Year of Manufacture
Where "Operation by Tee Key" is specified the valve or penstock shall be supplied
with a suitable yoke with a squared cap of standard size to receive the tee key.
The key shall be supplied at the rate of one key per two valves or two penstocks
unless the valve or penstock is to be installed in an isolated location in which case
one key shall be supplied for each fitting location.
Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected by grease.
Packing must be sufficient to ensure complete protection of the fitting during transit
and storage.
Valves under 300 mm diameter together with all hand wheels and other easily
detachable items on both valves and penstocks are to be packed in timber packing
cases and properly bound with steel packing bands.
All valves of 300 mm and over are to be protected with wood or plywood discs or
flanges together with straw rope and hessian wrapping.
All valves shall be open–end tested and copies of manufacturer’s test certificates shall
be submitted to the engineer prior to installation of the valves
19.6.2 Non-Return Valves

Unless higher pressure ratings are required for the pipelines non-return valves shall
have a pressure designation of 10 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanged valves shall have
their flanges to a pressure of 10 bar and be drilled accordingly. The face to face
lengths of the valves shall be either 2 x ND + 100 mm or to an approved international
standard, the longer length to be allowed for in all cases using make up pieces where
necessary to achieve the required lengths.
Non-return valves shall be manufactured to conform to the requirements of an

approved international standard. Valves shall be of the single door swing check type
and shall have bodies of ductile iron or cast iron with copper alloy / gun metal
seating for body and the swing door for sewerage application and with resilient
faced disks for irrigation application. Valve spindles and all construction bolts shall be
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Dubai Municipality
stainless steel grade 316 S16. Door to spindle connections shall incorporate a
keyway.
All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly
purposes shall be removed.
Wafer type valves are not acceptable for sewage application.
In sewerage, the valves shall be constructed to allow solid matter to fall clear of the
valve flap and shall have 90 mm solid passing capacity unless impracticable for the
specified size of the valve.
Valves shall be provided with a removable cover on top of the body casting, to
enable the hinge and door to be inspected or removed. Valves of sizes ND 400 mm
and above shall have at least 2 numbers of jacking screws of suitable sizes for
easy removal of the cover from the body casting.
The door opening shall be restricted to a maximum angle of 70° at the hinge,
measured from a plane passing through the hinge at right angles to the axis of flow.
Swing Check Valves shall be of anti-slam type and valve shall be provided with
extended door spindles fitted with lever arms suitable for balance weights.
Wherever specified, non return valve shall be provided with limit switch, operated by
external cams rigidly attached to the door spindle. The limit switch shall operate
when the valve door has moved through an angle of approximately 10°. The switch
shall be suitable for the environment in which it is installed.
All components of the valve shall be suitable for highly saline ground water and / or
for sewage of high concentration of hydrogen sulphide in dissolved or gaseous state
Valve shall be suitable for continuously fluctuating flow as well as steady flow and
swing door shall be suitable for frequent closing and opening without any undue
strain on door – seat or hinge pins.
Pressure rating for swing door-seat also shall be 10 bars and any leakage across door-
seat shall not be acceptable. Valve shall not leak across swing door at back pressure
as low as 0.1 bar or even lower.
Valve spindle/shaft to be lavishly sized and easily removable . Stuffing box and
gland arrangement for shaft sealing shall be extremely reliable and free from leakage.
Protective coating for inner and outer surfaces, shall be fusion bonded epoxy or
approved two component epoxy and shall be to 300 micron DFT and holiday- free,
and application of coating to be at place of manufacture. Construction bolts shall
be Stainless Steel Grade 316 and shall not be coated. Coating shall be guaranteed for
a period of five years from the date of commissioning and acceptance of the
pumping system by the employer unless otherwise detailed elsewhere and approved
by the engineer /employer
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19.6.3 Gate Valves for Sewage and Related Fluids

Unless higher pressure ratings are required for the pipeline, gate valves shall have a
nominal pressure designation of 16 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanges shall have a nominal
pressure designation of 16 bar and shall be drilled accordingly. The face to face
lengths of the valves shall be in accordance with an approved international standard.
Gate valves shall be manufactured to conform to the requirements of an approved

international standard and shall be metal seated, for sewerage application, with valve
bodies of ductile iron or cast iron and the seatings copper alloy faced. The gates shall
be of wedge pattern, copper alloy faced with inside screw non-rising stems of forged
bronze or stainless steel grade 316 S16. Valves shall have a packed stuffing box and
gland. Alternatively bolted glands with nitrile rubber O-rings / Sealing rings to an
approved international standard will be acceptable for valves 300 mm or less in
nominal diameter.
Where resilient seated gate valves are detailed(for TSE network only ) the valve
bodies shall be ductile iron or cast iron. The gates shall be of ductile iron or cast
iron and wedge pattern with vulcanised (firmly bonded) nitrile rubber or EPDM lining
and with inside screw non-rising stems of stainless steel or forged
Actuator operated valves larger than 300 mm dia. shall have copper alloy faced
guides and slippers. 300 mm dia. and smaller actuator operated valves installed
other than in a vertical position shall have machined guides and gates.
Whenever the valve is specified or shown on drawing to be installed at different

positions than stem in the vertical up-right position shall be provided with special fit to
achieve guiding between surfaces of disc and body. The manufacturer shall
guarantee for the minimum torque and function of the valve when it orients from
vertically installed positions.
Valves shall be provided with drain plugs.
All cast iron and ductile iron used for the manufacture of valves shall be to an
approved international standard.
19.6.4 Air Valves

Unless higher pressure ratings are required for the pipeline, or otherwise indicated in
the Contract Documentation air valves shall have a nominal pressure rating of 10 bar
which shall be marked on the valve body and shall be designed for a liquid
temperature of 52° C and air temperature of 70° C.
Air valves for pumped pressure pipelines shall be the special high pressure ‘Dual’
large orifice type. The following shall be used as a guide for the general sizing of
large orifice air valves:
Pipeline Bore Air Valve size Ball size

200 20 100
300 25 100
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Dubai Municipality
Pipeline Bore Air Valve size Ball size

350 50 100/125
450 80 100/125
600 100 125
900 150 125/200
1000* 200 150/200
*For larger mains air valves may be fitted in clusters of two or more as required.
For other duties, such as distribution mains single, small orifice type standard air
valves having a nominal 25mm male thread inlet and with a ball size of 100 mm shall
be used.
The test pressure for different components of the air valves shall be as follows:-
Body 20 bar
Seat 16 bar
Ball/Float 16 bar
All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. The air valve for sewerage application shall
consist of a compact body, all stainless steel SS 316L fabricated or properly
protected cast iron / ductile iron of approved International standard, hollow direct
acting spherical or concave float in S.S 316 or grade higher in corrosion resistance
and solid large orifice float in HDPE - stainless steel nozzle and woven dirt inhibitor
screen, EPDM rubber seals and seat.
The valve shall have an integral "Anti-Surge" Orifice mechanism which shall operate
automatically to limit transient pressure rise or shock induced by closure to less than
1.5 x valve rated working pressure.
The intake orifice area shall be equal to the nominal size of the valve. Large orifice
sealing shall be affected by the flat face of the control float seating against an EPDM
rubber 'O' ring housed in a dovetail groove circumferentially surrounding the orifice.
Discharge of pressurized air shall be controlled by the seating & unseating of a small
orifice nozzle on a natural rubber seal affixed into the control float. The nozzle shall
have a flat seating land surrounding the orifice so that damage to the rubber seal is
prevented. The valve construction shall be proportioned with regard to material
strength characteristics, so that deformation, leaking or damage of any kind does not
occur by submission to twice the designed working pressure. Connection to the valve
inlet shall be facilitated by flanged ends conforming to PN 16 rating of BS4504.
Flanged ends shall be supplied with the requisite number of stainless steel screwed
studs inserted for alignment to the specified standard.
The access cover for air valves shall be in such a position that the valves could be
easily removed for repair/maintenance.
Installation of the air valves shall be at locations shown on the drawings, as

recommended by the pipeline surge analysis or as decided by the Engineer on site.
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Dubai Municipality
19.6.5 Back Pressure Valves
The valve body shall be of ductile iron or cast iron with flanges to ISO 5752 series 16.
The valve shall be extra heavy construction with bronze seats, SS 304 stem, nitrile
seals and membrane, bronze and ductile iron closing system, bronze pilot and
strainer, brass accessories, internal and external epoxy paint coating.
The valve controls and maintains a minimum preset upstream pressure regardless of
variance in downstream demand and the throttling of the main valve closing system is
controlled by an adjustable pilot valve operating in conjunction with a needle valve.
The valve is to be provided with a setting range of 1.37 bar to 8.6 bars or as per the
project requirement.
19.6.6 Flap Valves

19.6.6.1 Metal Flap Valves
Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 520C.
Flaps and frames shall be of ductile iron or cast iron to an approved international
standard with end flange faced and drilled to an approved international standard.
Mating surfaces of flaps and frames shall be of an approved non-ferrous metal
machined to ensure a watertight fit in the closed position.
Hinge pins shall be robust in design and of stainless steel Grade 316 or phosphor
bronze to an approved international standard; all flaps shall be double hung and
seated off the vertical to assure positive closure
Springs shall be of stainless steel, Grade 316 S16.

All cast iron surfaces shall be cleaned by grit or shot blasting to be free from grease,
then coated as specified for the environment. Hinge pins and mating surfaces shall be
smeared with grease.
A positive stop shall be included to avoid over-opening of the flap.

A cast-lifting eye for flap shall be included for manual lifting of the flap.
19.6.6.2 S.S Flap Valves
Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 52° C.
Flaps and frames shall be of all stainless steel construction in Grade 316 or higher
with end flange faced and drilled to an approved international standard. Mating
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Dubai Municipality
surfaces of flaps and frames shall be of an approved non-metallic material to ensure

a watertight fit in the closed position.
Valve shall be double hinge type for optimum sealing, hinge pins shall be of Stainless
steel grade 316; flaps shall be double hung and seated off the vertical.
19.6.6.2 Plastic Faced Flap Valves
Flap valves shall be faced in an approved synthetic material so as to be corrosion-

free in the ambient conditions. The flap shall be weighted to assist closing and shall
be suitably braced and reinforced.
Hinge pins shall be of stainless steel and all flaps shall be double hung and seated off
the vertical.
Mating surfaces shall be accurately moulded or machined to ensure a watertight fit in

the closed position.
19.6.6.3 Butterfly Valves
Butterfly valves shall comply in all respects with approved International standards.
Body shall be with all flanges faced and drilled to PN 10 or PN16, as detailed, and
face to face length to ISO 5752-Series 13 or 14 as recommended by the engineer and
approved by the employer. Inner face of valve body shall have vulcanized (firmly
bonded) liner of 6 mm thick( minimum), hard rubber or EPDM, whichever is most
suitable for the flow medium, extending seamless over body seat face, bearing bore
and sealing faces of connecting flanges. The disc shall be made of Ductile Cast Iron,
Aluminium Bronze, Stainless Steel Grade 316 or Duplex Stainless Steel complying
with approved international standards and depending on the application. Discs of
ductile iron shall have vulcanized, firmly bonded, 6 mm thick(minimum), seamless
lining of hard rubber or EPDM whichever is most suitable for the flow medium.
Valves with discs of aluminium bronze or stainless steel shall have the inner face of
valve body lined with suitable material, of sufficient thickness, highly resistant to
mechanical stresses due to possible dragging of disc on the sealing seat during
operation. Liner shall be integral part of the body/disc and shall be durable for the life
of the valve. Valves with alternative coating or lining for the inner face of the body
and disc may be acceptable on submission of data sheets and all other documents, to
the engineer, confirming the suitability of the proposed coating material for the flow
medium.
Disk shall be mounted on stainless steel shafts located in PTFE lined self lubricating
bearings with synthetic nitrile rubber shaft seal.
The valve disc shall be generally double offset eccentric type fitted with a non-ageing
sealing element of EPDM (EPDM Profile Seal) or similar approved material held in
place by an adjustable one-piece stainless steel clamping ring secured with Stainless
Steel adjusting set screws mechanically locked in place (not resin bonded). The
profile seal shall provide a bi-directional tight shut off in accordance with ISO 5208
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Dubai Municipality
Cat.A.
The valve disc shall be as streamlined as possible to ensure lowest head losses and
secure movement without disk flutter. Disc shall be designed for optimum hydraulic
flow pattern with negligible swirl and turbulence of water at two stub ends on
opposite sides of the disc.
The disc shall be designed to withstand maximum specified differential pressure

across the valve in either flow direction. The valve shall be suitable for throttling
operation. Valves shall be suitable for downstream dismantling and dead-end-service.
Mill certificate records, for the body and the disc, detailing mechanical properties,
chemical composition etc. as per EN 10204 3.1B or any other approved international
standard shall be submitted with the valve.
The disc stub shafts shall be manufactured from Stainless Steel, and positively keyed
to the valve disk and incorporate a key securing device (valve discs pinned to stub
shafts are not acceptable).The shafts shall be designed to withstand the maximum
torque that will be imposed by the operator.
The stub shaft bearings shall be of maintenance-free self-lubricating PTFE lined

bushes, and shaft seals of EPDM or equivalent.
The epoxy coated valve gearbox shall be fitted with a sealed for life maintenance-free
travelling fork and nut gearbox, suitable for buried service duty and capable of easy
operation at full pressure differential equal to nominal pressure, embossed in cast iron
casing, grease packed, with ball thrust bearings coupled with hand wheel and position
indicator. Gear box enclosure shall be of protection class IP67 minimum.
Travelling fork and nut gearboxes or slider crank gear boxes shall be used depending
on the size of the valve and according to the pressure rating.
Hand wheels / extension spindles foot brackets etc.shall be provided as standard

wherever detailed. Headstock, if detailed, shall incorporate a valve position indicator
Body seat ring, if applicable, shall be replaceable and of stainless steel Grade 316.
Clamping ring (retaining ring) for rubber profile seal for disc to be of
Stainless Steel 316.
Requirement of double eccentricity for disc shall be waived and centred disc
butterfly valve shall be acceptable under the following conditions:
a) Disc shall be encapsulated in(firmly bonded) or vulcanized with suitable

abrasion resistant material of sufficient thickness or shall be of stainless
steel, duplex steel or aluminium bronze to an approved international standard
and replaceable sealing ring is not required.
b) Body shall be lined (firmly bonded) or vulcanized with an appropriate

material and liner shall be an integral part of the body; thickness of liner
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Dubai Municipality
generally varying from a minimum of 8 mm to 20 mm in disc sealing area

and 6 mm to 15 mm in other noncritical areas for valves of diameters vaying
from 100mm to 2000 mm. The liner shall be thick enough in shaft sealing
area to guarantee positive sealing in all disc positions.
c) Body liner shall be highly resistant to mechanical stresses due to possible

dragging of disc on the sealing seat during operation. Body liner shall be
guaranteed for long service life without any replacement
d) Valve shaft (two piece shaft) shall be inserted into the disc hubs for a distance
of atleast 150% of the shaft diameter.
e) There shall not be any contact of the pumping medium with the valve shaft
and shaft sealing shall be positive and long lasting.
f) Dismantling of shaft and disc shall be easy.
g) Positive sealing ( tight shut-off) with no leakage in either flow direction shall
be guaranteed.
Protective coating shall be 300 micron DFT fusion bonded epoxy and holiday- free,
and application of coating to be at place of manufacture. Construction bolts to be
S.S.316 and shall not be painted. Transit/ installation damages of protective coating
shall be made good using site repair pack supplied by the manufacturer. If coating /
lining on the inner face of the valve is found damaged the valve shall be rejected and
no field repair of the inner face will be allowed.
19.6.6.4 Knife gate valve
Valve shall be suitable for bidirectional flow and shall guarantee zero leakage shut
off against the full unbalanced head acting on either side of closed slide.
Valve shall have full bore opening available for flow in the fully open position
Valve body shall be nodular cast iron ( Ductile Iron) GGG50 or duplex stainless steel
depending on the application and the body shall incorporate specially contoured
flush-out corners in the invert, such that all solids in the blade guides pushed down
to the invert as the slide is closed are flushed into the flow by the increased velocity
of the medium. The valve body shall have increased clearance in the chest area to
minimise the possibility of solid material causing the valve getting jammed.
The valve slide shall be grade 316L stainless steel, ground on its faces and two long
edges, and shall have a leading edge radius larger than the valve bore radius,
incorporating a single chamfer to give a cutting action through solids in the line onto
the body flush invert, ensuring at all times a complete zero leak shut off.
The body/slide sealing system shall be outside the fluid flow path through the valve
so that it is protected from damage due to abrasion caused by solids and grit in the
flow and to ensure long, maintenance-free seal life.
Sealing to atmosphere shall be with replaceable elastomer sealing elements in the

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Dubai Municipality
chest of each side of the body, protected against damage by abrasive material in the
fluid.
Pressure Test :Pressure test at 1,5 times maximum allowable working pressure for valve
body. Pressure for seat tightness : 1,1 times maximum allowable differential pressure for
closed valve-No visible leakage allowed.
Knife gate valve for saline ware application shall be of full S.S construction
Pressure rating and flange drilling shall be PN10 unless otherwise specified
19.6.6.5 Plug Valves
Plug valves shall be of the non-lubricating, eccentric type and shall be designed
for a working pressure of 16 bars unless otherwise specified. Valves shall
provide tight shut-off at 1.1 time rated pressure.
Valves shall be of round port design; larger valves with rectangular port design
shall have shorter sides rounded to form semicircles. Plug valves shall have fluid
flow area 95 to 100 % of pipe bore the area being calculated by considering the
distance from plug edge to seat on opposite side with valve in fully open position.
Calculating the bore by considering the distance from seat to seat not
acceptable.
The plug valve body shall be cast iron / ductile iron of approved international
standard with welded-in overlay of 99% nickel alloy content on all surfaces in
contact with the face of the plug. Sprayed, plated, or seats screwed into the body
are not acceptable.
Valve flanges shall be rated to PN16 unless otherwise specified and drilled
accordingly for nut and bolt connection to mating flange.. Drilled and tapped
holes for flanges for connection to mating flange of pipe line not acceptable.
Plug valve shall be furnished with permanently lubricated sleeve type bearings
conforming to approve International standard. Bearings shall be of sintered, oil
impregnated type 316 stainless steel or bronze.
Valves shaft seals shall be of the “U” cup type, in accordance with approved
international standard and seals shall be self-adjusting and repack able without
moving the bonnet from the valve.
Valve shall be with suitable gear box
Valve shall have suitable end stops for full open and full close positions
External position indicators for plug shall be incorporated with the valve.
Valve shall be suitable for operation with electrical actuators
19.6.6.5 Elastomer check valves
The valve shall be suitable for highly saline ground water.

The valve shall be suitable for frequent opening and closing.
Connection to the pipe shall be with integral elastomer flange drilled to PN 10. Slip-
over pipe type of elastomer check valve not acceptable.
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Dubai Municipality
Retaining ring to be S.S 316, to right thickness and shall have a lifting eye welded to
it.
Suitability of the offered valve for the available maximum and minimum flow velocity,
maximum and minimum inlet pressures and maximum back pressure to be confirmed
by the manufacturer.
Valve shall resist “retraction” into the pipe under any situation.
19.7 PENSTOCKS
19.7.1 General
Fixings shall be of the drilled anchor type and made of stainless steel.
All penstocks shall be suitable for an on/off seating head of 10m minimum but in no
instances shall be less than 1.5 the maximum working head.
Penstocks shall conform to the following specifications:
a) Austenitic Ni Resist Cast iron

b) Stainless Steel
c) Plastic
The size of penstock to be used in any particular location shall be as described in the
Contract Documentation and Drawing and shall be approved by the Engineer.
The frame, doors, sealing faces and spindles of each type of penstock shall be as
specified in the appropriate clauses herein.
Unless otherwise described in the Contract Documentation all penstocks shall be

provided with hand wheels of adequate diameter with suitable gearing where
necessary to ensure that the required operating force applied by hand does not
exceed 220 KN.
Hand wheels shall have the words “Open” and Close” in Arabic and English with
arrows indicating the direction of rotation cast on them. The direction of closing shall
be clockwise and a vandal/weatherproof, clear polycarbonate tube cover shall be
securely fitted to protect the thread of rising spindles. The tube shall be clearly and
permanently engraved to indicate the position of the penstock.
Spindles shall have machine cut robust trapezoidal or square form threads as
necessary. They shall be of stainless steel. Extension spindle coupling shall be of
the muff type and they shall be drilled and provided with a stainless steel nut and bolt
for securing the spindle to the penstock spindle head which likewise be drilled to take
the bolt.
All penstocks shall be of the rising spindle type unless otherwise stated. Headstocks
shall be provided except in cases where the hand wheels can be mounted on the
penstock frames. Unless otherwise specified, penstocks in general to be designed
without thrust tubes and thrust in both directions of operation shall be absorbed by
the structure. For motorised /actuator operated penstocks, thrust tubes, if specified,
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Dubai Municipality
shall be provided between the penstock frame and headstock in order to absorb the
thrust in both directions of operation. Thrust tubes shall incorporate all necessary
fixing brackets and spindle guide plates
Permissible rates of leakage under the specified testing head shall be as follows:
On seating installation - 5 litres per meter of slide perimeter per hour.
Off seating installation - 30 litres per meter of slide perimeter per hour.
The slide perimeter shall be measured as the total length of contact faces between
the gate and frame in the closed position.
All materials used in the manufacture of penstocks shall conform to the approved
international standards.
19.7.2 Stainless Steel Penstocks

The frames and doors of stainless steel penstocks shall be of Grade 316 S31 or SS
316 Ti (DIN 1.4571) The design of the doors shall be such that the required working
pressures can be withstood without deflection or distortion that would affect the
operation of the penstocks. Any strengthening of doors by the provision of ribs and
gussets shall be carried out by welding and not by bolting.
Penstock door shall be designed with deflection not exceeding 1/600 of the width of
opening , deflection being measured at the bottom most edge of the door under 1.5
times working head or 10 metres of water, whichever is higher. Door shall be of
maintenance-free design and plate thickens shall not be less than 6 mm
Penstock shall be designed to achieve 1.5 time safety factor.
The side sealing faces may consist of simple metal to metal contact between the door
and frames or by synthetic rubber seals and plastic guides as necessary to withstand
the required working pressure without leakages.
Spindles shall be manufactured in stainless steel grade 316 S31. Spindle shall be
designed with a safety factor of 3.5 times, to avoid buckling on closing. The hollow
type spindle shall not be acceptable. The penstock shall be generally rising spindle
type (spindle nut shall not be located in penstock door) unless otherwise detailed. The
spindle nut shall be of high tensile material free from dezincification, lavishly sized to
avoid fatigue failures and nut, drive sleeves, and screw threads shall be easily
accessible for inspection and re-greasing. All the components of the penstock shall
be suitable for brackish water of very high salinity and also for sewage with
considerable quantity of hydrogen sulphide in dissolved or gaseous state.
The penstock shall be totally surface mounted on the wall and bottom of frame shall
not be embedded in concrete. The frame shall be fixed to the wall using Stainless
steel grade 316 resin anchors of suitable size. Penstock seating (seal) shall be easily
replaceable.
Adequate number of spindle support brackets (S.S 316) to be provided. Spacing of

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brackets shall not exceed 2 metres and all stem guides shall have teflon bushes for
friction-less sliding motion of the stem.
Penstock shall be close frame type and soffit member of the frame shall be rigid
enough to resist distortion during transportation and handling.
Detailed drawing showing all structural dimensions for the penstock proposed
shall be approved by the engineer. General specimen drawing shall not be acceptable.
All nuts and bolts shall be in metric standard sizes only. All screws used for fixing
sealing strips for doors shall be easily accessible and sealing strips shall be easily
replaceable.
Penstock shall be suitably rated for minimum on and off seating head of 10 metres
and shall satisfy 1.5 times maximum working head requirement.
Head stock or pillar for penstock shall be robust in design and shall be made of
stainless steel Grade 316 or 316 Ti. The base plates shall be sized and re-inforced
with 4 numbers of gusset plates.
The penstock shall be tested on site for the leakage rates at specified rated head. The
contractor shall make all temporary arrangements for testing the penstock on site.
Leakage rate shall not exceed the specified volume. Each penstock shall be suitable
for both on -seating and off -seating installation.
Guarantee: Penstocks shall have a comprehensive guarantee for a period of 10 years

for material and workmanship and if the material of any component of the penstock is
not in total compliance to the specification for the project and / or if material of any
component is inferior in quality, the manufacturer / supplier and the contractors shall
be responsible for replacement of the penstock at their own cost.
19.7.3 Plastic Penstocks

The frames of plastic penstocks shall be made from continuously welded stainless
steel grade 316 or higher. Frames shall be reinforced and gusseted to ensure rigidity
without dependence upon the bridge which shall be bolted for ease of removal.
The doors of plastic penstocks shall be made from sheets of approved rigid cellular
polymer sandwiched between sheets of approved rigid compressed composite
plastics. The linear coefficient of thermal expansion of the material shall not be
greater than 1.6 x 10 per o C. No PVC or GRP materials shall be used. The doors
thus formed shall have sufficient strength to withstand the required working pressures
without deflection, distortion or that would affect the water-tightness of the penstocks.
Totally enclosed steel matrices shall be incorporated in the door construction to
ensure adequate rigidity.
The sealing faces and side guides shall be to the approval of the engineer and shall
consist of plastic strips having a high resistance to sliding wear and a coefficient of
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friction of less than 0.10. The sealing strips shall be securely fixed to the inner faces
of the frames and shall incorporate removable stainless steel adjusting devices.
Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra

high molecular weight polyethylene material. The operating nuts for the spindle
retaining blocks shall be fixed in a visible position inside a separate gate lifting
bracket bolted on to the top of the door with stainless steel fasteners. The operating
nut or spindle retaining block shall not be contained within the door.
All plastic materials shall be nontoxic ultraviolet stabilized and shall have fire
resistance in accordance with an agreed internationally approved standard.
19.7.4 Actuators
Where electric actuators are required for valves or penstocks they shall comply with
the requirements of Section 18 the Electrical & Instrumentation Specification.
19.8 PRESSURE AND COMPOUND GAUGE FOR SEWAGE

Pressure gauges for use with sewage and sludge shall be Bourdon gauges. The
pressure transmission system shall be of the air-filled or oil-filled stainless steel
capillary tubing sleeved with suitable reinforced plastic tubing and diaphragm
transmitter. Pressure gauges for submersible pump installations shall be fixed in
control panel room and diaphragm transmitters in valve chambers unless otherwise
detailed.
For the air-filled system, the diaphragm shall be mounted in a clean-out housing. The
transmitter housing shall be mounted directly onto a 25 mm or greater bore straight
through diaphragm type isolating cock. The cock shall be mounted directly onto the
pressure tapping.
Where the gauge is mounted directly on the pressure tapping a Schaffer diaphragm
gauge may be used. Schaffer diaphragm gauges shall be fitted with 20 mm or
greater bore straight through diaphragm type isolating cocks.
All construction bolts for isolation valves and pressure transmitters shall be Stainless
steel grade 316.
All internal components of the gauge shall be robust in design and in stainless steel or
other suitable corrosion resistant material.
Pressure transmitters and directly mounted gauges shall be resistant to high

Vibrations and instrument connection for pressure transmitters shall have integral
vibration dampers wherever applicable.
All liquid filled (Glycerine filled) gauges shall have very effective sealing to prevent
liquid leakage from the gauge.
Transmitter body and diaphragm assembly shall be stainless steel grade 316. The
diaphragm assembly shall be durable and replaceable
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Gauges shall be graduated in metres of water and bars gauge, together with vacuum
where appropriate. The accuracy of the system shall be 1.50% of range or 2.50m
bar.
Gauges shall have 150 mm diameter circular faces and it shall be made of stainless
steel body. Gauge graduations shall be such that the gauge is never used
continuously beyond 60% of the maximum graduation.
The gauges shall not be connected to air release pipes or auxiliary suction pipes.
The gauges shall be fitted with a pressure snubber to dampen pressure pulsation.
The face shall have a warning label marked in red “IMPORTANT - TURN OFF WHEN
NOT IN USE” both in English and Arabic.
Before delivery, each gauge shall be tested and calibrated in accordance with an
approved international standard and the test certificate/calibration report to be sent to
the Engineer.
Alternatively, digital transmitters and display units of approved model and suitable
range may be used instead of mechanical transmitter and Bourden gauges
19.9 MECHANICALLY CLEANED BAR SCREEN (GENERAL FOR SEWERAGE

AND DRAINAGE APPLICATION)
19.9.1 Description
The Tenderer shall furnish and install mechanically cleaned coarse screens with
multiple rake blades at the locations shown on the drawings. Each screen shall be
manufactured from AISI 316L stainless steel shapes. Fabrication and assembly shall
be in conformance with these specifications.
Each screen shall be furnished complete with bar rack, dead plate, discharge chute,
side frames, covers, rake blades, drive chains, sprockets and bearings, scraper
assembly, drive motor, gear reducer, anchor bolts, controls and all accessories and
appurtenances specified or otherwise required for a complete and properly operating
installation.
The Tenderer shall coordinate all details of the equipment with other related parts of
the work. The Tenderer shall verify that all structures, piping, wiring, and equipment
components are compatible. The Tenderer shall be responsible for all design
including dimensions and structural requirements.
The power supply is 400 Volts, 50 Hz, 3-phase.
19.9.2 Performance and Design Requirements

The screen rake speed should not be less than 6 m/min.
Screen shall be designed for a screenings load of minimum 0.01 m3/m of rake blade
width on all rake blades.
All components shall be so designed that jamming at any point will not result in
structural failure, but will cause the drive motor to stall. All components, including the
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gear reducer, shall be designed to withstand, without damage or permanent

distortion, the full stalling torque of the drive motor and/or the maximum differential
head at any channel water depth.
19.9.3 Coarse Screen Design Specifications

19.9.3.1 Material
Screen shall be manufactured from AISI 316L stainless steel shapes (rods, angles,
and channels), pipes, and sheets. In particular, side frames and guides, bar rack,
rake assembly, scraper assembly, shafting, discharge chute, fasteners and anchor
bolts shall be made of this material.
All stainless steel components and structures shall be submerged in a chemical bath
of nitric acid and hydrofluoric acid (pickling bath) to remove any residues that may be
present on the material as a result of forming, manufacture, or handling. After
removal from the pickling bath, the equipment must be washed with a high-pressure
wash of cold water to remove any remaining surface debris and promote the
formation of an oxidized passive layer which is critical to the long life of the stainless
steel.
Chains shall be made of hardened stainless steel. Chain rollers shall be made of
polyamide.
Sprockets shall be made of stainless steel type 316L.
Lower sprocket bearings shall have a stainless steel casing including a shaft made of
white abrasion resistant chromated chilled cast iron and a friction bushing made of
zirconium oxide.
Upper sprocket bearings shall have a paint coated cast iron casing and include ball
bearings that are greased for life and shall be double-sealed with Nilos rings to
achieve protection IP67.
Safety stop mechanism shall be made of a special designed torque control by a

spring package system made in stainless steel. The control must be done for the
forward and backward operation of the screen. Electronic Safety Stop Mechanism
shall be provided as an added protection.
19.9.3.2 Construction
The bar screen shall remove debris (screenings) from the incoming wastewater by
means of a positively cleaned bar rack that is installed in a concrete channel. The
screen shall retain debris at the bar rack. A multitude of rake blades shall remove and
lift the debris to a discharge mechanism. Screens with single rakes shall not be
approved. Screens make use of brushes and spray water for screenings removal
shall not be approved.
The bar rack shall consist of equally spaced, straight bars that are inclined from the
horizontal with the inclination specified angle. The lower ends of the bars shall be
provided with a 8mm thick curved base plate such that the rakes positively remove all
screenings from the bottom of the bar rack. Rectangular bars shall have a minimum
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10mm x 60mm cross section and shall be equal spacing of 40 mm centre to centre
between the adjacent bars. The bar rack shall be securely fastened to the frame of
the screen and be readily removable.
The bar screen shall be provided with a dead plate extending from the bar rack to the
discharge chute. The dead plate shall be made of a minimum 8 mm thick stainless
steel plate and shall be stiffened by structural members so that it is flat without
undulation so that the tips of the rake’s teeth ride at a distance between 2 and 6 mm
over the dead plate. The dead plate shall be securely fastened to the side frames.
Sides of dead plate shall be 100 mm lip in order to prevent screenings from dropping
off sides of the rake.
A discharge chute shall be provided that fully encloses the discharge section of the
screen. An access hatch with hinges and handle shall be provided in the chute
permitting easy access. The discharge chute shall be mounted to direct screenings
into the appropriate receiving container or conveyor. The chute shall have a slope of
minimum 45 degrees. The screenings shall discharge into the screw compactor. A
pivoting lip plate supported on bearings shall prevent material from re-entering the
channel. The pivot shaft shall include a stainless steel hydraulic shock absorber.
The rake, apron, wiper and chute shall be so designed to avoid screenings from
dropping off from the rake while transporting screenings up and discharging into
discharge chute.
A frame shall be provided supporting all required loads. Side frames shall be made of
316L stainless steel plates and a minimum of four edges and shall have a suitable
width for the size of the screens. The side frames shall be connected to support
frames. The support frames shall be securely anchored onto the operating floor.
The screen shall be provided with easily removable covers made of stainless steel
plates. The covers shall be provided with turn locks and handles.
Neoprene strips shall be fastened to the side frames to seal the lateral gaps between
the side frames and the channel walls.
Each side frame shall include separate roller tracks to guide the rakes. The roller
tracks shall be bolted to the frame so that they can easily be replaced.
Drive chains for the rakes shall be roller type chains and shall be made of hardened
stainless steel. Drive chains, chain guides, sprockets and their bearings shall be
replaceable without removing the screen from the channel.
Chain rollers shall be made of polyamide.
Upper bearings shall be ball bearings, shall be greased for life and shall be double-
sealed with Nilos rings to achieve protection IP67.
Lower bearings shall be slide bearings in a stainless steel casing. They shall include
white abrasion resistant chromated chilled cast iron shafts and zirconium oxide slide
bushings. Bearings employing slide bushings made of plastic or metal material shall
not be accepted.
The rake blades shall each consist of several segments with teeth/tynes such that
only one of the segments needs to be replaced in case that a tooth is be damaged.
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Rake teeth / tynes shall be of curved stainless steel construction and teeth shall not
be less than 18mm thick and shall be of tapered self-relieving design.
A pivoting scraper mechanism shall be positioned at the point of discharge and shall
be attached to the side frames. The scraper shall clean the rake on each pass and
return to its rest position with minimal shock.
The gear reducer shall be a totally enclosed unit. The gear reducer shall be of the
helical worm type and have a service factor rating of 1.25 based on the design
running load. Gear reducer shall have ball or roller bearings throughout with all
moving parts immersed in oil and bearing enclosure to be to IP67 rating. Gear
reducers which require periodic disassembly of the unit and manual re-greasing of
bearings are not acceptable. During continuous operation the oil temperature shall
not exceed 200 degrees F (95 °C).
The rake assembly shall be driven by an electric motor. The motor shall be UL rated
for operation in Class 1, Div 1 environment. The drive motor for each unit shall be
400 V, 3Ph, 50 Hz, severe duty, squirrel cage induction brake motor, with a 1.15
service factor at 52C ambient temperature. The motor shall be closed coupled to the
reducer gear assembly. The motor shall have Class F insulation with Class B
temperature rise and shall be adequately rated (kW) and shall be explosion proof and
with protection IP68 even if not submerged. Cog wheel and pin rack assembly shall
have a minimum service life of 5 years in severe operating conditions in a space of
high concentration of H2S. Chain drives speed reducer and head shaft shall not be
acceptable. The gears on each drive unit shall be enclosed in stainless steel safety
guards. Motors, limit switches, isolators etc shall be rated to IP 68 and shall be
explosion proof. Bearings shall be sealed for life and shall be enclosed to IP67
rating.
19.9.4 Controls and Instrumentation

19.9.4.1 General
The control system shall be designed by the screen supplier.
The screen shall be pre-wired so that it only requires making the electrical
connections from the control panel to a junction box at the screens.
Local controls on screen:
a) One (1) NEMA 4X proximity switches for monitoring of the shaft’s rotation
speed.
b) One (1) NEMA 4X frame mounted junction box. The electrical components of
the rake shall be pre-wired to the junction box.
c) Screen shall be retuned back to parking position upon completion of full
cycle or when it shall be stopped as per PLC programme.
d) The machine shall be provided with local control station which should include
lockable LOR selector switch, forward-off-reverse”, spring return to “off”
selector switch and mushroom head emergency stop push button.
e) All cubicles for local controls installed in Screen house shall be in S.S, IP67
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and shall be suitable to be installed in hazardous area - Class 1, Division 2.

f) It is preferred to include starters and control of screen in main MCC. The
manufacturer shall provide softcopy of PLC control algorithm to incorporate
within the station main PLC. The manufacturer shall also coordinate with the
MCC vendor till successful commissioning is achieved and required
functionality is implemented.
g) Torque overload limit switch shall be provided to restrict the screens from
overloading due to mechanical or electrical or any other forces.
h) Where a considerably large screening system with multiple machine are
specified the manufacturer could supply a freestanding MCC to be installed
remotely in station MCC room with its own control system encompassing
PLC and HMI. The screen PLC shall communicate with the station PLC/RTU
and eventually configured at local/central remote SCADA system.
19.9.4.2 Water level sensors and float switch
Coarse screen manufacturer shall provide one ultrasonic transmitter with two
separate transducers and electronics package for continuously monitoring of the
upstream and downstream levels for control of screen operation. The transducers
shall be rated for Class 1, Division 2 hazardous locations and shall be intrinsically
safe without the use of additional barriers, complete with built-in temperature
compensation and submerged shield. The transmitter shall be mounted in the control
panel (free-issued by the screen manufacturer). Tenderer shall install the transducers
and provide wiring to the control panel.
Coarse screen manufacturer shall provide a float switch with intrinsically safe relays
and submersible cable for backup control and alarm. Tenderer shall install the float
switch and provide wiring to the control panel.
19.9.4.3 Control Panel
Refer to specification Section 17 – General Mechanical and Electrical Works &

Section 18 Electrical and Instrumentation Works.
19.9.4.4 Sequence of operation
In AUTO position the screen shall be controlled by the water level sensors. Screen
operation shall be started when the water level sensors monitor a certain water level
difference, when the float switch senses high water level, or when a certain time has
passed since the last operation of the screen. Screen operation shall be stopped with
an adjustable delay time after the water difference is below a certain value and after
the float switch ceases to indicate high water alarm, or after a certain run time has
expired (if operation was started by timer).
If the proximity switch senses a movement of the upper frame part while the motor is
running forward, the motor direction and therewith the rake movement is
automatically reversed for an adjusted period of time. Then the motor direction and
rake movement is reversed again to forward movement. If the upper frame moves
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again during the forward movement, return is repeated one more time. If the upper
frame moves a third time, the screen is shut off an alarm is rendered.
Reset is manually performed after correction of any cause for a trip-out.
In HAND position the operator shall be able to run the rake assembly by pushing the
respective FORWARD or REVERSE tip button.
19.9.5 Spares
The following Spare Parts shall be included for each of the upstream and
downstream coarse screens upon obtaining the Engineer approval and shall be
supplied together with the equipment:
a) 1 set of rake plates

b) 1 set of chain
c) 1 upper bearing
d) 1 lower bearing
e) 1 wiper for scraper
f) 2 shock absorbers for scraper
g) 1 proximity switch
h) 1 set of spares required for screens PLC (as applicable)
i) 1 set of spares required for screens Local control panel
j) And any other item recommended by screens manufacturer as operational
spares 2 years of trouble free operation.
Spare parts shall be packaged with labels indicating the contents of each package,
and shall be delivered to Owner as directed. Tenderer shall include the spare parts
price under mechanical screens in the Bill of quantities and the list of spares required
19.9.6 Installation and Testing

The equipment shall be factory assembled and witness shop tested. Shop test
reports shall be submitted to Engineer for review.
Installation of the equipment shall be in strict accordance with the contract documents
and the manufacturer’s instructions.
Supplier shall furnish the services of a factory-trained Service Engineer for one (1)
trip to inspect the installation, observe start up, and provide operator training.
The Service Engineer shall make all necessary adjustments and settings to the
controls and demonstrate proper and sequential operation of the screen. The screen
shall operate automatically based on the water level differential.
The screen shall operate automatically based on the water level differential.
Screens control philosophy shall be submitted to the Engineer for his approval prior to
placing the order of PLC system.
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19.10 SCREENS AND SCREENINGS HANDLING EQUIPMENT FOR SEWAGE

PUMPING STATION
The Screenings Handling Equipment for Sewage Pumping Station includes the
conveyor, washpactor, motors and other appurtenances.
Washpactors are normally to be operated automatically and provided with a manual

control device. Washpactor shall be interlocked with screen PLC.
19.10.1 Materials
Design washpactors and appurtenances for long, continuous, and uninterrupted
service; easy adjustment and replacement of parts.
Structural Steel: Provide in accordance with ASTM A36.
Iron Castings: Provide in accordance with ASTM A48 Class 30.
Provide Type 316 L stainless steel for fasteners and hardware.
Stainless steel in accordance with AISI 329, AISI 410.
Provide finish coats for all materials except stainless steel in accordance with this
specification documents.
19.10.2 Item Description

The Washpactor shall be capable of subjecting all incoming sewage screenings to
liquefaction, separation from dirty water, rinsing with clean water and final compaction
to achieve a clean de watered disposable end product. The product shall have
remaining moisture content in the range of 45-55%. Liquefaction shall take place
within a purpose designed tank allowing sufficient retention to achieve maximum
separation of faecal solids from other materials prior to the compaction process.
The dirty washing water and solids are to be separated within the integral Screw
Compactor. Wash water shall be introduced within the Screw Compactor chamber to
provide a final rinsing of separated screenings prior to compaction.
Maceration and disintegration of the total solids will not be accepted.
A screw conveyor shall transport screenings from the mechanically raked screens to
the washpactor. The length of the conveyor shall be in accordance with the Tender
Drawings. The screw housing for conveyor shall be in stainless steel grade 316.The
screw flights shall be 10 mm stainless steel, minimum, with torque tube of 50 mm or
more and of 4 mm thickness. The screw shall have replaceable wear shoes. The trough
shall have a 80 mm drain to remove the excess water. The bearing for the screw shall
be part of the drive system.
Drive motor shall be suitable for 400 v/3Ph/50 Hz supply and shall be IP68 and
explosion proof.
The screenings shall discharge from the washpactor via a flanged stainless steel
tubular chute(s) with sufficient length to discharge directly into the required collection
receptacle.
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A flanged/valved tank drainage point(s) shall be provided at the base of the

Washpactor tank to allow for collected grit flushing and drainage of the tank prior to
maintenance operation.
The complete Washpactor assemblies shall be manufactured from a grade 316 L

stainless steel. All internal small bore pipe work shall be stainless steel or ABS
plastic. The impeller and impeller housing shall be manufactured from a high grade
cast stainless steel and suitably treated to withstand an abrasive condition.
The Impeller(s) shall be directly coupled to the drive motor and sealed on the rotating
shaft by a silicon carbide/carbon mechanical seal. The impeller shall be purpose
designed for the liquefaction of the faecal solid within the Washpactor Tank.
The compactor screw(s) shall be supported at the drive end by an independent self-
aligning thrust and radial load bearing, the screw shall be driven by a shaft mounted
helical geared motor unit. It is not acceptable to support the compactor screw shaft
from the gearbox bearings.
The compactor screw(s) shall be fitted with a hard wearing nylon brush on the
periphery of the screw blades. The brush shall be fixed to the screw blades with
special clamps to allow adjustment of the brushes onto the compactor trough when
wear occurs.
A hinged assembly shall be fitted to the impeller housing(s) to allow for simple
removal of the unit from the Washpactor body.
The Washpactor shall be fitted with low level electrodes of the conductive type to
prevent the unit from operating in a dry condition.
The Washpactor tank roof shall be manufactured from glass reinforced plastic. The
compactor tank covers shall be manufactured from either glass reinforced plastic or
black RPC.
The Washpactor shall be fully electrically wired to a machine mounted junction box.
The Washpactor discharge chute(s) shall be fitted with a hinged extension unit.
19.10.3 Washpactor Performance Guarantee

1) The minimum dry solids content of the Washpactor’s washed screenings
product is 40%.
2) The maximum BOD5 of the Washpactors washed screenings product is 20
mg/g of dry solids.
19.10.4 Shop Tests
1) Motor Tests:
Standard commercial test.
2) Washpactor Tests:
a) Provide check list showing that materials, types and ratings of the screws,
motors and electrical connections and shop test are in accordance with the
contract documents.
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Dubai Municipality
b) Test for correct rotation and current draw.

c) Provide certified test data confirming performance guarantees.
d) The equipment shall be shop tested in the presence of the Employer and the
Engineer at the discretion of the Engineer the cost of which shall be borne by
the Tenderer.
19.10.5 Spare Parts
Furnish a list of spare parts items required for washpactor and deliver to Employer:
1) One set of manufacturer’s spare parts for each size of washpactor with all
parts identical and interchangeable for similar equipment.
1) One set of special tools.
2) Any other item recommended by screens manufacturer as operational spares
2 years of trouble free operation.
3) The tenderer shall include these items under the washpactor price in the Bill of
quantities and the list of spares required shall be approved by the Engineer
prior to ordering.
Install items in accordance with manufacturer's printed instructions.
19.10.7 Field Performance Tests

After installation and services of manufacturer's factory trained engineer, operate
each unit to demonstrate ability to continuously operate without vibration, jamming,
and overheating.
Make all adjustments necessary to place equipment in working order at time of

testing.
Remove and replace equipment at no additional cost to the Employer if unable to

demonstrate to the satisfaction of the Engineer that the mixer assemblies perform the
services specified and that they will operate free from vibration and overheating and
that the hoist system operates properly.
19.10.8 General requirements for all screening and compaction equipments

i. All anchor bolts used for installation shall be SS 316 resin anchors.
ii. All construction bolts including those for Carriage motor, gear box and
Plummer blocks shall be SS 316.
iii. Protective coating for motor, gear box and Plummer blocks shall be approved
two component epoxy to thickness 300 micron DFT.
iv. All limit switches shall be IP 68 even if not submerged and shall be easily
accessible.
v. Radial guide / cog wheel and bearing at the bottom and drive chain for raking
mechanism submerged in sewage shall be protected from fibrous materials,
timber logs , even metallic objects, sand and solids in flow stream by suitable
flow deflectors. Guaranteed service life for bottom bearing shall not be less
than 5 years.
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Dubai Municipality
vi. Raking mechanism shall be heavy duty and suitable to handle the larger
objects/rubbish like GRP sealing plates in sewage.
vii. The torque limiter shall be suitable for the limited number reverse / forward
operation of rake in the event of such heavy blockages. Electronic Torque
limiter suitable for highest ambient temperature and corrosive environment
specified shall be provided in addition to the mechanical torque limiter to
guarantee additional protection to raking mechanism and this device shall
activate on failure of the mechanical torque limiter in the event of heavy
blockages.
viii. All metal surfaces (except machined mating surfaces and stainless steel) shall
be blast cleaned as specified and coated with two component epoxy to 300
micron DFT
ix. Screening Equipment shall have all local control boxes of appropriate IP65
protection rating in S.S 316
19.11 BAR SCREEN AND SCREENINGS HANDLING EQUIPMENT FOR

DRAINAGE PUMPING STATION
The Screens and Screenings Handling Equipment for Drainage Pumping Station
includes the Bar screen, Raking machine, overhead monorail system, travelling
trolley, grab unit, portal frame structures, trash collection skips and other
appurtenances.
19.11.1 General
All equipment and components shall be designed for the Dubai, UAE climate having
salt laden dusty atmosphere.
Only tropical grade materials shall be used throughout the installation.
Sun shading shall be provided for all outdoor installations to ensure that plant and
equipment operates satisfactorily in the specified ambient conditions.
De-rating of electrical equipment and cables shall be done in accordance with the
specified climatic conditions.
Electrical panel and equipment shall be suitable for continuous operation in an

ambient temperature. The fact that control room be air conditioned shall not be taken
into account.
Upon the commissioning, the raking machine shall be tested and certified by
competent authorities (third party inspection) for SWL of 500 Kg.
19.11.2 Materials
Bar screens : Stainless Steel Gr.316L
Monorail Track : Hot Dipped Galvanised Mild Steel
Structural Columns : Hot Dipped Galvanised Mild Steel
Trolley Enclosure : Stainless Steel Gr.304
Trolley Frame : Hot Dipped Galvanised Mild Steel
Grab : Stainless steel Gr.316L
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Hydraulic hose drum : Stainless Steel Gr.304

Cable Drums : Hot Dipped Galvanised Mild Steel
Fixings & Fastenings : Stainless steel Gr.A4
Hydraulic Tank : Carbon Steel Epoxy Painted
Hydraulic Oil : As per vendor recommendation
Hoist Cable : Stainless Steel Gr. 316L
Cable Trolley : Stainless Steel Gr. 304
Sprockets : Carbon Steel epoxy coated
Chains : Stainless steel Gr. 316L
Dome Nuts : Stainless steel Gr. A4
Cases for External Switches : GRP or thermoplastic (UV resistant)
Cable Ducting : Stainless Steel Gr. 304
Cable Clamp : Aluminium
Structural Steel: Provide in accordance with ASTM A36.
Iron Castings: Provide in accordance with ASTM A48 Class 30.
Provide Type 316 L stainless steel for fasteners and hardware.
Stainless steel in accordance with AISI 329, AISI 410.
Provide finish coats for all materials except stainless steel in accordance with the
specifications.
19.11.3 Description
The screening handling equipment (Raking Machine) includes the overhead monorail
system, a travelling trolley, a grab unit and other appurtenances. The screenings skip
of minimum 6 m3 volume shall be provided and is shall consist of heavy duty wheels
and perforated at the bottom. The make & material of construction shall be as per
Dubai Municipality approved make for the skips.
The overhead monorail shall be formed from minimum 10 mm thick single plate to the
required section. The overhead monorail shall include a track for the drive and
support wheels fitted to the top of the travelling trolley.
The single overhead track shall be supported on hollow steel columns and extend
over the width of the bar screen and the screenings unload / dump area, where
screenings collection skip is located.
The trolley unit shall contain the hoisting unit for the grab and the hydraulic power
pack for the operation of the hydraulic cylinder on the grab itself. It is traversed by a
geared motor unit mounted on top of the trolley at one end. Polyurethane coated
heavy duty wheels fitted directly to the gearbox output shaft, run on the inside of the
monorail sections. A second pair of free running support wheels keeps the trolley
parallel with the track.
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Power to the trolley will be supplied by a trailing cable (festoon cable and track
system) which contains both power and control leads and is supported on cable
carriages also running in the monorail sections.
The grab unit shall consist of a series of fingers which are opened or closed by a
hydraulic ram. The hydraulic hoses, carrying power to the ram from the power pack in
the trolley, shall wound on one spring tensioned drum which will operate in sequence
with the hoisting drums for the grab support ropes. The grab is laterally held in the
upper position by spring loaded swing restrictor plates.
In operation, the trolley and grab with the fingers open, moves out along the monorail
until it is in the first raking position. Here a proximity switch on the trolley senses a
position plate on the monorail, the trolley stops and the grab is lowered.
As the grab descends, the downstream fingers engage with the screen bars and top
bars on the grab push any accumulated debris to the screen invert. At the invert, the
grab stops and the fingers are closed by the hydraulic rams. The grab is then raised,
together with any collected debris.
When the grab reaches its top position, the trolley is traversed back to the selected
dump position (skip location position / area) where the fingers are opened and the
debris is deposited. The trolley and grab then return to the next raking position.
The raking system should have minimum three raking position (or as required for the
screen width) for the overall width of the bar screen. Each raking position shall be
controlled by a proximity plate on the monorail and the position selected is
determined, in automatic mode, by a Programme Logic Controller (PLC). When all
positions have been raked, the trolley returns and stops at a pre-determined park
position.
If a large amount of debris or other obstruction prevents the grab reaching the screen
invert, slack rope devices on the trolley stop the lowering motion, the fingers are
closed and the grab lifted. The collected load is taken to the dump area and
deposited. The trolley then travels to the next raking position and continues its cycle.
The top and bottom hoist limits shall be determined by a rotating cam switch unit. In
addition to the switches for determining the raking and dump positions, limit switches
shall be provided to each end of the trolley to prevent it from contacting the end of the
monorail.
The hoist and slack rope proximity switches shall be backed up by direct contact
mechanical limit switches, as a safety precaution.
The hydraulic power to the grab shall be supplied by an electrically driven pump
directly mounted on a tank in the travelling trolley.
When the grab reaches the screen invert, the downward travel is stopped by the
preset limit switch, the hydraulic pump motor shall starts and a spool valve should
directs the oil to close the hydraulic ram.
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The electrical controls then continue the sequence until the trolley is in the dump
position where the spool valve moves to the open position and the hydraulic pump
motor is again started.
As soon as the ram is fully open, the hydraulic pump motor should stop and the
electrical sequence controls shall be re-activated.
In addition to the pressure and spool valves mentioned above, a controlled return flow
valves in the lines to the hydraulic ram and a pressure safety valve to the pump
discharge shall be provided.
A return filter with a renewable element shall be provided on the tank cover. The filter
element shall be spring loaded to facilitate bypass in the case of blocked element.
A timer shall be included in the PLC circuit to prevent loss of oil in the event of a pipe
fracture. A pressure gauge and oil level sight glass are also fitted.
19.11.4 Operation for Automatic Raking Machine

Manual Control at the Machine
With the selector switch on the control panel set to “Remote Manual”, the Raking
Machine to be operated locally by a pendant type push-button station which will be
plugged into a socket on the local control panel.
Push-buttons will be provided on the pendant to operate the traverse, hoist and
cylinder controls individually.
Automatic Control
With the selector switch on the control panel set to “Automatic”, the Raking Machine
to be operated by either of the following methods.
 By depressing the “start ” push-button on the interface
 By variable periodic timer control
When the start command is given, the trolley/grab will travel from the parked position
to the first screen raking position and commence automatic cycle as described.
19.11.5 Unit Control Panel

Electrical controls for the automatic operation of the raking machine shall be
contained within a single compartment wall mounting unit control panel.
i. Construction : 2 mm thick 316 stainless steel, folded and

welded, wall mounted enclosure
ii. Cable Ducting : Stainless Steel Gr. 304
iii. Protection : IP65
iv. Finish : Milled finish
v. Dimensions (each control panel) : 900mm high, 600mm wide, 320mm deep
vi. Locking Mechanism : Spanner locks
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The unit control panel components and starters shall comply with electrical
specification. The unit control panel shall be provided complete with 24vdc power
supply, PLC, communications module and human machine interface.
Pendent control station for field manual operation.
Audible and visual warning device to indicate that the machine is operating, mounted
on the leg of columns.
Junction boxes, power, control and signal cables complete.
19.11.6 Shop Tests

Provide check list showing that materials, types and ratings of the equipment, motors
and electrical connections and shop tested in accordance with the manufacturer
standard.
Test for correct rotation and current draw.
Provide certified test data confirming performance guarantees.
The equipment shall be shop tested in the presence of the Employer and the
Engineer and the cost shall be borne by the Contractor.
19.11.7 Spare Parts

Furnish a list of spare parts items required for screening handling equipment and
deliver to Employer:
i. One set of manufacturer’s recommended spare parts for screens and screening
handling equipment.
i. One set of special tools.
ii. Any other item recommended by screening handling equipment manufacturer
as operational spares 2 years of trouble free operation.
iii. The Contractor shall include these items under screening handling equipment
price in the Bill of quantities and the list of spares required shall be approved by
the Engineer prior to ordering.
19.11.8 Field Performance Tests
After installation and services of manufacturer's factory trained engineer, operate
each unit to demonstrate ability to continuously operate without vibration, jamming,
and overheating.
Make all adjustments necessary to place equipment in working order at time of

testing.
Remove and replace equipment at no additional cost to the Employer if unable to

demonstrate to the satisfaction of the Engineer that the mixer assemblies perform the
services specified and that they will operate free from vibration and overheating and
that the hoist system operates properly.
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19.11.9 General requirement for all screening and compaction equipment

All general requirements for screening and compaction equipment detailed for
sewerage are applicable for drainage also.
19.12 PUMPS
This Specification shall be read in conjunction with Section 17 & Section 18.
19.12.1 Pump Performance

a) The pump head versus flow characteristic shall be stable and rise continually to
close valve head and be non-over loading.
b) Pump testing to be in accordance with BS EN ISO 9906.
c) The closed valve head shall be a minimum of 110% of the duty head.
d) The motor shall have a continuous maximum rating which shall be 10% greater
than the maximum absorbed power at any point in the operating range of the
pump within the system characteristics. In each case the de-rating will be
sufficient to maintain the class B temperature rise in accordance with BS 4999
and PD 5000.
e) The net positive suction head (NPSH) required shall be compatible with that
available to enable the pump to operate without cavitation, over the full range of
flows at all sump liquid levels.
f) Contractors shall select the most economic pumps given the constraints of the
operating parameters, as operating costs will be considered in association with
the capital costs in the evaluation.
g) The Contractor shall carry out a feasibility study to determine the best capital
investment with respect to the hydraulic performance. OPEX (Operational costs)
i.e. pump running costs including power and whole life costs shall also be
considered and shall be issued to the Engineer / DM for approval.
h) Pump speeds shall not exceed 1500 rpm for pumps delivering less than 30 l/s
and shall not exceed 1000 rpm for pumps delivering greater than 300 l/s.
i) Contractors shall provide technical brochures, for the plant proposed and this
shall include full technical details of thrust bearings, lubrication, and sealing and
protection devices.
j) Where forced ventilation is necessary in order to maintain the design output,
details of the rating of fan motors used for this purpose shall be included in the
tender document. The additional loading represented by forced ventilation fans
will be taken into account when calculating overall system operating efficiency.
k) The velocity through the eye of the impeller shall not exceed 3 metres per
second. Although this does not apply for pumps with “free-flow” vortex type
impellers, it shall be used as a guide to prevent pump selection with excessive
velocities through the pump.
l) Minimum or maximum size impellers for the casing are not permitted. The
Contractor must confirm duty diameters as well as maximum and minimum
diameters in the pump technical schedule.
m) For pumping stations delivering flows in excess of 10m3/Sec, the Pump Supplier
shall cooperate with the Principal Contractor to construct a fully operational
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Dubai Municipality
1/10th scale model of the installation to determine the pumping station

performance at a range of flows.
n) This model shall be utilised to specifically determine the following:
iii. Grit deposition.
iv. Screenings settlement.
v. Initiation of eddy currents in the pumping station under all combinations of
pump operations.
19.12.2 Pump Casing

19.12.2.1 Material
a) The pump casing shall be high grade cast iron and be abrasive resistant, capable
of taking shock loads and incorporate lifting eyes located for removal of the
pump. However, for some applications stainless steel will be specified in the
technical schedules.
b) Pump casings and discharge pipe work, up to and including the isolation valves
and non-return valves, shall be rated for the maximum closed valve head
developed; inclusive of the maximum suction pressure or 16 Bar, whichever is
the greater. Pump casings shall be tested to twice the working pressure, or the
maximum surge pressure, whichever is the greater.
c) Pipe work including inline equipment downstream of the isolating valve shall also
be rated for the closed valve head developed unless it is open to atmospheric
conditions.
d) Collared lifting eyes shall be provided for each pump set in accordance with
Lifting Equipment Specifications.
19.12.2.2 Tappings, Hand holes & Drains
a) Tappings for pressure gauges shall be incorporated in the casing except for
submersible pumps. The drain plugs shall be provided at the lowest point of the
casing and automatic air release valves from the top of the casing except for
submersible pumps. Each shall be complete with isolating cocks and bleed lines,
to the bedplate tundish (for water pumps), to the pump sump for sewage pumps,
and shall be provided on each stage of the pump. The air release pipe work
shall be not less than 15mm bore, shall be of stainless steel, and shall be fitted
with crosses and couplings to facilitate rodding. A shut off valve of Saunders full
bore straight through type or similar shall be fitted at the high point(s) and a
check valve of approved manufacture shall be fitted above this. Drainage pipe
work shall be fitted as close to the lowest point of the pump suction as is
practicable. The minimum size drainage pipe work and valves shall not be less
than 50mm bore for sewage pump sets. Pipework shall be led to the drainage
system and shall not discharge direct to the floor.
b) For large sewage pumps which are not submersible, hand holes shall be
provided in the pump casing and suction bends to facilitate the clearance of
obstructions which may occur. The hand hole covers shall be shaped so that the
interior profile of the waterway conforms when the cover is in place.
c) Pump inlet and outlet flanges shall be rated to 16 bar as a minimum.
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d) Clean water and irrigation pump sets shall be fitted with pressure gauges with
minimum 3/8” BSP fittings on the suction (except submersible) and delivery
branches, complete with stainless steel or brass isolating cocks and snubbers.
For sewage pump sets tappings shall be 50mm NB and fitted with a diaphragm
seal between the sewage and the pressure gauge. Pressure gauges shall be
150mm nominal diameter “Industrial” type. Pressure gauges shall comply with
Section 16690: Pressure Gauges, Dial Thermometers and Pressure Switches.
e) Except for submersible pumps, pump casings shall be specifically designed for
bed plate mounting using support feet machined to a finish to suit its intended
bed plate and incorporating holes drilled and spot faced for holding down bolts.
The feet shall accommodate and transfer all loads to the supporting bed plate.
f) The casing halves shall be accurately aligned during assembly to match the
volute profiles and be doweled to ensure certain repositioning after disassembly.
Means shall be provided to facilitate the separation of the casing halves. On
larger castings this shall be by two or more jacking screws.
g) A separate removable suction casing shall be provided, to gain access to the
impeller without dismantling the discharge pipe work.
19.12.3 Casing Wear Rings
Casings wear rings shall be locked to prevent rotation by dowel or similar approved
method. Ease of replacement shall be a major design criterion. The wear rings shall
be of bronze for potable water or cast iron for sewage and designed such that
hydraulic pressure aids the sealing of the ring into the pump casing. Stainless steel
may be used. Casing wear rings shall be incorporated on all rotating / stationary
interfaces, except for low head sewage pumps such as Vortex types
19.12.4 Bearings
a) The pump shaft shall be supported at both ends by single row bearings with an
option to fit a pair of angular contact thrust bearings if required. Bearing
housings shall have the ability to be retrofitted with a pair of angular contact
bearings without re-machining. All vertical pumps shall be fitted with a pair of
angular contact thrust bearings at the drive end.
b) Bearings shall be either oil or grease lubricated, and shall comply with the
bearings section of this specification. Oil lubricated bearings shall be fitted with a
constant level oiler. “V” ring seals shall be provided on the bearing housings.
c) Except for submersible pumps, bearing housings shall be a separate component
and not integral with the casing, to allow replacement of bearings, seals and
sleeves without removing the top half casing when fitted with a spacer coupling.
d) Bearing housings shall have full flange bolting to bottom and top half casings with
a full registered fit. Except for submersible pumps, bosses shall be provided for
vibration monitoring transducers.
e) Where bearing lubrication is by oil, suitable means of filling and draining it shall
be provided together with a suitable means of level measurement.
f) Bearing temperature measurement / protection shall be as specified by DM for
certain non-immersible applications.
g) For aggressive sewage environments, stainless steel bearings shall be offered
as an alternative, for consideration by DM.
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19.12.4.1 Thrust Bearing
a) The axial thrust generated shall be taken by an appropriate thrust bearing

arrangement.
b) Thrust bearing arrangements incorporated into the motor housing are not
permitted.
c) Setting of thrust bearings shall account for dynamic loading albeit setting is
carried out with the machinery stationary.
19.12.4.2 Rolling Element Bearing
Ball or roller bearings shall be sealed for life. They shall be rated to give a minimum
life of 100,000 hours at maximum load without replacement. Bearings shall be
protected by water throwers and lip seals.
19.12.4.3 Water Lubricated Submersible Bearings
a) Submersible bearings in shaft driven pumps, such as for irrigation, shall be of the
water lubricated type with corrosion resisting outer shell and internal lining of high
resilience and abrasive resisting properties. The shaft should be protected
locally with shaft sleeves to ensure that particles in suspension in the water do
not cause premature wear.
b) Intermediate support bearings shall be housed in a spider arrangement spigotted
to the discharge column flanges to ensure concentricity. The upper water
lubricated bearings shall be maintained in a lubricated condition particularly on
pump start up, in order to avoid dry running of the bearing.
19.12.4.4 Plain/Bush Bearings
Bush bearings, where utilised, shall be in bronze or as otherwise specified in the

technical schedules, split for easy maintenance, and positively locked to prevent
rotation.
19.12.5 Sealing
19.12.5.1 General
a) The means of sealing shall be dependent upon the application and unless
otherwise required by the Contract shall be as follows:
i. Raw Water : Mechanical Seal
ii. Final effluent/irrigation: Mechanical Seal
iii. Potable Water/Irrigation Water: Mechanical Seal
iv. Sewage: Mechanical Seal
v. Sludge: Soft Packed Gland
b) Adequate access shall be provided to allow maintenance of the shaft sealing

arrangement together with drainage facilities to allow the piped waste of any
sealing lubrication water.
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19.12.5.2 Soft-Packed Gland
a) Gland packing shall be graphite impregnated PTFE, of approved

manufacture. Asbestos based packing will not be permitted.
b) The gland design shall incorporate the following:
i. A tapered “lead-in” at the mouth of the gland entry to facilitate packing
replacement and obviate the risk of damage on assembly.
ii. The surface finish of the adjacent metal parts shall be 0.4µm CLA on the
shaft gland sleeve and 1.6µm CLA on the stuffing box bore.
iii. Where running clearances are excessive, the packing shall be protected
by an independent ring of suitably robust material which reduces the
clearance to a minimum.
iv. The packing must not be used as a bearing.
v. All studs, dowels and adjustable nuts shall be manufactured from stainless
steel.
vi. Lantern rings shall be of gun metal or bronze or stainless steel for irrigation
and shall be split for ease of removal. Stainless steel lantern rings will be
used for all aggressive applications.
vii. Pumped water supplies to the lantern ring shall be free from abrasive
solids.
19.12.5.3 Mechanical Seals
a) Mechanised seals shall be designed to operate with a positive suction head and
delivery head as specified. The seals shall, not under normal conditions permit
any controlled leakage from the pump.
b) The Contractor shall specify the type, size and material of the mechanical seal he
intends to supply. It shall be the responsibility of the pump manufacturer to
ensure, and to demonstrate in supporting technical information submitted for
design approval, that the tolerances required by the seal manufacturer are not
exceeded. Checks shall be carried out on the pump casing and shafting for:
i. Shaft straightness
ii. Rotational balance
iii. Shaft run-out
iv. Bearing clearance – lateral and radial movement
v. Shaft tolerance and ovality
vi. Concentricity
vii. Seat squareness
viii. Coupling alignment
c) The Contractor shall ensure and demonstrate in supporting technical information

submitted for design approval, that the seat, face and component materials of the
mechanical seal are suitable for the media being sealed. Under operational
conditions thermal loading of the seal components shall be within the capacity of
the seal to ensure that wear rate is minimised.
19.12.5.4 Seal/Gland Drainage
a) Except for submersibles, seal/gland drainage shall be collected in a collecting try

formed integrally with the pump casing stuffing box. The tray shall not extend
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Dubai Municipality
high enough to submerge the gland in the event of drain, hole blockages.
Drainage shall be piped to the bed plate tundish located at the non-driven end of
the pump. A water thrower shall be fitted to the shaft between the pump seal and
the motor.
b) The final discharge shall be piped individually from each pump to the drainage
channel in the pump house basement. The drain pipes shall be 38mm dia
stainless steel tube fitted with couplings so as to facilitate removal of any
possible blockages. The tundish opening should be protected with a stainless
steel mesh insert.
19.12.6 Pump Shaft

19.12.6.1 Shaft Sleeves
a) Where shafts are exposed to the process fluid and where they pass through the
sealing gland they shall be fitted with keyed sleeves of bronze or stainless steel,
positively driven and which extend through the stuffing box. The finish of the
sleeve at the seal faces shall be highly polished (15 microns). Where a pump is
drawing water containing suspended solid material then stainless steel sleeves
shall be fitted. The sleeves shall be sealed with an “o” ring and keyed to prevent
rotation. The sleeve shall terminate in the cradle area, to prevent any water
ingress into the buildings.
b) The diameter of the sleeve shall not be taken into account when calculating shaft
stiffness.
c) Shafts shall be of stainless steel. The lower section of any shaft drives shall be
designed to be readily removable to facilitate maintenance.
d) In a dry shaft arrangement a lower grade of shaft material may be used with a
duplex stainless steel shaft protecting sleeve.
19.12.6.2 Balance
a) The whole of the rotating assembly, including impeller locking key(s) but
excluding the impellers shall be dynamically balanced as an integral component.
b) The impellers shall be dynamically balanced separately and then assembled to
the shaft, to form without further adjustment, a dynamically balanced whole.
19.12.7 Centrifugal Sewage Pumps
19.12.7.1 General
a) Submersible pumps shall be capable of running partially or totally submersed in a

wet well configuration without overheating. They shall also be capable of
withdrawal from the wet sump without the requirement for entry to the wet sump
for disconnection by maintenance personnel.
b) Pump and motor units shall be designed for a working life of 100,000 hours with
overhauls at not greater than 20,000 hour intervals. All components shall be
capable of renovation during overhaul making maximum use of readily
replaceable parts.
c) Pump motors shall be of premium efficiency.
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19.12.7.2 Casing
a) Except for submersibles, the pump casing shall be provided with adequate
access for internal inspection with the minimum of dismantling. External hand
hole covers shall be provided and the contour of the internal volute should not be
affected when the cover is in place.
b) The external surface of the pump casing shall be fusion bonded epoxy coated,
with a minimum thickness of 300 micron.
19.12.7.3 Impeller
a) The Impeller shall be selected by the manufacturer for its ability to handle
sewage. The impeller shall be of the screw, torque flow or semi-open mixed flow
types and made from high grade cast iron, or duplex stainless steel. Ni-hard cast
iron shall be used where high grit content is likely. Provision shall be made to
prevent the build-up of solids behind the impeller. Hydraulic balance holes are
not permitted.
b) Each pump shall be capable of passing a 100mm minimum diameter spherical
solid through the impeller and associated passages without , and be designed for
the sewage and conditions of Dubai. In exceptional circumstances where the
passage size has to be reduced to meet the duty then smaller passages down to
80mm shall be approved by DM.
c) The leading edges of the impeller shall be capable of shearing any rags or
plastics within the pumped media without chipping or splitting.
d) The impeller shall be positively secured to the high tensile steel or stainless steel
pump shaft and dynamically balanced as a whole.
19.12.7.4 Pump Inlet and Outlet
The inlet of the pump must be positioned so that the circulation of fluid to the intake
is not impaired by benching in the sump.
19.12.7.5 Submersible Pumps
Seals Design
a) The pump motor shall be protected by a tandem mechanical seal arrangement.

Lip seals are not permitted. The Contractor shall provide complete data on the
seal materials, seats, faces etc., and ensure suitability for the medium being
sealed.
b) On pumps greater than 5kW the mechanical seal performance shall be by
monitoring equipment to detect the following:
i. Moisture within the oil chamber.
ii. Moisture/water or oil within the motor casing.
iii. Temperature rise of the hydraulic driven end bearing.
iv. Loss of oil from the oil chamber.
Cooling
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Dubai Municipality
Cooling of the motors shall be provided by one of the following methods with the
Contractor supplying and installing all of the necessary equipment:
i. On units of less than 7kW cooling may be provided by the casing provided
that the application meets the manufacturer’s requirements for heat
dissipation. Cooling must be sufficient when pumping at sump levels at
top of pump volute.
ii. Oil cooled motor with a heat exchanger in the base plate to the pump bowl.
iii. Water jacket utilising sewage as the cooling medium. A filtering gap shall
be provided to prevent large solids blocking the cooling passages. This
cooling method is not permitted for sludge pumps.
iv. Air cooled for immersible pump sets installed in dry well conditions.
Motors shall be suitable de-rated for the maximum ambient air
temperature.
v. Motors provided with variable speed drives shall not be operated at a
speed below which heat dissipation is reduced below the manufacturer’s
recommendations.
Pedestal
a) The pedestal shall be manufactured from cast iron / stainless steel and shall
incorporate a boltless automatic connection between the pump and the discharge
pipe work and provision for locating and retaining the lower ends of the pump
guide system.
b) The outlet flange of the pump shall seat firmly on the outlet flange of pump stool
with the weight of the pump, and shall not leak when the pump is operating at
maximum pressure.
c) Where submersible pump sets are utilised in a drywell situation, the pump inlet
bend / duckfoot support shall include a quick release hand access to facilitate
impeller eye clearance.
Guide Rails
A guiderail system of stainless steel Grade 316L, schedule 80, tubing shall be provided
to ensure simple and effective removal and reinstallation of the pump set. The system
shall be vertical over its entire length, be retained at the bottom by fixings forming part
of the discharge connection and at the top by a bracket / access frame arrangement.
The guide system shall be retained at the lower end by the pump pedestal and at the
upper end by mounting brackets. Guide wires are not permitted.
Guides
The pump body shall be provided with either detachable or integral guides. The guides
shall be accurately manufactured to permit the lowering of the pump without swing or
seizure until connection is made with the pump discharge connections.
19.12.8 Horizontal Mounting

a) Horizontal pump sets shall have the pump and motor mounted on a common
bedplate of cast iron or fabricated steel which shall incorporate machined
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Dubai Municipality
reference surfaces to permit levelling of the assembled pump set on its

foundation. The bedplates shall be fully supported on sets of steel packers and
shims which shall be not less than 80mm wide or twice the width of the bedplate
frame drilled for positive location by the same. Not more than three packers shall
be used.
b) The pump shall be mounted on and bolted to the bedplate and unless positively
located be dowelled in its final position with not less than 0.75mm of brass
shimming between the pump and bedplate. The motor shall not be dowelled until
after final alignment on site has been subject to a pre-construction review by the
DM. Dowel pins shall be Grade A in accordance with BS 1804 Part 3 or
equivalent.
c) Back pull out pumps shall comply with is EN 25199.
19.12.9 Vertical Mounting

19.12.9.1 Close-Coupled
Close-coupled pump sets complete with motor shall be mounted on a rigid stool
incorporating the coupling, coupling guards and thrust bearing where applicable.
19.12.9.2 Shaft Driven
a) Where the design requires the pump to be mounted on a separate floor below
the drive motor because of the possibility of pump room flooding or for the
purposes of locating motors adjacent to switchgear, shaft driven pumps shall be
provided. The shaft may be open or enclosed and shall incorporate intermediate
steady bearings as determined by the transmitted power, speed, length and
diameter. Intermediate shaft lengths shall not exceed 3m and shall run below
their first critical speed, and be vibration free. Shafting shall be of high tensile
steel adequate to avoid the possibility of fatigue failure and flexible joints of the
“Hardy Spicer” or constant velocity joint type shall be provided.
b) Couplings shall be provided to permit the removal of drive shafts, bearings, etc
without removing the pump or motor. Couplings between the thrust bearing and
motor shall be accommodated within motor support stools.
19.12.9.3 Support
a) The shaft shall be supported such that the weight of the shaft is not transmitted
to the pump and motor bearings. A thrust bearing assembly shall be
incorporated into the drive motor stool to take the weight of the shaft and include
all necessary ventilation and cooling coils if required.
b) Each intermediate shaft shall be independently supported and designed such
that there is no transmission of vibration between supports via walkways, support
steelwork, etc.
c) The Contractor shall be responsible for the design, provision and erection of all
support steelwork for the support bearings.
d) The Contractor shall provide balancing test sheets for the balancing of the
complete fabricated shafts at the Works, for approval under the submittals
section of the general workmanship section of this specification.
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19.12.9.4 Support Stool
The support stool shall be manufactured from either close grained cast iron, ductile
iron or fabricated steel. The stool shall be founded on a separate foundation plate
permanently bolted and grouted to the structural floor. The motor stool shall be
located relative to the motor by a machined spigoted flange and to the foundation
plate by the same or dowel pins together with the necessary number of securing
bolts. The upper face of the motor stool shall not be less than 600mm above the
finished motor room floor level.
19.12.9.5 Bearings
a) The intermediate bearings shall be self-aligning ball or roller type housed in

plumber blocks fixed and dowelled to the supporting steelwork, complying with the
bearing section of this specification. Bearing support steelwork shall be sufficiently
rigid to contain any vibration.
b) Bearings lubrication shall be by refillable lubricators giving indication of lubricant
content.
19.12.9.6 Lubrication
Lubrication points or support bearings, universal joint sliders, etc shall be readily
accessible from permanently fixed access platforms provided under the contract or
piped to ground level unless otherwise specified.
19.12.9.7 Balance
After manufacture and assembly, including setting pre-load in the universal coupling
bearings, the shaft assembly shall be dynamically balanced. Completed balancing
records shall be submitted for approval.
19.12.10 Couplings
19.12.10.1 General
a) Couplings shall be provided to permit the independent removal of the pump

or motor.
b) Couplings shall be of the flexible multi-pin and bush type, having not less
than six pin-bushes. Each bush shall have an inner sleeve to allow rotation
on the pin. Bushes shall not be in direct contact with the pin. All pins shall
have shoulders to allow positive location and securing to the bosses.
c) Bosses shall be a tight fit on the shafts and secured with fitted keys.
d) Couplings shall be supplied in matching balanced sets and shall be
machined, balanced and marked before leaving the manufacturer’s
premises.
e) Couplings and all other exposed rotating parts shall be enclosed by guards
and comply with the general workmanship section of this specification.
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Guards over couplings shall be designed to be readily removable without

dismantling any other item or accessory.
19.12.10.2 Coupling Alignment
After coupling alignments the DM shall witness and review the machine alignments
which shall be recorded.
a) The layout of the pump sets shall take into account access to the rotating
elements with adequate clearance between adjacent pumps, pipe flanges,
valves etc. to allow easy access to all parts of the installation for
maintenance.
b) The pipe supports shall be so arranged so that the pump flanges are relieved
of all external loadings from the pipe work. During site erection the
Contractor shall take particular care to ensure that none of the component
parts are stressed due to misalignment of the pipes of other items.
19.12.12 Sump Pumps / Drain Pumps
a) Where specified, sump pumps shall be provided in dry wells where natural
drainage is not possible and in wet sumps which are required to be fully
drained down after a pump cycle, for example, storm pump sump.
b) Sump pumps shall be fully automatic with integral non-mercury level control
switches. Integral level float switches shall not operate on mains voltage.
They shall be free standing and suitable for use with 300mm x 300mm x
300mm drainage sumps.
c) Delivery pipe work shall be ABS terminating with a check valve and isolating
valve adjacent to the drainage sump. For dry well applications, a flexible
hose 3000mm long shall connect the pump to the pipework, complete with
hand tightened threaded pipe union to facilitate removal of the pump without
affecting the pipe work.
d) Sump pumps mounted in wet sumps shall be guide rail mounted and comply
fully with the submersible pump specification.
e) Sump Pumps / Drain pumps shall include complete with all the pipe
supports, electrical power supply, cabling, trunking, ducting and starters,
controls as necessary for proper operation as required by Engineer.
Rotary Pumps are required to pump storm/groundwater or raw sewage containing
rags, fibrous material and general waste matter including grit and other abrasives,
partially treated sewage, sewage sludge and/or grit laden sewage.
Pumps shall be designed to pump satisfactorily solids of 90 mm diameter unless

otherwise specified. Freedom from choking is essential and is more important than
high pumping efficiency.
Pumps unless otherwise specified shall be designed to have stable head/quantity

characteristics, so as to avoid large changes of quantity with small changes of head.
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The pumps shall be capable of operating with the sump surcharged to its maximum
level and the Pump motors shall be rated accordingly.
The fluid velocity at entrance to pump impellers shall not exceed 3.6 m/s for pumps
with suction pipework larger than 200 mm dia. nor 5.5 m/s for smaller pipework. The
fluid discharge velocity shall not exceed 3.6 m/s for all pumps.
Pump bodies, covers, brackets, bearing housings, wearing plates, eye rings, support
brackets, etc., shall be manufactured from close-grained cast iron or nickel iron.
Pump castings shall be of substantial construction to give long life under abrasive
conditions and to enable them to withstand shock loads caused by solids in
suspension.
Impellers shall be of duplex stainless steel for sewage and storm/groundwater

pumps.
Impellers shall be keyed onto shafts.
Shafting shall be of stainless grade 316 S16 or equal of adequate size to avoid the
possibility of fatigue failure. The duty speed range shall be well below the first critical
speed. At any change in diameter of the shaft the shoulder shall be generously
radiused to reduce stress concentration.
The rotating elements shall be dynamically balanced before final assembly.
Pump casings shall be hydraulically tested before assembly to a pressure of 1.5

times the closed valve head of the pump plus the maximum suction pressure.
Cathodic corrosion protection shall be provided for the storm/ground water pumps.
Pumps shall be performance witness tested at the manufacturer’s works by the

Engineer in accordance with the appropriate standard using clean cold water. Unless
otherwise specified pumps shall be tested with the motor which will drive them after
installation.
Mass produced pumps shall be tested at factory or at site or required both (as per
Engineer discretion) to prove the duty/guarantee point of pumps.
Special pumps (i.e. those for which the impeller is specially trimmed or otherwise
designed) shall be tested to prove the duty/guarantee point and to develop
Quantity/Head, Quantity/Power, Quantity/Efficiency curves for the pump at operating
speed, or if the pump is multi or variable speed, at maximum and minimum speeds.
19.12.14 Submersible Pumps

Submersible pumps shall comply with the General Requirements for Pumps.
They shall be close coupled units comprising a single, stainless shaft, a squirrel cage
electric motor and a single entry, end suction pump.
Stainless steel lifting frames or eye bolts shall be fitted to casings for connection of
lifting chains.
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The motor shall be induction type with squirrel cage rotor, housed in an air filled
watertight chamber. The motor shall have IP 68 protection, the stator winding and
stator leads shall be insulated with moisture resistant class H insulation, rated for
180°C but with Class-B temperature rise. The motor shall be specifically designed for
continuously submerged pump usage and shall be rated for operation both when
submerged in sewage or ground water at ambient temperature and when in air The
motor shall be designed for a minimum of 10 starts per hour.
Over temperature sensors (thermal switches or/and thermistors) shall be embedded

in stator coils to monitor the temperature of each phase winding. These sensors shall
be set to open at 140 C° and shall be used in conjunction with and supplemental to
external motor over load protection and shall be connected to the control panel. In
addition, at least one analogue sensor shall be embedded in one of the phase
windings to enable continuous measurement and recording of winding temperature.
Motor shall also have leakage sensor for stator housing for motor-capacity 7.5 kW
and above
Motors above 30 kW rating shall also be fitted with a lower bearing temperature
monitor and stator housing liquid level monitor. The monitoring equipment shall be
designed and installed so that automatic re-starting of the motor is not possible in the
event of a fault. The monitoring units shall be manufactured by the pump supplier
and supplied as free issue to the control panel manufacturer to form part of the
control panel.
Motors shall have a voltage tolerance of plus or minus 10 %.
The power and monitoring cables for motors shall be sized to IEC standards and shall
be of sufficient length to reach the control panel without joints. The motor and cables
shall be capable of continuous submergence without loss of watertight integrity to
depth of at least 30 metres. The cables shall be tough-rubber–sheathed insulated
flexible, highly resistant to heavy mechanical stresses and each core shall be of tinned
copper wires. Pump cables shall be SIEMENS / PIRELLI types N SS HOU-J /
S1BN8-F depending on the size of motor, or equivalent Suspension of cables shall be
with stainless steel cable socks from stainless steel suspension brackets, each cable
shall have separate cable socks.
Two mechanical seals shall be fitted on the shaft between the electric motor and the
pump impeller. The space between these two seals shall be oil filled.
Performance chart shall be provided showing curves for torque, current, power factor,
input / output KW, NPSH required and efficiency. This chart shall include data on
starting and no load characteristics.
Discharge bends shall be of close grained cast iron or stainless steel and shall
provide both pump support and lower guide rail/rope location. The pump discharge
connection system shall be designed so that the weight of the pump provides a
clamping force. Sealing between the pump and bend shall be achieved by the weight
of the pump and there shall be no leakage at the joint between the faces.
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Mounting brackets for the pump shall be of Grade 316 S16 Stainless Steel or close
grained cast iron to an approved international standard.
Guide rails and holders shall be manufactured from stainless steel grade 316 S16
rigidly supported at both ends.
Lifting chains shall be of stainless steel, shall be rated for overhead lifting and shall
include shackles for connection to pump lifting points. They shall be at least 1.50 m
longer than the guide rails. Suspension of chains shall be from stainless steel
suspension brackets.
The lifting chain shall be fitted with a stainless steel tag detailing the safe working
load, the test load and the date of testing and the name of the testing authority.
Pumps in general shall be compliant to the following requirements:
Pump shall be suitable for minimum 10 starts an hour.
Protective coating shall be of 300 micron DFT, holiday-free and shall be suitable for
highly saline ground water and also for sewage with high concentration of hydrogen
sulphide. The coating shall be guaranteed for a minimum period of two years from the
date of commissioning and acceptance by the employer.
The pumps and ancillaries to be in total compliance to specifications in all respects

other than any deviation, due to technical reasons, agreed by the engineer and
approved by the Employer.
Pumps shall operate at best efficiency at the specified duty point.
Pumps shall be suitable for healthy operation over a wide area on the performance
curve without any abnormal vibration or symptom of cavitation. Pumps with operating
point at lower part or higher part on performance curve at the specified duty point
shall not be acceptable.
Pumps shall be designed to pump satisfactorily sewage with a large fibrous materials
and rags without clogging ; impeller shall be non-clogging type .
Pumps shall have suitable wear rings for the impeller and the volute casing.
Pump / Motor protection sensors shall have all wire leads brought out separate using
suitable multi core cable up to the monitoring unit fixed in the control panel. Provision
of integrated sensor module in the terminal box for pumps with common wire leads to
the monitoring unit in the control panel shall not be acceptable. Sensors and
monitoring / control unit shall be totally reliable with longer service life in ambient
temperature of 52 degree celsius in the Emirate of Dubai.
Pumps shall be quite in operation free from cavitation and vibration /rattling over
entire path of performance curve and shaft speed shall not exceed 980 RPM unless
otherwise specified for any particular application.
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Pump guide system: Guide rails longer than 6 metres shall have suitable intermediate
supports; guide rails shall not be supported on riser pipes.
Pump cables shall have suitable additional S.S support bracket to protect the cables
from sharp bend at cable entry on terminal box for motor and brackets shall not
have sharp edges which could damage cables. All propeller pumps with cables in the
flow stream shall have proper cable suspension arrangements to protect the cables
from rubbing against any portion of the discharge column while the pumps are in
operation. Pump cables shall not be tied to lifting chain or rope.
Pump materials shall be according to Table 19-3
Table 19-3 Schedule of Pump Materials

Cast parts Cast iron
Studs, nuts, screws and washers Stainless steel Grade 316 S16
Lifting handle Stainless steel
O-rings Nitrile rubber (700 IRH)
Stationary wear ring Nitrile rubber-clad steel
Rotating wear ring Stainless steel
Upper Mechanical shaft seals Tungsten carbide/Tungsten carbide
Lower mechanical shaft seals Tungsten carbide/Tungsten carbide
Impeller for Storm/Ground water Duplex Stainless steel
Impeller for Sewage Duplex Stainless steel / Close grained Cast
Iron / High chromium Cast Iron (Hard Iron
EN 12513:2011)
Shaft Stainless steel
19.12.15 Axial Propeller Pumps

19.12.15.1 Materials
The pumps shall be of at minimum, the following grades of materials:

i. Impeller (Propeller) Duplex Stainless Steel.
ii. Diffuser Casing: Grey cast iron EN-JL1030 (A 48 Class 30B)/
Stainless steel Grade 316
iii. Casing Wear Ring: Stainless steel EN-1.4571 (A 276 Type 316 Ti)
iv. Inlet nozzle: Grey cast iron EN-JL1030 (A 48 Class 30B) /
Stainless steel Grade 316
v. Shaft: Stainless steel EN-1.4021+QT800 (A 276 Type
420)
vi. Bearing cover: Grey cast iron EN-JL1030 (A 48 Class 30B)
vii. Cable sheath: Waterproof synthetic rubber compound
viii. Elastomer components: Nitrile rubber (NBR)
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ix. Lifting clamp at stopper: Stainless steel EN-1.4462 (A 182 Grade F51)
x. Motor casing cover: Grey cast iron EN-JL1040 (A 48 Class 35)
xi. Lifting clamp: Non-alloy structural steel EN-1.0038
(A 283 Grade B)
xii. Bolts, nuts: Stainless steel A4 (EN-1.4571) (A 276 Type 316)
19.12.15.2 Pump Construction
a) The pump shall be of submersible centrifugal, single stage pumps for installation
in a discharge column driven directly by a fully submersible dry squirrel cage
induction motor. The pump shall be suited for continuous operation in a
submerged condition.
b) The head-capacity curve shall have a single flow rate for each pumping head
value and have a continuously rising head characteristic from the specified
design point to the minimum flow rate so as to ensure stability and control in
individual and/or parallel operation. The operating range of the pump, as
specified, is defined by the maximum and minimum operating heads against
which the pump will be required to operate. At no point within the operating range
shall the pump’s power demand exceed the rated power of the motor.
19.12.15.3 Casing
a) A diffuser casing with a self-centring, force-locked seating for installation in a

discharge column shall be used. Designs requiring additional anchoring or
rotational protection shall not be acceptable. Perfect sealing between the casing
and the discharge column shall be accomplished by an O-ring seal. The single
piece pump casing shall be made of suitable thickness to allow for long pump
life. The inlet nozzle shall have baffle plates for a vortex free inflow. The external
diameter of the pump shall be preferably small in order to minimize discharge
column diameter and friction losses.
b) Critical mating surfaces where watertight sealing is required shall be machined
and fitted with O-rings. Fittings will be the result of controlled compression of
rubber O-rings in two planes and O-ring contact of four sides without the
requirement of a specific torque limit. Rectangular cross-sectioned gaskets
requiring specific torque limits to achieve compression shall not be considered as
adequate or equal. No secondary sealing compounds, elliptical O-rings, grease
or other devices shall be used.
19.12.15.4 Wear Ring
The pump shall be provided with a replaceable wear ring in the pump casing to insure
efficient sealing between the volute and suction inlet of the impeller. It shall be firmly
secured to prevent rotation or displacement.
19.12.15.5 Impeller
The axial propeller shall be of a centrifugal, fiber repellent and self-cleaning, design
for high efficiency pumping of surface water and groundwater. The free passage of
the pump shall be not less than 75 mm. The propeller hub and the 4 blades of fixed
angle of attack shall be a one piece casting of the material as specified. It shall be
smooth, well finished, free from blowholes and imperfections, and be dynamically
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balanced. The impeller shall be positively locked to the shaft with a key and lock nut
designed not to loosen, but be easily removed for maintenance.
19.12.15.6 Pump Shaft
The common pump/motor shaft shall be of sufficient size to transmit full driver output
with a maximum deflection of 0.05 mm (0.002 inches) measured at the lower
mechanical seal. The pump/motor shaft shall be of stainless steel or be completely
isolated from the pumped media through the use of a stainless steel shaft sleeve.
19.12.15.7 Bearings
The shaft shall rotate on at minimum 3 / 1 antifriction bearings. The bearing system
shall be adequately designed so as to be capable of handling all axial thrust loads
plus any and all radial loads. The pump bearings shall be regreasable.
19.12.15.8 Shaft Seal
a) Each pump shall be provided with two totally independent, mechanical seals,
installed in tandem, each with its own independent single spring system acting in
a common direction. The sealing shall not depend on the direction of rotation.
b) The primary, impeller-side seal shall operate in a large flooded chamber formed
by cast recesses in the impeller and backplate. The impeller-side seal shall be of
bellows type mechanical seal.
c) The primary and the secondary seal faces shall operate in a generously
proportioned lubricant chamber that hydrodynamically lubricates the seal faces to
allow for extended periods of dry-running operation without the need for external
seal lubrication or cooling systems.
d) The lubricant chamber liquid shall be an environmentally friendly and nontoxic.
e) The seal face material of the primary seal shall be of at minimum Silicon Carbide
versus Silicon Carbide (SiC/SiC) for excellent hardness and chemical resistance
across the entire "pH" range. The secondary seal shall be of Carbon versus
Silicon Carbide (Carbon/SiC) for best emergency running properties. The seal
faces must be of a solid material capable of being re-lapped. The seals shall
require neither routine maintenance nor adjustment, but capable of being easily
inspected and replaced.
f) Mechanical seal metal parts shall be of CrNiMo-stainless steel.
g) Seals shall be non-proprietary in design, and shall be available from another
vendor in addition to the pump manufacturer.
h) Conventional double mechanical seals with a single or multiple springs acting in
opposed direction, cartridge-type mechanical seals; seals with materials other
than those specified; shall not be considered as adequate for this critical sealing
area.
19.12.15.9 Bolts and Nuts
All nuts or bolts exposed to the pumped media shall be of stainless steel grade 316
as specified.
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19.12.15.10 Nameplate
Each pump shall be provided with a stainless steel nameplate firmly attached to the
pumping unit. It shall be clearly and durable inscribed with the manufacturer's name,
year of manufacture, pump-type, serial number, and principal rating data. For easy
identification of the submerged pumping unit, a second equal nameplate shall be
supplied along with its documentation for attachment outside the wet well.
19.12.15.11 Protective Coating
a) All exterior metal surfaces of the pump shall be subject to following preparation
and coating procedure except name plates, bright parts and stainless steel parts.
b) The preparatory treatment of cast and welded components shall be
accomplished in accordance to Sa 2 1/2 to SIS 055 900. (Identical to ISO 8501-1
/ ISO 12 944-4 and DIN 55928, Part 4).
c) Scale, rust and coatings shall be removed by steel grit blasting to such an extent
that that any residues on the surface remain visible only as a light tinge due to
shaded pores. Cleaning of the sandblasted surfaces shall be done by vacuum
cleaning, blasting or brushing off.
d) The primer when using Zinc dust or Zinc phosphate base shall have a dry film
thickness of not less than 50 microns.
e) An abrasion and shock-resistant, non-porous 2 component epoxy resin base
coating shall be used. It shall be resistant against many diluted acids and brines
as well as grease, oil, solvents and seawater and especially suited for use in
hydrous media. The solids content shall be not less than 82%.The shop-applied
top coat shall have a dry film thickness of not less than 320 microns. The colour
shall be as approved by the Engineer.
f) Name plates shall be masked or removed prior to surface preparation and
coating. Polished parts and surfaces (shafts, couplings) shall be preserved /
protected against corrosion.
19.13 ODOUR CONTROL EQUIPMENT

19.13.1 General
Odour problems are typically associated with the development of anaerobic
conditions (septicity) in sewage or sludge resulting in the formation of a range of
malodorous compounds by the action of bacteria. The main compound associated
with sewage and sludge odours is hydrogen sulphide (H2S), which is also a toxic and
corrosive gas.
Odorous compounds cause a problem if they are released to atmosphere and if there
are residential/trafficked areas close to the site that may be affected. An assessment
shall be taken of the likely impact the pumping station/treatment works shall have on
the locality and the deodorisation requirements fitted/sized accordingly to DM’s
approval.
19.13.2 Ventilation and Odour Treatment

a) All buildings containing sewage or sludge processes will need some form of
ventilation to avoid build-up of potentially hazardous (explosive or toxic)
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atmospheres.
b) The odour control system shall be designed for removal Sulphide Odour up
to 99.99%(minimum) at the discharge of the odour removal unit stack.
c) The design of the ventilation and odour control system shall take in to
account the handling of potentially hazardous gases, and the zone
requirements of the area in which it is installed.
d) Odour releasing units (such as screens or belt presses) within a building
shall be locally enclosed, and a proportion of the required ventilation air
drawn from the body of the building towards the odorous unit to ensure
odours do not escape into the body of the building.
e) Siting of stacks and emergency vents shall be away from potential
complainants.
f) The choice of odour treatment process and the number of treatment stages
depends on:
i. Flow rate of air to be treated.
ii. The strength and composition of the incoming air and whether intermittent
or continuous.
iii. The percentage removal required (the standard of odour treatment
required to avoid an odour problem shall be derived from odour dispersion
modelling).
iv. Space availability and zoning requirements of the proposed location.
g) The design of odour control unit, ductwork, chemical storage and associated
equipment shall take into account expected temperatures:
i. 25 - 35ºC sewage.
ii. 0 - 55ºC ambient.
iii. 90ºC maximum radiating temperature (surfaces).
iv. Up to 30ºC air vented from the sewerage system to an OCU.
h) Preferred odour treatment technology is:

i. Two stage odour control system comprising of bio scrubber / bio trickling
filter as Stage 1 and Wet chemical scrubber as Stage 2, using
alkali/oxidant such as sodium hypochlorite with sodium hydroxide.
ii. Polishing treatment or treatment at small or remote sources (such as
subsidiary sewage pumping stations) shall be achieved with activated
carbon odour control units. In cases, where activated carbon is used,
carbon shall suitable for re-generation with water.
iii. Post treatment of vented air or lightly odorous air by ducting to the
activated sludge process shall be considered.
iv. Post treatment of ventilation air, for example using carbon, shall be
considered at sensitive sites and at pumping stations.
i) The same technology shall be used throughout a site, for ease of

operation. At existing sites, existing technology shall be duplicated unless
agreed otherwise by DM.
j) Several sources should be combined to a single odour control unit, possibly
providing more than one stage of treatment
k) Odour control units shall be designed and sized to maintain negative
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pressures within the space housing the odorous gases

l) Odour control equipment shall be designed to remove the range of odorous
compounds expected. The treatment process, the number of units and the
number of stages of treatment required shall be based on the inlet / feed
characteristics of odorous gases to the odour removal system and the
desired outlet characteristics of treated air from the odour removal system
19.13.3 Materials
a) Ductwork, casings, sun covers and louvres shall be constructed of
chemically reinstated glass reinforced plastic.
b) Glass Reinforced Plastic (GRP) shall meet the following specification:
i. Polyester Resin – ortho and isophthalic chemical resistant grades to
BS3532.
ii. Glass Reinforcement - water resistant E Type chopped strand mat or
woven glass fabric to BSEN14181 and BS3749.
iii. Surface Finish - Gelcoat - Flowcoat isophthalic resin to BS3532.
iv. All drilled, cut or otherwise exposed edges are to be sealed with polyester
resin.
v. Any non-GRP materials are to be fully encapsulated within the GRP
laminate.
vi. BS4994 and DIN DVS 2205.
c) Materials requiring corrosion protection shall be in accordance with Section

7.
19.13.4 Enclosures and Covers
a) In some instances to contain and collect odours covers, or an enclosed
building, are only way to ensure that odour release can be controlled. If
processes are enclosed within a building, additional local covering is likely to
be necessary to ensure that the working atmosphere is safe. Processes that
are commonly provided with local covering are:
i. Inlet works (may also be within a building).
ii. High rate filters.
iii. Sludge storage tanks.
iv. Sludge liquor sumps.
v. Sludge import facilities.
vi.
b) Provision of covers will create a confined space where high concentrations of
potentially hazardous gases may develop, requiring appropriate measures in
terms of zoning (including for ventilation fans and/or odour treatment) and
personnel access. Fan-assisted extraction/ventilation may be needed to:
i. Inlet works (may also be within a building).
ii. Convey odours to an odour treatment system.
iii. Prevent the accumulation of high levels of odours that could be displaced
during operations.
iv. Reduce the level of corrosion below covers.
v. Reduce condensation and consequent corrosion.
vi. Prevent the accumulation of high levels of potentially hazardous
chemicals.
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vii. Ensure that working conditions meet Health and Safety requirements.
c) Choice of materials for covers will need to take into account: strength,
thickness, durability, weight, cost, aesthetics, supplier and operational
requirements.
d) Covers shall be resistant to corrosion, both from external forces such as
weathering and UV radiation, as well as internal chemical attack due to the
hydrogen sulphide, sulphuric acid or organic acids below covers.
e) Fibre reinforced plastic (with appropriate choice of resin, UV absorbers and
light stabilisers) and aluminium are commonly used. Vinyl ester resin is
considered to have excellent corrosion resistant properties. Aluminium with
the correct choice of alloy is also corrosion resistant, although susceptible to
corrosion if splashed with sewage.
f) Covers shall withstand wind loadings and static loads.
g) Materials for covers and supports, and any equipment below the cover shall
be resistant to corrosion. Where possible, motors, etc., shall be located
outside the cover.
h) Suitable platform access and walkways shall be provided to any equipment.
In general, facilities to allow access of personnel onto covers shall not be
provided.
i) Inspection and access hatches will be required for repair and maintenance
purposes. Alternatively, cover sections may be designed to be removable.
j) Where possible, design shall be such that equipment below covers can be
easily and quickly removable.
k) Covers shall be sealed as far as possible. Inspection/access hatches shall
be sufficiently durable so that they continue to be effectively sealed for the
design life of a piece of plant.
l) Overflow and discharge pipes shall be designed and constructed to prevent
a route for air under covers being discharged to the atmosphere.
19.13.5 Ductwork (Incorporating Dampers)
19.13.5.1 Ductwork
a) Ductwork, in general, shall be designed and installed in accordance with

Heating and Ventilation Contractor’s Association (HVCA) Specifications
DW144 (sheet metal ductwork) and DW154 (plastic ductwork).
b) Ductwork shall be designed in accordance with duct pressure Class B
(medium pressure) with respect to static pressure and air leakage (refer to
DW/154), however, the maximum ductwork gas velocity shall be 10 m/s. For
the critical leg, the maximum pressure drop shall be 2 Pa/m.
c) Ductwork shall not be installed underground unless otherwise approved.
Similarly, inverted sections of ductwork shall not be incorporated, unless
otherwise approved.
d) Unless otherwise specified, ductwork installed outdoors shall be made from
PVC-U reinforced with GRP.
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e) Ductwork for foul air draw off and all foul air ducts interconnecting the
scrubbers shall constitute standard GRP pipes rated for 6 bars and drilled
to PN6 from DM approved suppliers. All bends and other fittings
incorporated in ductwork shall be standard , factory built,GRP fittings flanged
and drilled to PN6 .Insitu drilled flanges will not be acceptable.
f) All joints in ductwork/manifold shall be effectively sealed. Gasket shall be full
face and made of an approved material.
g) Flexible connections of appropriate material shall be provided, where
necessary, to accommodate differential movement and prevent the
transmission of vibration.
h) Flexible connections / dismantling joints shall be incorporated with all volume
and control dampers in foul air pipe work.
i) All flexible connections and dismantling joints shall be double flanged and
drilled to suit the related flanged draw off pipes and fittings; wraparound type
of flexible connections will not be acceptable.
j) All ductwork shall be provided with flanged connections at all joints and at its
termination points unless otherwise approved for any particular joint due to
technical reasons.
k) Ductwork shall be securely fixed to rigid supports. All ‘secondary’ fixtures and
fixings shall be made of stainless steel (grade 316) unless otherwise
specified.
l) Ductwork shall be designed to prevent the accumulation of windblown sand
or rainwater on its upper surfaces.
m) Ductwork shall incorporate all necessary drain points to allow removal of
condensate. Drain traps shall be rated for a minimum of 1.5 times the
ductwork pressure differential.
n) Ductwork shall incorporate all necessary access ports for the connection of
pressure gauges, gas velocity sensors, etc. and for sampling. If
practicable, access ports shall be positioned in straight lengths of ductwork,
at least 3 ductwork diameters from dampers. Access ports shall be provided
with facilities to prevent ingress of air when not in use and shall be located so
that monitoring instruments are easily accessible/ visible from ground level.
o) The ductwork colour shall be as specified on the Technical Schedule. Colour
shall be provided by non-degradable pigments in the ductwork external
surfaces. Ductwork shall be colour banded in accordance with BS 1710.
p) Ductwork shall be earthed to prevent the build-up of static electricity and
have a maximum resistance of 108 Ω in accordance with BS 5958 1 and 2.
Any equipment operating procedures or precautions required to prevent the
build up of static electricity shall be provided with the Tender.
q) Ductwork shall be provided with all necessary access ports/hatches to
facilitate cleaning of interior surfaces.
19.13.5.2 Control, Balancing and Isolating Dampers (Incorporating Non-Return Flaps)
a) All necessary control, balancing and isolating dampers shall be provided to

ensure effective, fail-safe equipment operation.
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b) All isolation dampers shall guarantee effective sealing on closure and shall
be leak tight.
c) Non-return flaps shall be effectively sealed in their closed position and offer
minimum resistance to gas flow in their open position.
d) Damper and non-return flap spindles shall be made of stainless steel (grade
1.4401 to BS EN 10088-1).
e) Damper blades > 400mmm in diameter shall be made of stainless steel
(grade 1.4401).
f) Where possible, damper position shall be clearly visible from ground level.
Dampers shall be lockable and their blade positions clearly indicated so
that settings can be recorded during commissioning.
g) Dampers used for bypass purposes or for isolating ductwork for man-entry
shall be completely leak-proof (i.e. butterfly-type dampers shall not be
used).
19.13.5.3 Fire Dampers
a) All necessary fire dampers (electrically actuated and non-electrically

actuated) shall be provided to prevent/control the spread of fire.
b) Fire dampers shall have at least the same standard of fire resistance as the
building element through which the ductwork passes, subject to a minimum
rating of 2 hours, in accordance with BS 476: Part 20-23.
c) Fire dampers shall be of the folded, interlocking blade, shutter type.
d) The fire damper operating mechanism shall be one of the following:
- Steel retaining strap with fusible link
- Fusible phial in cartridge housing
- Bi-metallic thermal release
e) Access facilities shall be provided in the damper casing/adjacent ductwork to
allow safe inspection/maintenance access to the damper blades and
operating mechanism.
f) Damper position shall be clearly visible from ground level.
g) Fire dampers to be fitted in walls/floors shall incorporate suitable casing
fixtures (lugs, etc.) for attachment to the building structure.
h) Fixtures shall be provided with facilities to accommodate differential
movement between the damper and building structure.
19.13.5.4 Pre-filters (e.g. Dust Filters, Grease Filters and De-misters)
a) Pre-filters shall be designed to enable easy/safe access to all

components/systems requiring inspection/maintenance and
removal/replacement.
b) Pre-filters and their housings shall be made from SS316L or better corrosion-
resistant materials.
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Dubai Municipality
c) Pre-filters shall be securely fixed in their housings. Seals shall be provided to

prevent leakage of air between pre-filters and housings.
19.13.5.5 Odour Control Unit Housings
a) GRP housings shall comply with the relevant category of BS 4994.1987 Cat
1
b) All joints in housings shall be sealed to prevent the leakage of fluids
c) All fixtures and fixings shall be made of SS316L or an appropriate corrosion
resistant polymeric material.
d) Housings shall be designed to enable easy/safe access to all
components/systems requiring inspection and maintenance and
removal/replacement.
e) Housings shall be provided with suitable flanged connections for connecting
to inlet/outlet manifolds, outlet stacks, ductwork, drainage facilities and/or
monitoring instruments, as appropriate.
19.13.6 Carbon Deodoriser Units

a) Carbon deodoriser units shall be based on the use of Activated Carbon
suitable for re-generation without removing carbon from the deodoriser
housing.
b) They shall be of the carbon filter type. Housings shall be manufactured from
a chemically-resistant grade of glass reinforced polyester and fittings shall be
stainless steel grade 316L, unless otherwise stated. Seals and gaskets shall
be PVC or neoprene.
c) The filters shall be single- or double-pass, as required for the areas to be
controlled, to provide efficient use of carbon and to promote life expectancy.
The media shall be provided in disposable cells to allow easy replacement
and disposal. Should pre-filters be used, they shall be manufactured in
resilient plastic random mesh which are washable and long lasting.
d) A full specification of the type and grade of activated carbon proposed
together with automatic regeneration process shall be included with the
Tender.
e) Design Parameters are as follows:
viii. Concentration of H2S gas in wet well: 250ppm static (Sulphide gas
concentration).
ix. Sulphide concentration in solution: 50 mg/l.
f) The type of activated carbon selected must be effective in dealing with

odours arising from maximum concentrations of hydrogen sulphide and other
sewer gases.
g) The Tenderer shall state the expected life of the activated carbon and
guarantee sufficient supplies for the first year of operation. Offered carbon
shall have guaranteed service life of 5 years inclusive of re-generation. The
cost of the activated carbon shall be entered in the appropriate schedule.
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Dubai Municipality
h) The activated carbon shall be packed in disposable cells for ease of

maintenance.
i) Fan motors shall be direct coupled and suitable for installation within a Zone
1 potentially explosive hazardous area and shall comply with Electric Motors
Specifications.
j) Where the odour control system is fan-assisted all parts exposed to the
fumes shall be stainless steel construction, heavy gauge and resistant to
attack or of approved non-metallic material and the motor and drive shall be
sealed from the exhaust gas path.
k) Each deodoriser unit shall be installed complete with adjustable dampers
and isolation valves. Multiple inlets shall each have individual valves and
dampers.
l) Each odour control unit shall have at least two numbers (1 duty/1standby) of
foul air draw off fans of totally S.S.316 construction. Approved isolation
dampers shall be provided at inlet and out let of each fan to facilitate removal
one fan for maintenance while the other fan is working. Suitable backflow
preventers shall be provided at outlet of each fan. Suitable flanged flexible
dismantling joints shall be incorporated with all dampers and backflow
preventers.
m) Suitable flap valves shall be provided to allow the circulation of fresh air into
the well as necessary, so that the deodoriser can operate.
n) The deodoriser shall be supplied with a differential pressure gauge and a
visible indicator to show the level of H2S contamination in the activated
carbon.
19.13.7 Bio filter Units
a) Biofilters shall utilise peat media for the bio-oxidation of H2S. Peat is a typical
lignitic material which is capable of absorbing large quantities of water and
has with good compaction resistance. Alternatives may be offered as options
for consideration at the tender stage.
b) The filter shall be manufactured from GRP with rigid polyethelylene foam
infill, boltable sectional panels, removable cover and base. Polyethelylene
foam (25mm thickness) shall be fully-encapsulated and provide thermal
insulation for site conditions.
c) Shading may be necessary to protect the biofilter from direct sunlight.
d) The GRP panels shall be suitable for outdoor locations, UV stabilised with a
colour-impregnated gel coat finish. Sectional panels shall be provided with
substantial flanges utilising stainless steel fittings. Panels shall be formed
with 100mm deep internal webs to prevent short-circuiting of air and
incorporate suitably reinforced external base flanges capable of withstanding
wind loadings on the unit arising from wind speeds up to 50m/sec.
e) The bases shall be provided with adequately sized effluent drains.
f) A sprinkler system shall be sized to maintain the required filter bed media
humidity. The sprinkler system manifold branches shall be fitted with isolation
valves, suitably sized externally located strainers, union connections and
spray heads. An overlapping sprinkler spray pattern shall be provided and on
large installations, zoning may be provided, controlled via solenoid timer
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Dubai Municipality
switches.
g) Pipework shall be PVC-U, ABS, or where necessary for superior mechanical
strength, stainless steel.
h) Final effluent shall be utilised for the wetting of the media, where available.
Alternatively, potable water with necessary pH chemical dosing control shall
be provided.
i) The media support decking shall be manufactured from injection-moulded
polyethylene to provide a substantial deck designed to accommodate the
media loading. A plenum chamber (500mm minimum depth) shall be
provided to enable the installation of an air ductwork manifold system
providing a uniform flow rate with minimum pressure drop through the
support decking. The minimum support deck aperture size shall be 25mm x
25mm, rigidly interconnected and supported, with a minimum decking free
area of 40%. Air shall be passed through the media in either "upward or
downward" flow pattern.
j) The Bio filter panel sections shall be rigidly secured, where necessary, by a
tie bar system to adequately resist the internal load of the peat media. Tie
bars shall be installed in a square matrix configuration with necessary
diagonal bracing connected via stanchion heads. Tie bars shall be stainless
steel grade 316L and be bolted to enable tensioning after assembly to
accommodate pressure and wind loadings.
k) A suitable bulking material shall be provided to allow for air percolation
through the peat bed media and assist in reducing the resistance to the air
flow. Heather is a preferred material which shall be capable of lasting the life
of the bed and be resistant to rotting. The media shall be bio-degradable and
non-hazardous, being suitable for safe site disposal.
l) Interconnecting ductwork shall be provided in accordance with the Section
19.14.5: Ductwork. Control dampers shall be fitted in ductwork branches,
main extract branches and on the fan inlet side as an integral part of the
ductwork system.
m) Condensate shall be drained from all low points within the system and
adequately sized inspection hatches shall be provided wherever access is
required for periodic maintenance of internals.
n) Exhaust air shall be discharged through a vertical chimney terminating with
accelerating cone designed to provide dilution and dispersion.
o) The chimney shall be fitted with eddy shedders and shall be restrained by
steel guy wires. The chimney design shall be approved by DM.
p) H2S and methane monitoring shall be provided to control automated
dampers and the provision of alarm situations at times of excessive
saturation and potentially explosive mixtures. Monitors shall be provided in
all buildings where access is required.
19.13.8 Chemical Absorption Units
19.13.8.1 General
a) Chemical filters shall be suitable for treating sources of malodour to below

the perception threshold levels associated with sewage gas.
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Dubai Municipality
b) The odour control plant shall be of a packed tower of two- or three-stage

chemical type.
c) For smaller plants or lower concentrations, a two-stage scrubber system
comprising of sodium hydroxide (caustic soda, NaOH) and sodium
hypochlorite (NaOCl) shall be used.
d) For some installations or higher concentrations, a three-stage scrubber
system, with the addition of a sulphuric acid (H2SO4) stage, will be
necessary.
e) All Air Handling Units (AHUs) shall be designed to provide negative pressure
within the conditioned space, which shall be achieved by a balanced
ventilation system.
f) The minimum design parameters are as follows:
i. Concentrations of H2S in wet well: 500ppm,
ii. Mercaptans: Trace only.
iii. Amines (mono/di/tri): 10ppm.
iv. Ammonia: 50ppm.
v. Concentrations of H2S in solution: 50mg/l.
vi. Number of air changes per hour in sump 4 minimum. (More if the
Contractor deems it necessary)
vii. Removal of mercaptans: No requirement.
viii. Pressure drop per scrubber stage: No greater than 28mm Wg.
19.13.8.2 Component Parts
The complete unit shall comprise the following:

a) Duty/standby extract and supply fans.
b) Scrubber towers:
i. Sulphuric acid (as required) dosing pumps, duty/standby.
ii. Sodium hydroxide (as required) dosing pumps, duty/standby.
iii. Sodium hypochlorite (as required) dosing pumps, duty/standby.
iv. Recirculation pumps dosing pumps, duty/standby.
v. Water supply pumps dosing pumps, duty/standby.
c) Regenerable water softener.
d) Sulphuric acid storage tank of 1 weeks storage at maximum usage.
e) Sodium hydroxide storage tank of 1 weeks storage at maximum usage.
f) Sodium hypochlorite storage tank of 1 weeks storage at maximum usage.
g) Drench showers and hose supply.
h) Electrical equipment, including instrumentation and control.
i) Access platforms, ladders, etc.
19.13.8.3 General Mode Of Operation
a) The units shall be self-contained and be provided with a spun stainless steel
wire type pad and capable of operating at a minimum face velocity of 2 m/s.
The removal efficiency shall be 99% for all aerosol droplets above 15
microns.
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Dubai Municipality
b) Gases shall be extracted and ducted to the inlet of the first stage scrubbing
tower passing vertically through a packed bed section complete with a
recirculation system set above the packing elements.
c) This liquid shall flow downward, counter-current to the gas flow.
d) In the packed bed section, the gas constituents shall be dissolved and
diffused into the scrubbing liquid by means of the large liquid/fume interfacial
surface contact area provided by the packing elements.
e) The treated gas air stream shall then flow through the knitted pad type mist
eliminator. The entrained liquid droplets removed from the air stream
agglomerate in the knitted fibres are returned to the recirculation system.
f) Liquid to the spray headers shall be recirculated from the base tank with
evaporation losses and a continuous overflow, from the discharge side of the
duty pump, replaced by water make up via a ball float valve. The bleed off
rate will be determined by site operating conditions.
g) Liquid level in the recirculation tank shall be monitored by a level element,
using conductivity rods, providing a low liquid level alarm signal and a low
signal to stop the pumps, to avoid a condition of dry running. High liquid level
alarm shall also be provided.
19.13.8.4 Stage 1 Operation (Sulphuric Acid)
a) The chemical condition of the recirculation liquid of this stage shall be

monitored by a pH probe, enabling the bleed-off rate to be adjusted to
maintain the liquor within limits and control the addition of 20% sulphuric
acid.
b) Treated gases shall then pass from the side exit of the scrubber to the inlet
of the adjacent second stage scrubbing tower.
19.13.8.5 Stage 2 Operation (Sodium Hydroxide and Sodium Hypochlorite)
a) Here a similar course of events to the first stage shall occur, but an additional
Redox probe shall be provided in the sump to control the addition of sodium
hypochlorite.
b) The pH probe in this secondary tower shall control the addition of 50%
sodium hydroxide solution.
c) The final treated gases shall then be ducted to the inlet of the duty/standby
extraction fans for discharge via the exhaust stack, or via suitable louvres if
the extract fans are fitted on the scrubber inlet.
19.13.8.6 Scrubbing Tower Ancillaries
a) The scrubbing towers shall include conductive resin strips behind weld lines,
nozzle fitting joints in vessel shell, etc. to enable a full spark test to be carried
out. This will permit checks to be made on the integrity of the inner
thermoplastic shell after installation and at any time during the lifetime of the
vessel.
b) Scrubbing towers shall have uniform wall thickens and each scrubbing tower
shall have a corrosion-resistant thermoplastic liner, wrapped externally with
glass reinforced UV-stabilised white pigmented polyester resin. It shall be
designed in accordance with BS 4994 and consist of a vertical cylindrical
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Dubai Municipality
tower to be manufactured in flanged sections with flat base. Flanges drilled

in-situ not acceptable.
c) The sump section of the units shall hold recirculating scrubbing liquor pumps
and be complete with internal baffle, flanged connections and water level
measurement.
d) A recirculation pump feed to include:
i. Overflow.
ii. Make-up water inlet, incorporating float valve,
iii. Drain outlet.
iv. Chemical dosing points.
e) A gas bed section comprised of:

i. Support plate and support ring.
ii. Packed bed of random packed cascade mini rings (if required).
iii. Flanged access cover, to permit removal/replacement of packed bed rings.
iv. pH probe
v. Redox probe (if required).
f) A spray assembly system fitted with:

i. Flanged connections for spray bar assemblies.
ii. Lower and upper inspection doors.
iii. Spray system with spiral type non-clogging nozzles.
g) A mist eliminator section comprised of:

i. Demister ring support;
ii. Horizontally mounted aerofoil blade mist eliminator.
iii. Drain back to sump.
h) A conical transition section with discharge outlet to be mounted onto conical

transition section. (This may comprise a separate stack, or outlet louvres.)
i) Gaskets shall be from flexible EPDM sheet.
j) All materials shall be chemical resistant with support plates and fasteners
etc. in 316L stainless steel. i.e. high chloride-resistant stainless steels are
required because of the high salinity levels.
k) Design calculations shall be submitted in respect of the discharge height
required to prevent downwash of H2S occurring due to the effects of adjacent
structures.
l) An automatic condensate drain and trap shall be provided.
m) A self-contained pre-filter unit shall be provided with synthetic panel filters to
40% ASHRAE standard. The filter shall have continuous bonding between
the periphery edges of the filter pack and the inside of the enclosing frame to
eliminate any possible air bypass.
n) The enclosing frames shall be constructed of rigid, water-resistant waxed
board. Units shall be securely loaded in side access frames which will assist
access for maintenance.
o) The filter thickness shall be 50mm minimum with a free open area of 96%.
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Dubai Municipality
p) The chemical filter section shall contain media in vertical beds which shall be
suitable for horizontal air flows. Overall bed depth shall be adjustable from
200mm minimum up to 750mm in 250m increments.
q) The air flow rate shall be designed in order to achieve a dwell time of two
seconds over the media section.
r) The media shall be capable of providing adequate odour control for peak
loadings of hydrogen sulphide up to 500 ppm whilst the average loading is
anticipated to be 50 ppm.
s) An adequate means of access for inspection and replacement of the media
shall be provided.
t) A media analysis service shall be provided in order to determine the life
expectancy and replacement frequency date (twice annually) for a five year
period.
19.13.8.7 Air Fans and Associated Plenum
a) Duty/standby air fans shall be installed and sized to maintain negative

pressure within the odour space.
b) Extract fans shall be sized to provide the minimum number of Air Changes
Per Hour (ACPH) for the area specified:
a. Toilets 12 ACPH
b. Stores 6 ACPH
c. Workshops 15 ACPH
d. Garages/Car park areas 8 ACPH
e. Messes (two speed) 6 20 ACPH
f. Motor Room 10 – 20 ACPH
g. Dry Well 20 ACPH
c) They shall be suitably rated for their duty and be selected to operate at or
near their best efficiency point.
d) Foul Air draw off fans shall be totally of S.S 316 construction or they shall be
constructed of approved materials that are not susceptible to attack by the
component gases to which they are exposed. Each odour control unit shall
have sufficient number of foul air draw off fans to work on duty /stand by
operation philosophy. Actuated, isolation dampers shall be provided at inlet
and out let of each fan to facilitate removal of one fan for maintenance while
the other fans are working. Suitable backflow preventers shall be available at
outlet of each fan. Suitable flanged flexible dismantling joints shall be
incorporated with all dampers and backflow preventers.
e) Fresh Air feed fans shall be of S.S 316, Aluminium or GI construction or they
shall be constructed of approved materials that are not susceptible to attack
by corrosive environment to which they are exposed. There shall be
sufficient number of fresh air feed fans to work on duty /stand by operation
philosophy. Isolation dampers shall be provided at out let of each fan to
facilitate removal of one fan for maintenance while the other fans are
working. Suitable backflow preventers shall be available at outlet of each fan.
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Dubai Municipality
Suitable flanged flexible dismantling joints shall be incorporated with all

dampers and backflow preventers. Fresh air feed fans shall have heavy duty
washable filters at inlet to the fans.
f) Fans and their drive systems shall be securely fixed to rigid supports.
g) Where the odour control system is fan-assisted all parts exposed to the
fumes shall be non-metallic or stainless steel grade 316 construction, heavy
gauge and resistant to attack.
h) The impeller shall be secured to the impeller shaft and shall be secured
against circumferential movement. The impeller shall not be pinned to the
shaft nor shall shaft movement be relied on to ensure that the impellor is
locked in position.
i) Pulley and V-Belt transmissions shall incorporate a minimum of two belt
drives. V-belts shall be designed with a service factor of 1.6, based on the
minimum absorbed power of the fan.
j) The motor and drive shall be sealed from the exhaust gas path.
k) Substantial outlet and inlet plenums with external stiffeners and flanges shall
be provided for connection to the external ductwork.
l) Ventilation ducting shall be of GRP, Stainless Steel any other approved
corrosion resistant material. Material thickness, stiffening and joint
arrangements for all fabricated ducts shall be in accordance with an
approved International Standard to provide adequate strength and to assure
rattle free operation and to prevent air leakage. Suitable noise attenuators
shall be incorporated in ducting wherever necessary. Insulation shall be
provided as required.. All duct work joints shall be flanged joints and GRP
ductwork shall constitute standard GRP pipes rated for 6 bars and drilled to
PN6 from DM approved suppliers. All bends and other fittings incorporated in
ductwork shall be standard , factory built,GRP fittings, flanged and drilled to
PN6 .Insitu drilled flanges shall not be acceptable.
m) Ducting shall be complete with all necessary supports. Stainless steel nuts
and bolts shall be used for all ducting joints and all supports and brackets .All
supports and brackets, in general, shall be hot dip galvanized except in
locations otherwise specified. All anchor bolts for fixing brackets and
supports to the structure shall be resin anchors S.S Grade 316. Ducting shall
be in suitable sections to facilitate removal, repair and replacement, if
required. All ducts, supports, brackets and fixings in wet wells for pumping
stations shall be stainless steel.
n) Ducting shall be sized so that the air velocity within the main ducts shall not
exceed 5.5 m/s and 3.0 m/s at the outlet louvers.
o) Flexible connections and anti-vibration mountings shall be provided as
necessary between the ductwork and fans and provision shall be made for
thermal expansion.
p) Where ducts pass through walls roof or floor slab the gap shall be sealed
with a non degradable approved material.
q) Condensate shall be automatically drained from all low points.
r) Inspection panels shall be provided wherever access is required for periodic
maintenance of mechanical plant.
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Dubai Municipality
s) Test holes for commissioning purposes shall be provided on each ductwork

branch.
t) Ductwork shall be tested for gas tightness.
u) Supply and extract four-way type diffusers shall be installed complete with
balancing dampers and be suitable for corrosive atmospheres. Suitable
mounting supports shall also be provided.
v) Fan motors shall be direct-coupled units suitable for installation within the
Zone 2 potentially explosive hazardous area.
w) Dual-speed motors shall be provided for all fans. They shall be controlled via
gas sensors that switch to low speed setting to minimise running costs. High
speed operation shall be initiated on recording of high gas level
concentrations and thermostats located within the conditioned space.
x) The fan units shall be supplied with anti-vibration mounts incorporating
efficient impeller design to ensure minimal noise levels.
y) Regulation of the air flow shall proceed on satisfactory operation of the fan
sets. Balancing of air flows within the ventilating duct system shall be carried
out to the satisfaction of DM. Adjustment of regulating dampers to achieve
the specified air flow rates shall be completed prior to locking.
19.13.8.8 Outlet Stack
a) The Exhaust air shall be discharged through a vertical chimney terminating

with accelerating cone to provide dilution and dispersion.
b) The outlet stack shall be designed to withstand wind loadings in accordance
with BS6399-2.
c) The stack shall be provided with an accessible sampling point.
d) The stack shall be provided with an accessible access ports/hatches to
facilitate the cleaning of the internal surfaces.
e) Lightning protection requirements shall be assessed in accordance with the
DM Specifications.
19.13.8.9 Chemical Dosing Pumps
The Chemical Dosing pumps shall be of the double diaphragm type and have as a
minimum standard:
i. Hypalon chemical diaphragm.

ii. uPVC metering head.
iii. Viton valve seats.
iv. PTFE faced working diaphragm.
v. Caustic soda - stainless steel valve balls.
vi. Sulphuric acid and sodium hypochlorite - glass valve balls.
vii. Capability of altering dosing rate from 10-100%.
viii. Integral pressure relief valve.
ix. Pulsation dampers.
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Dubai Municipality
19.13.8.10 Water Softener
The water addition/softening systems shall each incorporate the following, as a

minimum:
i. Break tank with air gap or approved double-acting check valve, complete
with isolating valve.
ii. Softener isolating valves.
iii. Duplex style non-return valves.
iv. Dual cylinder style water softeners, rated for continuous output with
integral meter initiated water power regeneration.
v. The softener shall use a fine bead resin bed in conjunction with a brine
solution.
vi. The softener shall be rated for 28 days use without the salt storage being
replenished.
vii. Flow regulating ball type valves.
viii. Flow indicator sensors, variable with adjustable high and low sensor.
19.13.8.11 Chemical Storage Tanks
The storage tanks shall conform to BS 4994 and each incorporate the following
features, as a minimum:
i. Double barrel type tank designed to contain leakage of chemical between

barrels.
ii. Visual cat-and-mouse style contents gauge.
iii. Level transducer (low/high).
iv. Tanker Fill Panel.
v. Bulk fill lines consisting of manual plug valves, and connections suitable
for bulk tanker filling.
vi. Lined plug outlet valve.
vii. Diaphragm drain valve.
viii. Overflow pipe, to direct chemical into bund in a safe manner which avoids
splashing of operators or equipment.
ix. Vent pipe.
x. Covered top.
xi. Construction:
xii. Sodium hydroxide - polypropylene/GRP.
xiii. Sodium hypochlorite - polyvinyl chloride/GRP.
xiv. Sulphuric acid - polypropylene/GRP.
xv. Each tank shall be contained in a separate bunded area, which shall
provide containment for 110% of the tank volume.
19.13.8.12 Instrumentation
a) pH transmitters shall be provided with 230V high and low alarm contacts,
range 0-14 pH, fully programmable complete with electrodes and dip probes.
b) Redox transmitters shall be provided with 230V high and low alarm contacts,
range 0-14 pH, fully programmable complete with electrodes and dip probe.
c) One conductivity type level measurement device of the 24V rod type shall be
provided in each scrubbing tower.
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Dubai Municipality
d) One recirculation flow meter with 230V magnetic low flow switch shall be
provided.
e) One bleed flow meter shall be provided.
f) One differential air pressure switch for extract fans shall be provided.
g) One pump pressure gauge and switch shall be provided for each pair of
dosing pumps.
h) One hydrogen sulphide monitor shall be provided in the inlet to system.
i) One hydrogen sulphide monitor shall be provided in the outlet to the system.
j) An ultrasonic level sensor shall be provided for each of the storage tanks.
k) All pipework shall either be of polypropylene or PVC material, flanged or
solvent welded.
l) The following valves and accessories shall be provided as a minimum:
i. Hand-operated uPVC (ball) isolation valves on each side of the
recirculation pumps.
ii. Hand-operated uPVC (ball) isolation valves on each side of the dosing
pumps.
iii. Non-return valves at pump outlets.
iv. Injection valves on recirculation line dosing.
v. Strainers on inlets to all pumps.
vi. Isolation valves for all pump outlet pipework.
vii. Pulsation dampers in the dosing pump outlet pipework.
viii. Drain and flushing facilities at all low points in the pipework.
ix. All pipework shall be contained so that in the event of a burst or leak the
chemicals are directed into the secondary containment.
m) Hydrogen Sulphide and methane monitoring shall be provided to control
automated dampers and the provision of alarm situations at times of
excessive saturation and potentially explosive mixtures. Monitors shall be
provided in all buildings where access is required.
n) Toxic gas detection unit shall be capable of detecting Hydrogen Sulphide
levels in the range of 0-1000ppb (minimum range) prior to discharge.
o) The detection unit principal operation shall consist of a dry colorimetric
cassette system providing quick responsive indication (10 sec) dependent on
tape stain. Colour changes shall be measured by an electro-optic detection
system. Microcomputer control resulting in a digital signal matched to preset
alarm programme relayed to the telemetry unit via 4-20mA signal (Audio and
Visual).
19.13.9 Two-Stage Odour Control System
Essentially, the system will comprise of a two stage process – Bio trickling filter /
Bioscrubber followed by a Caustic-Hypochlorite /Peroxide scrubber operating in
series. The inlet concentration and minimum over-all contaminant removal rates shall
be as in Table 19-4
Table 19-4 Typical Odour Quality Standards (approximate)
% removal rate Ave Outlet

Inlet Concentration
Compound (across the 2- concentration
(ppm)
stage process) (ppb)
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Dubai Municipality
Avg. Peak Avg.

Maximum Odour
< 500 OU/m3
Discharge
Hydrogen
100 250 99.99 10
Sulphide, H2S
Mercaptans, R-SH 2 5 99.5 10
Ammonia, NH3 1 4 95 50
Dimethyl Sulphide,
1 4 99.5 5
DMS
To achieve < maximum odour
VOC 20 40
discharge
19.13.9.1 Performance Specification
The odour level shall not exceed 5 OU/m³ at 100%ile on 1 hourly averaging basis
measured at the site boundary, based on ‘BS EN 13725:2003 standard odour control
method’. Odour dispersion modelling shall be used to verify that this standard can be
achieved at the site boundaries. The Tenderer shall guarantee that there will be no
malodours perceived beyond the site boundaries.
Guaranteed overall H2S removal across the 2-stage treatment process shall be
>99.99% based on average inlet concentration.
19.13.9.2 Process Description
Odorous air shall be extracted via new GRP ductwork and collected for treatment into
the odour control unit (OCU)
The incoming gas flows upward through the biotrickling filter / bioscrubber towers
over a biomass support bed. Hydrogen sulphide, dimethyl sulphide, mercaptans and
other odorous compounds are absorbed into the liquid phase, and oxidised by the
biomass. The biomass within each tower is split into two or three beds, each
operating at different pH. The operating pH defines the biomass present, and thus the
type of odour compound removed by each bed. Hydrogen sulphide and ammonia is
removed by the 1st and 2nd beds (the most acidic), followed by DMS, mercaptans and
VOCs in the 2nd and 3rd beds (neutral pH).
The highly acidic waste liquor from the bio trickling filter / bioscrubbing towers is
drained and neutralized before it is discharged to the sewer.
Gas leaving the biotrickling filter / bioscrubber enters the base of the caustic-peroxide
scrubber. The odorous gas enters the packed tower and is contacted counter-
currently with the scrubbing liquor (a solution of sodium hydroxide and hydrogen
peroxide) over the mass transfer media. The remaining hydrogen sulphide, dimethyl
sulphide, mercaptans and other odorous compounds are absorbed into the liquid
phase. Liquor saturated with odour compounds collects in the column sump. The
liquor leaving the sump is dosed with 50% sodium hydroxide solution and 30%
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Dubai Municipality
hydrogen peroxide solution to replenish liquor concentrations after the required

neutralisation and oxidation reactions have occurred and prior to the liquor re-
entering the packed column.
A percentage of the re-circulating liquor is wasted to keep oxidation products and

carbonate levels below that in which precipitation occurs.
The caustic-peroxide scrubber shall be designed to treat the full incoming odour load
in case of complete failure of the bio trickling filter / bioscrubber.
The ductwork shall be configured so that each of the towers within the bio trickling
filter / bioscrubbing plant and packed towers can be independently bypassed to allow
maintenance without complete plant shutdown.
The treated air shall be discharged to atmosphere via a self supporting stack at a
velocity of 15 to 20 m/s to ensure good dispersion while maintaining the noise at
acceptable level.
19.13.9.3 Treatment Units
a) The number of treatment stages within each treatment unit shall be as stated
on the Technical Schedule.
b) Each treatment stage shall comprise a random or structured porous bed of
inert media and its associated support structure. The volume and
arrangement of the inert media shall be such that the rates of mass transfer
of odorants from the gas to the liquid phase within each treatment stage are
optimised to achieve the specified performance.
c) The configuration of the inert media bed(s) shall be as stated on the
Technical Schedule.
d) The type and composition of the inert media shall be as stated on the
Technical Schedule.
e) The inert media shall be compatible with and/or resistant to the scrubbing
liquid and have sufficient compressive strength to resist all operational loads
without excessive deformation.
f) The type of scrubbing liquid (i.e. chemical reagent) and target operating
parameters (i.e. pH, Redox potential etc.) shall be as stated on the Technical
Schedule.
19.13.9.4 Scrubbing Liquid Make-Up System
a) Full details of the scrubbing liquid make-up system shall be provided with the
Tender.
b) Chemical dosing systems shall comply with WIMES 8.02.
19.13.9.5 Scrubbing Liquid Recirculating System
a) Full details of the scrubbing liquid re-circulating system shall be provided with
the Tender.
b) If possible, liquid distributors shall be of the pipe manifold or weir trough type
(i.e. spray nozzles shall not be used).
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19.13.9.6 Scrubbing Liquid Discharge System
a) Full details of the scrubbing liquid discharge system shall be provided with
the Tender.
b) Excess/waste scrubbing liquid shall discharge to the point specified/stated on
the Technical Schedule.
c) The scrubbing liquid discharge system shall incorporate a sampling point and
tundish to enable verification of the scrubbing liquid composition and correct
operation of the make-up system.
19.13.9.7 Media Disposal
a) The method of disposal and the waste classification of the spent media shall
be as stated on the Technical Schedule.
b) The time required to completely remove all the spent media from each unit
and replenish it with fresh media shall be as stated on the Technical
Schedule.
19.13.9.8 Caustic-Peroxide Scrubber (Wet Scrubber)
Section 19.13.8 shall be followed.
19.13.10 Hoses
a) In each area where chemicals are dosed or stored and there is the possibility
of chemical spillage, hose reels shall be provided as a minimum standard.
b) They shall comply with BS 5274, BSEN 671-3 and BS 5306 part 1.
c) Each hose end shall be fitted with an adjustable jet spray shut-off of high
impact nylon, and a separate isolating valve.
d) They shall comprise the swinging open type of reels.
e) The Contractor shall supply low pressure low velocity systems.
19.13.11 Drench Showers
a) Drench showers shall be swinging chain operated type with a stainless steel
valve that locks on.
b) Each shower shall have a light to indicate its position.
c) Drench showers shall not be fed directly from the mains, unless a heater is
incorporated to reduce any thermal shock to the user.
d) They shall be fed from surface-mounted water tanks.
e) An emergency eye/face wash fountain with a flexible hose shall also be
incorporated into the drench shower.
f) Operation of the shower/emergency eye wash shall transmit an alarm to the
main MCC/SCADA system/Regional control system.
g) Safety signs shall be attached securely by each shower.
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19.13.12 General requirements for odour control units for main sewage pumping
stations
a) All external pipe work and fittings shall be UV stabilized.
b) All anchor bolts shall be resin anchors in SS 316.
c) All chemical storage tanks shall have proper filling points, with fool proof
and colour coded hose couplings. All chemical filling points shall have an
approved wall mounted coupling cubicle with lockable door and a proper
drain pipe for the base of the cubicle.
d) For towers more than 4.0 m high, access platforms, ladders and stairways
shall be provided to facilitate the operation monitoring and maintenance of the
equipment.
e) All Droplet separators / Mist eliminators shall be highly reliable and
maintenance-free and drops of scrubber liquid shall not be carried forward to
final air treatment unit, or to the atmosphere.
f) Approved Biological scrubbers to be incorporated in the first stage and
chemical scrubbers to be connected in series with first stage to reduce
chemical consumption and operating cost of the plant.
g) Sampling points shall have proper process piping and mist eliminator /dryer to
avoid air with droplets of scrubber fluid entering the H2S monitor
h) All dampers and isolation valves for all sampling points shall be easily
accessible.
i) All scrubbers shall have suitable manholes with bolted clear blank flanges at
appropriate location for regular observation scrubber fluid.
19.14 VENTILATION
19.14.1 Wall Mounted Air Conditioning Units
Air cooled 'window type' air conditioning units, as supplied by an approved and
accepted manufacturer, shall be installed in positions approved by the Engineer.
They shall be provided complete with slide out chassis and frame, suitable for clear
openings set not higher than 1.5m above floor level. They shall be suitable for
continuous efficient operation in the climatic conditions prevailing and the materials of
construction (particularly concerning the fins or extended surfaces of the refrigerant
to air heat exchangers) shall be subject to the Engineer's approval.
Both fresh air and re-circulated air shall be filtered and the filter shall be arranged for
ease of removal from the main unit for cleaning and replacement.
Depending on the size of the room space and the heat load therein, the air
conditioning units shall be of 1 ton, 1.5 tons or 2 tons refrigeration capacity
(equivalent to an air cooling capacity of 13,250; 19,880 or 26,500 B.T.U.’s per hour)
or multiples thereof.
Heat load calculation shall be approved by the engineer and air conditioners for MCC
rooms shall have additional 25% of calculated heat load added to decide the capacity
of the unit. Sufficient number of units shall be provided and they shall work on duty-
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standby principle and there shall be provision for timed automatic duty changeover.
This requirement is general and applicable for all types of air conditioners.
Each unit shall be provided with a manually adjustable thermostatic air temperature
control and such other controls necessary to allow the following modes of operation:
1) Off.
2) Fan only with two speeds.
3) Cooling at two possible fan speeds.
4) Re-circulation of air from room, through unit and back to room.
5) Part re-circulation of air with some exhaust air flow.
6) Part re-circulation of air with some fresh air inlet flow.
Each unit shall also be fitted with an automatic delay timer in the compressor control
circuitry to prevent the compressor having to start against gas pressure in the event
of an interruption in the power supply or the cooling mode being switched off and on
rapidly.
19.14.2 Centralised Air Conditioning Systems

Centralised air conditioning systems shall comply with the requirements of the
Particular Specification.
The system shall be complete with all necessary ductwork, diffusers, air grilles etc.
Where required, two single package units shall be provided and installed. Each unit
shall be capable of providing 60% of the total cooling load.
Machinery shall be from an approved manufacturer, of types readily available in

Dubai and suitable for installation in direct sunlight. Filters, re-heaters and/or
humidifiers shall be provided as necessary to maintain the condition of the
equipment.
Supply and return air ducting shall be run in the void above the suspended ceiling
where applicable. Air vents to conditioned areas shall be via slot diffusers integral
with the suspended ceiling. The whole system shall be designed to give an even
temperature distribution throughout the air conditioned areas.
Single package units shall be of the type with two compressors and split coils
arranged so that the failure of a compressor shall not lead to total failure of the air
conditioning to any area. The two units shall be identical to limit the quantity of
spares.
Work on installation of air conditioning systems is only to be undertaken by an

approved local air conditioning Tenderer or by an international air conditioning
Tenderer who is associated with an approved local air conditioning Tenderer.
It is recommended that the Tenderer engages the services of an air conditioning

specialist who is familiar with local requirements and conditions to design and specify
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the system and liaise with Dubai Electricity and Water Authority, regarding approvals
and inspections.
Copies of the design calculations, unit specifications and system descriptions and
drawings are to be submitted to the Engineer for approval by Dubai Municipality who
will finally be responsible for the air conditioning system. Dubai Municipality will
require two additional copies of the operating manuals for the air conditioning system.
Representatives of the Dubai Municipality will require to be in attendance during
commissioning.
A five year guarantee shall be provided against all malfunctions of the compressor by
the Dubai Electricity and Water Authority approved local air conditioning Tenderer
appointed.
19.14.3 Split Unit Air Conditioners

All materials used in the manufacturing of the units shall be produced to approved
International Standards. The cooling tubes shall be manufactured from solid drawn
copper and shall be tested to 20 bars. Fins shall be of Aluminium and shall be
permanently bonded to the tube. Cabinets shall be manufactured from pre-galvanised
sheet steel and the outer panels electrostatically powder coated with epoxy and
stoved. Panels shall be removable for access.
Condensate trays shall be fitted and the outlets piped to a suitable drain point.
Fans shall have corrosion resistant steel impellers. Motors shall comply with the
relevant parts of the Specification. Anti-vibration mountings shall be provided.
Air filters shall be fitted having 90% efficiency. If they are of the throw-away type a
five year supply of spare elements shall be provided.
The condenser unit shall be suitable for outdoor installation and condenser coils shall
have special anticorrosive coating suitable for installation in sewage pumping stations
The coils shall be pressure tested to 20 bars and fins shall be permanently bonded to
them.
Motors shall be weatherproof and shall comply with the relevant parts of the
Specification.
Compressors shall be hermetically sealed. Crank-case heaters and anti-vibration

mountings shall be provided.
High and low pressure switches and overload protection shall be provided and also
an anti-recycling timer.
The units shall be sized to maintain a dry bulb temperature of 26°C and a relative
humidity of between 40% and 60% when the external shade temperature is 52°C and
the external relative humidity is 50%.
19.15 CENTRIFUGAL FANS (AIR BLOWERS)

Centrifugal Fans to be used as air blowers shall be of heavy duty, single inlet direct
drive type. They shall be suitable for handling temperature up to 80°C, dust free air,
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and aggressive gases and moisture normal to the sewage environment. The fan
shall be low-noise, corrosion resistant and explosion proof when handling aggressive
gases in sewage.
The blower shall be designed to handle, as a minimum, the rated air volume against
the stated head, as indicated in the Contract Documentation.
19.15.1 General Construction

Mating flanges and/or flexible connection, as appropriate, shall be provided for the
inlet and outlet. Fan inlet shall be provided with sand traps and filter.
The fan shall be mounted together with motor support pedestal on a common base
frame. Fan blades, casing and other parts normally in contact with gases shall be of
stainless steel or plastic construction.
The fan shall have a backward curved centrifugal impeller which shall be overhung on
the motor shaft.
Driving motors shall be of well-known manufacture and shall be supplied with anti-
condensation heater and thermistor. Motor shall be in accordance with Section 18 -
General Specifications for Electrical & Instrumentation Works
Blower Enclosure panels shall be of GRP modular construction materials consisting

of chopped strand mats, roving and unsaturated polyester resin to approved
international standards.
The GRP material shall be composed of 0.5 mm minimum thickness gelcoat to

provide chemical resistance, layers of chopped strand mat reinforcing in resin content
60-70% by weight. Woven roving glass fabric layers to provide strength and rigidity
with resin content 45-55%, surface layers shall consist of “C” glass surface mat (45-
50 gm per square metre) with resin content of 90% by weight.
All cut edges shall be made smooth using a resin top coat and are to be gel coat
sealed. Rigidity of the enclosure can be increased by adding sufficient stiffeners.
The enclosure shall be U.V. resistant, have high impact resistance, high abrasion
resistance, low sound absorption dB 10-15 in the 100 - 500 Hz range, low thermal
conductivity of 1.4 W/m² 0C and be non-combustible.
19.16 LIFTING EQUIPMENT

19.16.1 Electrically Operated Traversing Cranes
Cranes shall be electrically operated traversing type and be complete with gantry rails
and all accessories including a set of slings.
The gantry joists and rails shall be provided with provision for jointing and fixing to the
structure. The lifting capacity of the equipment shall be sufficient for the heaviest
load which will be obtained when erecting or dismantling the plant or other parts of
the installation. The capacity of the cranes proposed shall be stated in the equipment
supply schedule.
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The crane shall be tested at the maker’s works at 25% above the rated load, and test
certificates shall be provided.
Load tests shall be conducted at site in the presence of Engineer to witness the load
test. The load test shall be carried out on site by an approved independent body. The
proof load applied for certification shall be 50% in excess of the Safe Working Load
(SWL) which shall be clearly marked on the lifting block and on the runway beam.
The test date is to be displayed on the runway beam. Load test by the approved
independent testing authority at 1.5 SWL to be repeated at the end of Defects Liability
Period.
Local authority inspection and approval is to be obtained prior to its operation and
handover.
The crane shall be of the double girder travelling type. The traveller carriage shall run
on bridge rails which shall be securely fixed to the gantry.
The crane shall be provided with a maintenance platform over the full span. The
maintenance platform shall be provided with double handrails throughout and a fixed
ladder access.
Longitudinal and traverse motions shall be provided for the crane and shall be such
that operation is speedy without impairing safety in working. The hook and load
chains shall be such that the hook will reach to the maximum depth.
Ball or roller bearings shall be employed on all motions and the load hook shall
revolve on a ball swivel. All gears shall be machine cut and all runway wheels
machined. A reliable braking and locking arrangement shall be provided.
The crane structure shall be designed in accordance with the requirements of an

approved international standard.
Two hoist speeds shall be provided, not exceeding 3 m/min across the working range
of the crane. Cross travel speeds shall be approximately 15 m/min. All motions shall
be electrically driven. The speeds of all motions shall be confirmed in the appropriate
schedule the speeds on all motions.
The load shall be carried on a flexible steel wire rope coiled onto a cast iron barrel
having right and left hand machine cut spiral grooves to ensure a true vertical lift.
The load rope shall be of sufficient length to reach the maximum depth. The load
hook shall comply with an approved international standard and shall revolve on a ball
swivel. A safety catch shall be fitted to the hook.
The crane shall be remote controlled on all motions from a non-metallic pendant push
button station. Buttons shall be of the hold-to-operate type. The pendant enclosure
shall give protection to IP54 requirements. Operation of the crane shall be possible
from any position across the full span. The pendant legends shall be inscribed in
English and Arabic. The remote control shall be wireless.
The power supply to the hoist shall be of festooned cable type running on a rigid
support system. An earth conductor shall also be provided.
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The electrical equipment shall be controlled at 230 volts. The transformer shall be
protected by HRC fuses on both primary and secondary circuits.
A main supply isolator shall be provided and mounted at operating height from
ground level. Three sets of red "conductor alive" warning lamps shall be provided.
All motors and electrical equipment shall be rated in accordance with the climatic and
other Specification requirements.
The integrity of the hermetic seal to the box girders is to be maintained. All cables
shall be enclosed in a steel conduit which is to be fastened to the exterior of the
girder.
Crane shall be suitable for humid and highly corrosive atmosphere.
All movements of the crane are electrical and protected by suitable limit switches.
Hoists shall have built-in limit switches for upper and lower limits.
Longitudinal travel of girder and cross travel of trolley shall have limit switches on
both ends. This is in addition to rubber buffers (end stopper) fixed at ends of carriage.
The crane with all ancillaries including bolts and nuts shall be in total compliance to
the specifications in all respects.
Protective coating shall be 300 micron DFT and colour to be agreed. Load hook shall
be Signal Red in colour.
Head room for the crane hoist shall be adequate for lifting the tallest equipment/
Pump in the pumping station and loading it in the truck stationed in the loading bay
inside the station.
19.16.2 Manually Operated Lifting Equipment

A close lift, hand operated gear driven lifting block, on a single runway beam, shall be
provided when specified in the Contract Documentation. The Safe Working Load of
block and beam shall be at least 25% above the weight of the heaviest item which will
require lifting for maintenance purposes. Equipment shall have the following
minimum ratings: 500 kg for the hoist and 1000 kg for the beam.
The whole assembly including beam, gear driven travelling trolley, pulley block and
chains shall be subject to a capacity test carried out on site by an approved
independent body or local authority. The proof load applied for certification shall be
50% in excess of the Safe Working Load (SWL) shall be clearly marked on the lifting
block and on the runway beam. The test date is to be displayed on the runway beam.
Load test by approved independent testing authority at 1.5 SWL shall be repeated at
end of Defects Liability period.
The bottom block shall be of the steel fully swivelling type with a safety catch fitted to
the hook.
A secondary load chain/cable and hook shall be supplied, suspended from the trolley.
The chain/cable shall be fixed length so that the hook is suspended approximately
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1000 mm below the bottom flange of the beam. The hook and chain/cable shall be
tested to the same safe working load as the main hoist. The secondary load
chain/cable shall be used to support a lift at intermediate levels whilst the main load
chain is re-slung.
All components of the travelling trolley and pulley block shall be suitable for humid
and corrosive atmosphere with traces of hydrogen sulphide
Load chain shall be of special alloy steel or stainless steel suitable for humid and
corrosive atmosphere with traces of hydrogen sulphide
All relevant requirements for motorised lifting equipment shall also be applicable to
manually operated lifting equipment.
19.16.3 Lifting Frames

Lifting Frames shall comprise an "A" frame or portal supporting a composite beam
over the lift centre lines which will carry a hoist block with traverse. The composite
parts of the device shall comply with the relevant specification clauses.
19.16.4 Lifting Davits

Lifting davits shall comprise of a simple single mounting; capable of traversing the
span of the area of lift and be fitted with a chain block as Clause 19.17.2 above. A
socket shall be provided which is to be cast into the reinforced concrete of the
associated structure.
19.17 GAS DETECTORS

19.17.1 Portable Gas Detectors: General
The detector shall be housed in a robust case sealed to comply with an approved
international standard. The case shall be provided with harness-type straps to allow
the equipment to be worn. Alternatively, a purpose-made carrying case, also with
harness straps, shall be supplied. In use, such a carrying-case shall allow the display
to be clearly visible.
The detector shall be explosion proof with an internationally recognised certification

as “intrinsically safe” allowing use in hazardous areas. The detector shall be suitable
for gas groups commonly found at sewage treatment works.
The detector shall be powered by a rechargeable nickel cadmium battery pack which
shall be replaceable. A fully charged battery pack shall operate the detector
continuously for a minimum of 10 hours. In use, low battery power shall initiate an
audible alarm.
The detector shall incorporate sensors to detect gas concentrations and initiate
alarms as follows:
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Mode Display range Alarm initiate
combustible gas or 0 - 100% by volume of air, > 20%

vapour calibrated for methane
hydrogen sulphide 0 - 25 ppm >10 ppm
oxygen 0 - 25% by volume of air >24% <19%
The display may be switchable between the three modes. However, should any one
of the three gas hazards occur, a warning lamp shall light and an audible alarm shall
sound, irrespective of the position of the switch.
Due to the limited life of gas sensor cells, the cells in the detector or any spare cells
provided shall be less than 3 months old at the time of handover to the employer.
Each cell shall have its date of manufacture indicated on its cover.
The detector shall be provided with an extension tube 2 m long and manual pump for
sampling inaccessible places.
Only equipment which is supported by a service workshop in Dubai authorised by the

manufacturer shall be provided.
19.17.2 Portable Gas Detector

One complete set of portable gas detection equipment shall comprise:
1) 1 No. Portable gas detector complete with sensors for combustible gas,
hydrogen sulphide and oxygen, and including rechargeable battery pack,
harness/carrying case and extension tube.
2) 1 No. Single way charger to suit above battery pack
3) 1 No. Stainless steel probe for extension tube
Test gases in 20 litre canisters:
1) 1 No. 2.5% methane in air

2) 1 No. 25 ppm hydrogen sulphide in air
3) 1 No. 17% oxygen in nitrogen
4) 1 No. box to house above equipment, suitable for wall mounting and labelled
“Portable Gas Detector”.
19.18 SURGE SUPRESSION & CONTROL

19.18.1 General
a) Where surge suppression equipment is required to be provided under the
Contract, the initial sizing of such equipment will have been carried out by
the DM or his representative. The Contractor shall be responsible for a final
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assessment of the pressure transients, based on the actual pump selection

and final pipework design.
b) The successful Contractor shall undertake a further more detailed analysis of
the system at the detailed design stage, using a proprietary computer based
hydraulic transient analysis software package modelling the suppressed
hydraulic performance of the system. The software package shall be one that
is approved by DM. The final design of the surge suppression equipment
shall be determined using the modelling capabilities of the software package.
c) A detailed surge analysis report shall be produced for each of the above
simulations. The form of the analysis and the report shall be such that it can
be reviewed by the DM. The cost of analysis shall be deemed to have been
included in the cost of the surge protection equipment.
d) Surge analysis modelling shall be undertaken by suitably qualified and
experienced specialists approved by the DM. The specialist shall be
recognised by a specialist hydraulic Institute.
e) The surge control system shall be designed to:
i. Limit maximum positive pressures in the delivery mains to the maximum
allowable surge rating for the pipe at all parts of the system.
ii. Limit minimum negative pressures in the suction & delivery mains to the
maximum allowable surge rating for the pipe at all parts of the system
(particularly important for GRP pipes).
iii. Prevent liquid column separation occurring where this is detrimental to the
system.
iv. Friction factors selected for the analysis shall be approved by DM.
f) Surge control system performance shall be verified by field site tests at all
duty conditions. The Contractor shall provide a chart recorder and surge
measuring equipment to develop a permanent record for each duty tested.
g) Surge vessels shall be provided where sewerage, potable water or TSE
pumping system pressure transients exceed the operating capabilities of the
associated suction and delivery mains under electricity supply failure
conditions.
h) Surge vessels shall be designed in accordance with PD 5500 or BS EN
13445 "Unfired Fusion Welded Pressure" Vessels.
i) Due allowance shall be made to ensure all materials are compatible with the
medium being pumped and also compressed air.
j) The following options for surge suppression may be considered bladder
vessel, air valves, damped reflux valves, pump flywheel controlled start
stopping of pump set or actuated delivery and suction line isolation valves.
k) Maximum surge pressures shall be controlled within the surge pressure
rating of the rising main pipe material.
19.18.2 Intersection of Welds
Longitudinal seam welds shall not cross at any intersection with circumferential welds
but shall be offset a minimum length corresponding to 90° of shell circumference.
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19.18.3 Vessel Geometry

a) Surge vessels shall be fabricated from Carbon Manganese steel, and full
details shall be supplied by the Contractor. The vessel shall comprise two
domed ends with an intermediate cylindrical section. Vertical mounting is
preferred. Not less than two lifting lugs shall be provided for lifting of the
complete vessel.
b) The inlet and outlet pipework shall be designed to the same criteria as the
vessel terminating in flanged connections to BS 4504 or equivalent rated in
association with the pumping plant pipework. A drain line shall be provided
complete with isolating globe valve and flanged hose connection suitable for
direct coupling of a flexible 2" hose.
c) The vessel shall be supplied complete with sight glass(es) and associated
fittings internal inspection port, manhole access, level control switches,
pressure gauges and safety pressure relief valves.
d) Support legs shall be thick section equal angle incorporating drilled feet for
levelling and bolting down of the vessel.
19.18.4 Sight Glasses
a) The Contractor shall supply two flanged entries for 20mm O.D. sight glasses
on the vessel having a minimum viewing length of 600 mm. The liquid level
should be uninterrupted over the length. The maximum operating pressure
of the sight glass shall be higher than the design pressure of the vessel. In
the event of glass failure the vessel shall remain pressurised.
b) The sight glass shall be provided with flanged bronze isolating valves
complete with ball check and displacement device, to prevent loss of liquid
upon gauge breakage, plus drain cock.
c) The sight tube shall be protected with a stainless steel guard and all round
polycarbonate protector. When necessary the sight glass shall be supported
at the centre from the surge vessel side wall.
d) Site glasses shall be sun protected.
19.18.5 Inspection Port
Where applicable, an elliptical inspection port approximately 320 x 220mm oval of the
type that incorporates an internal "pull up" plate with self-sealing joint tightened by
exterior draw bolts on a port bar shall be provided in the cylindrical section of the
surge vessel below top water level.
19.18.6 Main Access Flange

a) A man access hole of not less than 600mm internal diameter shall be
provided in the cylindrical section of the vessel to permit access from ground
level. This shall be covered with a suitable flange which shall be bolted onto
a fabricated flange on the manhole.
b) The man access flange cover shall be provided with a lifting swing davit
which shall incorporate a lifting screw, so that the whole flange cover may be
lifted up and then swung out from the entry port. The davit may be fabricated
onto the cylindrical wall of the vessel.
c) Service points shall be provided, four of these points shall be drilled and
tapped entries for level control switches, a further drilled and tapped entry
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shall be required for the supply air and pressure gauge line and one other
entry point shall be provided with a flanged entry for the safety relief valves.
All entry points into the main access flange shall be bossed out to suit the
size of the tapping or hole.
19.18.7 Safety Relief Valves & Pressure Gauge
a) A three way plug valve, with no neutral, shall be mounted on the main
access flange, with two in number safety relief valves mounted either side of
the plug valve outlets. The safety valves shall be suitable for air/water and
rated for the pressures likely to be experienced. They shall be adjustable and
incorporate a manual lift device or wedge for testing purposes.
b) A pressure gauge shall be mounted not less than 1m above floor level, have
a 100mm diameter face and be complete with isolating and a drip leg drain.
19.18.8 Bolting & Gaskets
a) All nuts and bolts for all flanges and fittings shall be stainless steel to BSEN
10088.
b) Gaskets shall be rubber insertion of other suitable Elastomer material
approved for use with sewerage or potable water (as applicable). Spiral
wound gaskets are not permitted.
19.18.9 Radiographic Testing

The Contractor shall allow for 100% radiographic testing in accordance with BS EN
12517-1
19.18.10 Welding
a) Welding shall only be carried out by qualified and experienced welders in
accordance with PD 5500 or equivalent, by reference to the following:
i. EN288 or equivalent Approval Testing of Welding Procedures.
ii. EN287 or equivalent Approval of Welders working to Approval Welding
Procedures.
19.18.11 Marking of Vessels
a) The Contractor shall mark clearly with their respective safe working pressure
in lettering not less than 80mm in height in gloss paint.
b) A brass plate shall also be fixed to the vessels which will state:
i. Name of manufacturer with address.
ii. Identification number.
iii. Client's Order number.
iv. Shell Thickness.
v. Corrosion allowance.
vi. Shell diameter.
vii. Head diameter.
viii. Head thickness.
ix. Head corrosion allowance.
x. Degree of X Ray inspection.
xi. Tan length.
xii. Design Pressure.
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xiii. Hydraulic Test Pressure.

xiv. Weight.
xv. Length.
xvi. Inspection Date.
xvii. Inspector’s initials.
xviii. S.W.P.
19.18.12 Compressors
a) Compressors shall be the oil-less piston type and shall be mounted adjacent
to the surge vessel. They shall comply with the compressed air Section of
the specification. Duty/standby compressors shall be provided. Each
compressor shall be capable of producing a volume of air at the working
pressure in conjunction with the surge vessel, be controlled by two of the
level probes mounted within the vessel, and have a capacity of not less than
1 litre/second Free Air Delivery at ambient temperatures, humidity and
pressure.
b) The compressors shall be of rugged design to provide a reliable and efficient
operation with a minimum of maintenance. In particular the suction and
discharge valves and pressure regulating system shall be designed to
guarantee a long and trouble free life. The compressor shall be provided with
air filtering, down-loading valve and the non- return valve shall be fitted with
resilient seats and be fitted directly to the surge vessel.
19.18.13 Automatic Air Volume Control System
a) The automatic air-volume control system, in conjunction with solenoid valves,
tank-mounted sensor probe and the air compressor units, shall control the
air/water ratio in the vessel, and maintain the air/water ratio within a range
compatible with the surge control system design. Remote indication of
excessive high or low water level in the tank shall be provided brought out to
electrical contacts for cabling by others.
b) An integral control panel shall be provided complete with all necessary
controls, relays, and time delay circuits, to fully control and actuate the air
add/vent solenoid valves. Solenoid valves shall be energized to open.
c) Solenoid valves for air service shall have forged brass or bronze bodies with
Teflon seats. Internal plungers, core tube, plunger spring, and cage
assembly shall be 316L stainless steel. Valve actuators shall be 240 volt a.c.
Seals shall be Teflon. Valves shall have a maximum operating pressure and
a maximum differential pressure of 2 MPa (290-psi). Solenoid valves shall be
energized to open.
The Contactor shall be responsible for supplying suitable pumping plant and surge
suppression equipment (if any) to ensure that transient pressure surges do not
exceed the following limits:
a) less than 5m below atmospheric pressure at any point along the pumping
main,
b) greater than 50% of the pressure rating of the pipes and fittings installed on
the pumping main.
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These limits shall not be exceeded under any condition of normal working or power
failure.
The Tenderer shall include for all necessary surge suppression equipment. The
equipment (if any) should be compatible with the characteristics of the pumping plant
proposed. It is therefore recommended that the Tenderer should perform his own
assessment of the pressure transients.
To confirm the results of his initial assessment, the Tenderer shall instruct the pump
manufacturer to carry out a comprehensive pressure surge analysis on the complete
hydraulic pumping system under all operating conditions, and submit three copies of
a report and calculations on the surge in the system within 3 months of contract
commencement to enable surge suppression equipment to be manufactured in time
for delivery and installation if found necessary.
19.19 Supports and Fixings

Unless otherwise specified all supports, fixing bolts, screws, etc., and other fixings
shall be provided, shall be of minimum Grade 316 S16 stainless steel and shall be as
follows;
1) Threaded and fitted with 3mm thick washers beneath bolt and nut. The length
shall be such that when tightened down with a nut & bolt the threaded portion
will not protrude more than half a diameter of the bolt.
2) When fastening galvanised components or aluminium alloy components. PTFE
washers shall be fitted beneath the stainless steel washers for both bolt head and
nut.
3) Stainless steel grade 316S31 shall be used for construction of pumps, fastening
galvanised or aluminium alloy components, holding down and anchor bolts.
Notwithstanding the above, the Contractor shall consider galvanic corrosion between
various metals when selecting materials for proposal.
19.20 Support for Pipework and Valves

All necessary supports, saddles slings, fixing bolts and foundation bolts shall be
supplied to support the pipework and its associated equipment in an approved
manner. Valves, meters, strainers, and other devices mounted in the pipework shall
be supported independently of the pipes to which they connect.
All brackets or other forms of support, which can conveniently be so designed, shall
be rigidly built up of sections.
No point of passage of pipes through floor or walls shall be used as a point of

support, except with the approval of the Engineer.
19.21 SUPPORTS AND ANCHORS

19.21.1 Process Piping
1) Support piping as described hereinafter and as shown by the support details
on the Mechanical Drawings.
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2) Unless otherwise specified herein, all standard pipe hanger and support
materials, design, manufacturer, selection and installation shall comply with the
standards of the Manufacturers Standardization Society of the Valves and
Fittings Industry, Inc. (MSS), Vienna, Virginia (001-703-281-6613).
3) See referenced standard specification for MSS pipe support element types.
Element types are presented to aid the Tenderer in identifying and providing
acceptable pipe supports.
4) No attempt has been made to show all required pipe supports in all locations on
the Drawings. The absence of pipe supports and details on any drawings shall
not relieve the Tenderer of the responsibility for providing them throughout the
plant.
5) Where piping connects to equipment, support the piping by a pipe support and
not by the equipment.
6) Size pipe support systems to withstand the loads imposed by the weight of the
pipes filled with water, plus any insulation. Select commercial pipe supports
and hangers for a minimum safety factor of 5.
7) Anchors:
a) Design anchors for the design load specified under paragraph Horizontal
Pipe Supports. The direction of the applied load shall be either parallel to, or
perpendicular to the pipe, whichever produces the greatest stress in the
anchor.
b) Provide anchors for piping smaller than 75 mm as specified in these
specification documents, Expansion Compensation.
8) Support stacked horizontal runs of piping along walls using a metal framing
system.
a) Use standard structural shapes or prefabricated structural members such as
“ Uni-strut” to construct the framing system
b) Pipes cannot be supported from the pipe above or below.
9) Support horizontal piping runs 300mm and smaller along concrete or masonry
walls using welded wall brackets.
10) Single runs of uninstalled pipe smaller than nominal 75 mm may be supported
from masonry walls with steel or stainless steel clips as appropriate. Piping
clamps which resist axial pipe movement through the support shall not be used
for plastic pipe.
11) The minimum design load rating for structural building attachment shall be based
on an allowable stress of 20 percent of the minimum tensile strength of the
material at service temperature. Castings shall include a casting quality factor of
0.80 of the allowable stress specified.
12) Attach hanger support rods to steel beams with beam clamps, to concrete with
inserts or flanges fastened with flush shells. Use only stainless steel insets with
stainless steel rods. Isolate dissimilar metals to prevent galvanic corrosion.
13) Do not use point bearing supports (e.g. C-clamps) with PVC piping. If riser
clamps are required, use only the full circumferential type. Provide supports at
manufacturer’s recommended spacing or 1.5m, whichever is less. If operating
temperatures are sufficiently high to lower the strength on PVC pipe, support
continuously using light metallic angles or channels and special hangers.
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Pipe support component type shall comply with the following requirements:
1) General Service (0 C to 50C):
Application Type (MSS SP-58) Notes

Horizontal Bare Pipe
Attachments
U-Bolt Hangers 24
Rings 6,11 1
Clevis Hanger 1
Clamps 3
Hanging Rollers 41,43
Supporting Rolls 44,46
Saddles 36,37,38
Horizontal Insulated Pipe
Attachments
Clips 26
Clevis Hanger 1 2
Hanging Rollers 41,43 2,3
Supporting Rollers 44,46 2,3
Protective Shields 39,40
Saddles 36,37,38 2
Vertical Pipe
Riser Clamps 8,42
Hanger Rod Fixtures
Turnbuckles 13,15
Swing Eyes 16,17
Clevises 14
Building Structural Attachments:
Inserts 18 4
C-Clamps 19,23
Beam Clamps 20,21,25,27,28,29,30
Welded Attachments 22,57,58
Brackets
2) Hot Pipe Service (50C to 225C):
Application Type Notes

Horizontal Bare Pipe 5
Attachments
Clevis Hanger 1 1,2
Hanging Rollers 41,43 2,3
Protective Shields 39
Supporting Rolls 44,46 2,3
Saddles 36,37,38 2
Vertical Pipe
Variable Spring 51 5
Hanger
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Hanger Rod
Fixtures -- 5
Building Structural:
Attachment -- 6
Notes:
1. Use for piping 60 mm and smaller.
2. Provide insulated piping with rigid pipe insulation insert
specified under Section 15260.
3. Provide insulated piping with protective shield.
4. See Section 05500 for acceptable anchors or fasteners.
5. Required support components are the same as for general
service.
19.21.1.1 Materials
a. All stainless steel pipe supports and all submerged piping supports, guides,
and fasteners or those installed below channel and wet well cover slabs shall
be type 316 stainless steel.
b. Acceptable piping hanger and support component materials for exposed
piping shall comply with the requirements of MSS SP-58 and these
specifications.
c. Provide hangers, rods, clamps, protective shields, metal framing support
components, and hanger accessories for exposed piping of stainless steel
(for stainless piping system) or hot dipped galvanized steel (for all other
piping systems). Hot dip galvanizing shall be in accordance with ASTMA
153 or A 386 unless noted otherwise on drawings.
d. Copper Piping: Use copper plated hangers or cushioned clamp type system.
1. Hanger Rods: Threaded either ends, threaded one end, or continuous threaded.
2. Inserts: Stainless steel. Malleable Iron case or galvanized steel shell and
expander plug for threaded connection with lateral adjustment, top slot for
reinforcing rods, lugs for attaching to forms; size inserts to suit threaded hanger
rods.
3. Sleeves:
a. Pipes through Non-Fire Rated Beams, Walls, Footings, and Floors: Form
with steel or stainless steel pipe as appropriate.
b. Pipes through Fire Rated and Fire Resistive Floors and walls, and
Fireproofing: Prefabricated fire rated sleeves including seals, UL listed.
c. Round Ductwork: Form with galvanized steel.
d. Rectangular Ductwork: Form with galvanized steel.
e. Fire Stopping: A sealant system to match the fire rating of the barrier.
4. Caulk: As specified within these specification documents.
5. Fasteners: Bolts, nuts, concrete anchors and anchor bolts shall be as specified
within these specification documents.
19.21.2 Building Services Piping
19.21.2.1 Pipe Hangers
a) Ferrous Piping up to 150 mm nom. Diameter: Adjustable galvanized steel

clevis complete with galvanized steel pipe covering shield for insulated
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piping.
b) Fire Protection Piping up to 50 mm nominal diameter: use of adjustable
galvanized steel band (FM approved) shall be permitted. Copper plated
hangers shall be used for copper piping.
c) Ferrous Piping over 150 mm nom. Diameter: adjustable, cast iron pipe roll
with steel axle, sockets, lock nuts etc. Pipe covering protection saddle shall
be used for insulated piping.
d) Copper Piping (non-insulated): adjustable galvanized steel band with rigid,
preformed, 6 mm thick felt, pipe isolator.
e) Copper Piping (insulated): Adjustable galvanized steel band with steel pipe
covering shield.
f) Multiple Hangers: Steel channel/angles, suspended or attached to frame
work. Pipe hanger/supports shall be as previously specified (make
appropriate selection). For piping placed above the cross member, the use
of U-bolts shall be permitted.
g) Use stainless steel components as specified above for stainless piping
systems.
19.21.2.2 Floor Supports
a) Ferrous Piping up to 150 mm nominal diameter: Adjustable pipe stanchion

saddle support complete with U-bolt, stand pipe with adjuster and floor
flange, use galvanized steel pipe covering shield for insulated piping.
b) Ferrous Piping over 150 mm nominal diameter: cast iron pipe roll with base
and stand, reinforced concrete or structural steel pedestals shall be provided,
as appropriate, to locate the base. Pipe covering protection saddle shall be
used for insulated piping.
c) Copper Piping (non-insulated): adjustable pipe stanchion saddle support
complete with U-Bolt, stand pipe with adjuster and floor flange and rigid
preformed felt, 6 mm thick, pipe isolator.
d) Copper Piping (insulated): Adjustable pipe stanchion saddle support
complete with U-Bolt, stand pipe with adjuster and floor flange and
galvanized steel pipe covering shield.
e) Use stainless steel components as specified above for stainless steel piping
systems.
19.21.2.3 Vertical Piping Supports
a) Ferrous Piping up to 150 mm nominal diameter: Galvanized steel riser

clamps and /or offset pipe clamp. Solid wood inserts shall be used at the
supports for insulated piping.
b) Ferrous Piping over 150 mm diameter: Gusset plates with integral bearing
plates (minimum thickness equal to that of the pipe) welded to pipe and
resting on cross channels over heavy duty vibration isolation pads (50
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durometer). The cross channels shall be offset to accommodate the piping

insulation and the vapour barrier sealed around the gusset plate with mastic
sealants. ‘Z’ cleats shall be welded on the cross channels at the ends of the
bearing plates to restrict movement.
c) Copper Piping up to 50 mm nominal diameter (non-insulated): Galvanized
malleable iron wall clamps with rigid, preformed felt, pipe isolator.
d) Copper Piping over 50 mm nominal diameter (non-isolated): Galvanized
steel offset riser clamp with isolator.
e) Copper Piping (insulated): Galvanized steel offset clamps over insulation.
f) Use stainless steel components as specified above for stainless steel piping
systems.
19.21.2.4 Distribution Piping In Shafts And Chases
a) Copper Piping: Semi-circular copper straps with ears for attaching to walls.
19.21.2.5 Pipe Anchors
a) Horizontal Ferrous Piping (non-insulated): Galvanized steel anchor chair and

U-bolt attached to structural steel framework.
b) Horizontal ferrous Piping (insulated): Steel plate (minimum thickness as that
of the pipe and length equal to the diameter) welded to pipe, projecting
beyond the insulation; attached to structural steel framing by bolting or
welding. The vapour barrier shall be sealed around the plate with mastic
sealants.
c) Vertical Ferrous Piping (non-insulated): Steel hold down anchor clamp and
base plate attached to reinforced concrete or structural steel supports. The
clamp shall be back welded to the pipe after installation.
d) Vertical Ferrous Piping (non-insulate): same as the support of vertical
insulated ferrous piping over 150 mm nominal diameter; excluding the
vibration isolation pad. The bearing plate shall be welded or bolted down to
the cross channel.
e) Horizontal Copper Piping: Galvanized steel anchor and U-Bolt over 150 mm
long wood inserts all round, attached to structural frame work.
f) Vertical Copper Piping: Galvanized steel offset riser clamps, over 150 mm
long wood inserts all round.
g) Use stainless steel components as specified above for stainless steel piping
systems.
19.21.2.6 Hanger Rods
a) Steel Hanger Rods: use stainless steel or galvanized mild steel rods with
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Dubai Municipality
continuous male thread as appropriate.
19.21.2.7 Hanger Rod Attachments
a) Turnbuckles: Provision shall be made for adjusting the heights, where

required.
b) Ball Hangers: Provision shall be made for allowing angular movement of the
hanger rod, where required.
c) Threaded Rod Couplers: stainless or galvanized steel unit, as appropriate,
machined from, bar stock for joining two lengths of threaded hanger rods.
Back nuts shall be provided on both sides of the coupler.
19.21.2.8 Building Attachments
a) Concrete Inserts: Stainless steel malleable iron or galvanized steel concrete

inserts as appropriate for the piping system. Complete with adjustable insert
nut. Suitable for hanger rods of size 22 mm diameter and under. Stainless or
galvanized steel continuous concrete insert may be provided at the
Tenderer’s option.
b) Self Drilling type Concrete Inserts: Stainless or galvanized steel self drilling
expansion type concrete inserts for hanger rods up to 12 mm diameter may
be provided at the Tenderer’s option.
c) Supports Rails (cast-in type): Stainless or electrozinced steel sections with
anchor lugs and filler strip. Complete with hammerhead nut or extension
pieces, as appropriate for the piping system.
d) Support Rails (surface mounted type): Stainless or electrozinced steel
sections with anchor lugs and filler strip. Complete with hammerhead nut or
extension pieces as appropriate for the piping system. The rail shall be
single or double as appropriate.
19.21.2.9 Flashing
a) Metal Flashing: 0.5 mm thick galvanized steel.

b) Lead Flashing: 24.5 kg/sq.m sheet lead for water proofing; 5 kg/sq.m sheet
lead for soundproofing.
c) Flexible Flashing: 1.25 mm thick sheet compatible with roof and wall
waterproofing.
d) Caps: Galvanized steel, 0.8 mm minimum; 1.5 mm at fire resistant elements.
19.21.2.10 Sleeves
a) Sleeves (for pipes through fire rated and fire resistive floors and walls):
Schedule 40 stainless or galvanized steel pipe sleeve, as appropriate for the
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piping system; packed with 96 kg/cu.m density fibreglass and caulked with
approved fire rated sealant at both ends.
b) Sleeves (for pipes passing through non-fire rated beams, walls, footings and
dry floors): Schedule 40 stainless or galvanized steel pipe sleeve, as
appropriate for the piping system; packed with 96 kg/cu.m density fibreglass
and caulked with approved type sealant at both ends. Sleeve shall be
extended 50 mm (2 inch) above the finish floor level, for vertical piping.
c) Sleeves (for ferrous pipes passing through external retaining walls): Cast iron
or ductile iron with integral puddle; packed with 96kg/cu.m density fibreglass;
caulked at the inside end with approved sealant and at the outside end with
hemp yarn and lead.
d) Sleeves (for cast iron drain, waste and vent piping through wet floors): PVC
pipe sleeve or wooden box to form the opening. After curing of the concrete,
this sleeve shall be removed and on completion of cast iron pipe installation,
the opening shall be filled with non-shrinkable grout and both sides of slab
shall be trowelled smooth and level.
19.21.2.11 Escutcheons
a) Set screw type escutcheons, with size sufficient to completely cover exposed
penetrations shall be provided at all pipe penetrations.
b) This shall be finished with prime coat where adjoining surface is to be field
painted, with baked enamel white finish where adjoining surface is fibre
board and chrome finish where adjoining surface is tiled with ceramic,
marble, etc.
19.21.2.12 Finish
a) All hangers supports inserts, shields and saddles for Building Services Piping
shall be stainless steel or shall have galvanized finish; as appropriate for the
piping system.
b) Hangers and supports for copper piping shall be copper or copper plated,
when used in direct contact with the copper piping.
19.21.3 Execution
19.21.3.1 Inserts
a) Provide inserts for placement in concrete formwork for suspending hangers

from reinforced concrete slabs and sides of reinforced concrete beams.
b) Provide hooked rod in concrete for inserts carrying pipes over 150 mm
nominal diameter.
c) Where concrete slabs form finished ceiling, install inserts flush with the slab
soffit.
d) Where inserts are omitted due to error, drill the slab through from below and
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provide a through bolt with square steel plate and nut above. Recess items
into slab and grout flush.
e) Where resin type anchors are used, select the type and quality to suit the
concrete into which it is to be installed.
19.21.3.2 Pipe Supports and Hangers (General)
a) Hanger or support assembly shall be capable of taking up the filled weight of

piping for half spans on either side plus 100 kg, with minimum overall factor
of safety of five.
b) Install hangers with minimum 12 mm space between finished covering and
adjacent work.
c) Place hanger within 300 mm of each horizontal elbow. Hanger shall have a
minimum vertical adjustment of 38 mm.
d) Provide multiple or trapeze hangers where several pipes can be installed in
parallel and at same elevation. Provide amply sized structural sections for
multiple trapeze hangers, and braces, supporting frames etc. calculations
shall be provided.
e) Support riser piping independently of connected horizontal piping.
f) Support piping at either side of flexible connections (at the system side only
on connections to equipment).
g) Do not attach supports, hangers or anchors to the building structural
elements wherein their installation, weight or expansion stress will result in
damage to the structure.
h) Apply one coat of zinc rich primer to the weld and surrounding areas, where
pipe support members are welded to building structural framing after
scraping and brushing the area clean.
i) Support piping buried in raft slabs or trenches as detailed on the Contract
drawings. Make the support capable of holding the pipe in position against
buoyant forces exerted during pouring of concrete.
j) Use fender washers and lock nuts with threaded hanger rods.
k) Where special slab construction (like omni slab) is used, install support rails
anchored to concrete portions for installing hangers.
l) Provide riser clamps at mid span for vertical piping up to and including 25
mm nominal diameter.
m) Support Fire Protection piping independently of other piping.
n) Provide away bracing on 3000 mm maximum centres unless otherwise
19.21.3.3 Supports and Hangers for Cast Iron Piping
a) Support horizontal cast iron piping at either side of the joints (at least one on
every piece of pipe) at intervals not exceeding 2.50M.
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b) Provide supports for fittings grouped together in horizontal runs, as

appropriate.
c) Anchor piping at horizontal changes in direction, at cleanouts and at start of
horizontal lines.
d) Provide floor clamps at every floor and offset riser clamps below the branch
take off joint in vertical risers.
19.21.3.4 Supports and Hangers for Steel Piping
a) Support horizontal piping as scheduled below.
Pipe size Maximum Spacing Hanger Rod Dia

(mm nominal diameter) (metres) (mm)
Up to 25 mm 2.0 8
32 to 50 mm 3.0 10
65 and 75 3.6 12
100 to 150 4.0 16
200 to 300 4.5 20
350 mm and over 5.0 22
b) Riser clamps /supports shall be provided at every floor, for vertical piping.
19.21.3.5 Supports and Hangers for Copper Piping
a) Horizontal piping shall be supported as scheduled below.
Pipe size Maximum Spacing Hanger Rod Dia

(mm nominal diameter) (metres) (mm)
Up to 25 mm 1.8 8
32 to 50 mm 2.0 10
65 and 75 3.0 10
100 to 150 3.6 12
b) Provide riser clamps with shield at 60 cm above floor level and at branch
take offs for vertical piping.
19.21.3.6 Sleeves
a) Set sleeves in position in form work and provide additional reinforcement

around sleeves.
b) Where sleeves in concrete structural elements are omitted due to error, the
required openings shall be cored only after obtaining written permission of
the Engineer. Sleeves with puddle flanges resting on the concrete surface
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Dubai Municipality
shall be placed and the sleeves fixed in position by non-shrink grout. Cutting
of holes by chiselling shall not be permitted.
c) All sleeves in wet areas shall be projected by at least 50 mm above the finish
floor level.
d) Erect sleeves in the formwork perpendicular to the wall face. Fix rigidly to
resist displacement during pouring of concrete.
e) Verticality of flange faces and alignment of bolt holes with connected
equipment (valves etc.) shall be checked and ensured after the pouring of
concrete. Make adjustment where required.
19.21.3.7 Flashing and Sealing
a) Pipes passing through external retaining walls: Clamp a layer of

waterproofing membrane to the pipe and flash over the wall waterproofing
membrane.
b) Pipes passing through roof slab: Provide flashing sleeve with integral
flashing flange. Clamp roof waterproofing membrane in the flashing flange
and fill around with approved type grout.
c) Roof Drains: Coordinate construction details. Develop actual dimensions for
elements like the extension filter etc. so that the required size can be cut at
the factory.
d) Area Drains and Planter Drains: Coordinate construction details. Provide
900 mm diameter lead flashing at the drain to direct the seepage into the
drain.
e) Water Storage Tank Drains: Provide flashing, 900 mm diameter at the drain
with non-toxic synthetic membrane and integrate the same with the tanking,
where provided.
f) Sanitary Fixtures: Seal the joints of all sanitary fixtures at walls and floors
with transparent, hard setting, age proof, sealant.
g) HVAC Piping and Ducting passing through Weather or Water proofed Walls,
Floors and Roofs: Provide flexible flashing and metal counter flashing as
appropriate.
h) Sound Control: Provide acoustic lead flashing around ducts and pipes,
penetrating equipment rooms; in accordance with manufacturer’s instructions
for sound control.
i) Roof Curbs: provide curbs for mechanical roof installations, with a minimum
height of 400 mm above roofing surface. Provide flexible sheet flashing and
counter flashing with galvanized sheet metal to make the assembly
watertight.
19.21.3.8 Adjusting and Cleaning
a) Hanger Adjustment: adjust hangers so as to distribute loads equally on all

attachments.
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Dubai Municipality
b) Support Adjustment: Piping and equipment shall be brought to the proper

level by providing grout under the supports.
c) Cleaning: all factory finished surfaces shall be cleaned and any marred or
scratched surfaces shall be repaired with manufacture’s touch-up paint; to
the approval of the Engineer.
19.22 VENDOR LIST

Tenderer to select the equipment from the list of recommended vendor list given in
Table 19-5 below and they shall select only one manufacturer or supplier from the list
below and mention in the tender proposal.
It is Tenderer’s responsibility to ensure that the offered make / supplier fully comply
Tenderer to confirm the technical details of the product offered by filling the relevant
technical schedules (including country of origin) as per the format provided in the
tender specification and shall submit in the tender proposal. Technical schedules with
incomplete information will be considered as incomplete proposal.
Tenderer may propose for any equipment item(s) where vendor name are not
specified or not included in the recommended vendor list in the table below. Such
proposal will be subject to Engineer clarifications during tender clarifications and
tender evaluation. All the necessary information required by Engineer will be
requested and it shall be submitted by Tenderer immediately to the Engineer for
tender assessment.
Table 19-5 Vendor List

Sr. Item Manufacturer
1 Submersible pumps for KSB / ABS / ITT Flygt Ltd. /Grundfos
sewage & Axial flow pumps
for drainage
Centrifugal Pumps in CORNELL / KSB
Drywell.
2 Valves AVK, Denmark / Econosto / Erhard, Germany /

Biwater / Saint-Gobain Pipelines plc / Dezurik /
VAG / Noreva / MIV Croatia / CSG UK /
HAWLE South Africa
3 Air valves Vent O Mat / ERHARD / ARI South Africa /
HAWLE/ VAG/ AVK
4 Penstocks Ham baker / VAG / Erhard / Adam Hydraulics /
Simon-Hartley / Biwater /KWT Neatherland/
Industrial Penstock
5 Bar Screen / Screening OVIVO / Huber, Germany / Passavant,
equipment Germany.
6 Washpactor & Screw Huber / Passavant / Jones Attwood
conveyor
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Dubai Municipality

7 Sump Pumps / Drain Grundfos / Ebara / ABS / ITT Flygt Ltd / KSB /
pumps KAPRARI
8 Positive Displacement Dresser Roots / Ingersol Rand
Blowers
9 Centrifugal Blowers Universal / Howden / Dresser Roots / Ingersol
Rand
10 Submersible Mixer ABS / Flygt / KSB
11 Supports and Anchors B-Line Systems Inc., Highland, IL / Unistrut
Corporation, Wayne, MI / Grinnel Supply Sales
Company, Exeter, NH. / ZSI, Livonia, MI.
12 Split System Air Airtemp / Climatrol / BDP Co./ Carrier NC
Conditioning units Group, Carrier Corp./ General Electric Co./
Mistubishi Electric Corp. / Trane Co. / National
13 Duct Hardware Ventfabrics, Inc / Young Regulator Co.
or similar equivalent
14 Duct Access Doors Air Balance Inc. / Duro Dyne Corp. / Register
& Grille Mfg.Co.Inc / Ruskin Mfg.Co /
Ventfabrics, Inc / Zum Industries, Inc., Air
Systems Div
15 Flexible Connections American / Elgen Co. Energy Div / Duro Dyne
Corp./ Ventfabrics, Inc.
15 Chemical Metering Pumps Diaphragm metering pumps: Wallace &
Tiernan / Pulsafeeder / Aldos, Germany /
Prominent / LMI / Milton Roy
Calibration Chambers: Charles Crowley Co. /

Milton Roy
Pulsation Dampeners : Zemarc Corp / Milton

Roy
16 Single Stage Centrifugal Ingersoll Rand / Atlas Capco / Kaeser
Compressor
17 Safety Showers Haws / Hughes Safety Showers Ltd. /
Speakman
18 Shaftless Screw Conveyor Huber / Passavant
19 Belt Conveyor Sevar , Germany / Taunton Engineering, USA
20 Vibration Isolation Metraflex of Chicago, IIinois (USA) / Mason
Industries, Smithtown, New York (USA) /
Vibration Mountings and Controls Inc.,
Blomingdale, New Jersey (USA)
21 Lifting device Demag / Morris
22 Genset Caterpillar / Perkins / FG Wilson / MTU
23 Odour control System Envicon / Corodex /IPEC Belgium /Amtrad /
Amairair International
24 Flange Adaptors and DMJ MIV Croatia/ Viking Johnson UK/ HELDEN UK
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Dubai Municipality

25 Ductile Iron Pipes and MIV Croatia
Fittings
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DUBAI MUNICIPALITY
DEPARTMENT
SECTION 20
FIRE ALARM AND FIREFIGHTING SYSTEM
DM/SRPD Section 20 Fire Alarm and Fire Fighting System Rev 00 June 2016

Dubai Municipality
DM/SRPD Section 20 Fire Alarm and Fire Fighting System Rev 00 June 2016 Page i of ii

Dubai Municipality
SECTION 20
FIRE ALARM AND FIRE FIGHTING SYSTEM
CONTENTS
20.1. FIRE ALARM AND FIRE FIGHTING SYSTEM ............................................................. 1
20.1.1. GENERAL ............................................................................................................. 1
20.1.2. CODES AND STANDARDS ................................................................................. 1
20.1.3. FIRE FIGHTING AND FIRST AID EQUIPMENT .................................................. 2
20.1.4. FIRE PUMP SETS .............................................................................................. 13
20.1.5. Fire Hydrant ........................................................................................................ 20
20.1.6. Sprinkler System ................................................................................................. 21
20.1.7. CLEAN AGENT FIRE SUPPRESSION SYSTEM (FM-200 / HFC-227ea) ......... 26
20.1.8. FIRE ALARM AND VOICE EVACUATION ......................................................... 33
20.1.9. EMERGENCY LIGHTING SYSTEM ................................................................... 42
20.1.10. Fire Door ............................................................................................................. 48
20.1.11. Pipes, Fittings and Supports ............................................................................... 49
20.1.12. HDPE Pipe ......................................................................................................... 52
20.1.13. Accessories ........................................................................................................ 52
20.1.14. APPROVED SCHEDULE OF MANUFACTURERS: ........................................... 53
DM/SRPD Section 20 Fire Alarm and Fire Fighting System Rev 00 June 2016 Page ii of ii

Dubai Municipality
20.1. FIRE ALARM AND FIRE FIGHTING SYSTEM
20.1.1. GENERAL
20.1.1.1. Ratings
a) The Contractor is responsible for the quality and the satisfactory operation of the
installations entrusted to him, as well as for compliance with the performance
stipulated in this document.
b) Consequently, for his own account and under his own responsibility, he must carry
out all calculations and select the necessary materials and equipment.
c) The Contractor shall supply all materials necessary to make up effective and
operable fire alarm, firefighting and exit lighting systems for the facilities.
d) All instrumentation and electrical equipment will be enclosed to suit the Hazard
Class of the area.
e) The same applies to equipment selection, for which the information given in this
document must be deemed as indicative and defines only the minimum
requirements.
f) All Materials should have at least been certified by two independent Certification
Organizations from International Testing Laboratories & Accredited Certification
Bodies as LPCB/ BSI Kitemark / Vds / UL and or FM.
g) The drawings shall show isometric details of clean agent storage containers,
mounting details and proposed pipe runs and sizes. Electrical layout drawings shall
show the location of all devices and include point-to-point conduit runs and a
description of the method(s) used for detector mounting.
h) A complete sequence of operation shall be submitted detailing all alarm devices,

shutdown functions, remote signalling, and agent discharge for each system.
i) Submit drawings, calculations and system component data sheets for approval to
the local Fire Prevention Agency, and all other Authorities Having Jurisdiction before
starting installation.
20.1.2. CODES AND STANDARDS
a) All the systems shall be designed and installed in accordance with the requirement
of International Codes and Standards and Local Authority having Jurisdiction. They
shall be particularly in accordance with the following NFPA / BS EN / Vds standards:
i. NFPA 10, Standard for Installation of Portable Fire Extinguishers

ii. NFPA 11, Standard for the low, medium and high expansion foam
iii. NFPA 11A, Standard for low, medium and high expansion foam system
DM/SRPD Section 20 Fire Alarm and Fire Fighting System Rev 00 June 2016 Page 1 of 58

Dubai Municipality
iv. NFPA 12, Standard for carbon dioxide extinguishing system

v. NFPA 13, Standard for the Installation of Sprinkler Systems
vi. NFPA 14, Standard for the Installation of Standpipe and Hose Systems
vii. NFPA 15, Standard for water spray fixed system for fire protection
viii. NFPA 17, Standard for dry chemical extinguishing systems
ix. NFPA 17A, Standard for wet chemical extinguishing systems
x. NFPA 20, Standard for the Installation of Stationary Pumps for Fire
Protection
xi. NFPA 22, Standard for Water Tanks for Private Fire Protection
xii. NFPA 24, Standard for the Installation of Private Fire Service Mains and their
Appurtenance
xiii. NFPA-25, Standard for Inspection, Testing, and Maintenance of Water
Based Fire Protection Systems
xiv. NFPA-70, National Electric Code
xv. NFPA 72, National Fire Alarm Code
xvi. NFPA 92A, Standard for Smoke Control Systems
xvii. NFPA-101, Life Safety Code
xviii. NFPA-110, Standard for Emergency and Stand by Power systems
xix. NFPA-170, Standard for Fire Safety Symbols
xx. NFPA 204, Standard for Smoke and Heat Venting
xxi. NFPA-220, Standard for types of Building Construction
xxii. NFPA-221, Standard for Fire Walls and Fire Barrier Walls
xxiii. NFPA 780, Standard for the Installation Lightning Protection Systems
xxiv. NFPA-2001, Standard on Clean Agent Fire Extinguishing systems
xxv. NFPA 5000, Building Construction & Safety Code
xxvi. OSHA, Code of federal regulations, Title 29, Part 1926
xxvii. BS EN3 for portable fire extinguishers
xxviii. BS EN 1866 for mobile extinguishers
xxix. BS EN 671-1 for fixed firefighting system
xxx. BS 5041-3 for dry riser inlet
xxxi. BS EN 54 Standard for installation of Fire Alarm System.
20.1.3. FIRE FIGHTING AND FIRST AID EQUIPMENT

a) All First Aid Equipment (Fire Extinguishers, Hose Reels, Fire Hose Rack, Fire
blankets) shall have been certified by two Certification Organizations from

Dubai Municipality
International Testing Laboratories & Accredited Certification Bodies as LPCB

Approval / BSI KITE mark approval and or UL listed/FM Approved.
20.1.3.1. Fire Extinguishers
20.1.3.1.1.General
a) Fire Extinguishers shall be manufactured to comply with BS EN 1866 (Mobile)

standards.
b) Fire Extinguishers shall comply with NFPA-10 or BS 5306 for the installation.
c) The classification of fire extinguishers shall consist of a letter that indicates the class
of fire on which a fire extinguisher has been found to be effective, preceded by a
rating number (Class A, Class B and Class F only) that indicates the relative
extinguishing effectiveness.
d) The distribution of fire extinguishers shall comply with the prescribed requirements
of NFPA-10, as shown on the drawings and the specific requirements of the local
Civil Defence Authorities.
e) Cabinets housing fire extinguishers shall not be locked.
f) Portable fire extinguishers shall be maintained in a fully charged and operable

condition, and kept in their designated places at all times when they are not being
used.
20.1.3.1.2.ABC Dry Powder Fire Extinguisher
a) ABC Dry powder fire extinguishers shall be manufactured in accordance with BS

EN3 for portable extinguishers and BS1866 for mobile extinguishers and shall be
operated by means of a lever/squeeze handle operated valve provided with a safety
pin which shall avoid inadvertent operation and the valve shall be capable for
controlling partial discharge. The cylinder shall have minimum working pressure of
14bar. The temperature shall range from -20° to 60° C.
b) The extinguisher must have a plastic base (Only for portable). It must be coated
externally by electrostatic polyester powder and oven baked for corrosion
resistance. The cylinder shall be made special cold rolled steel sheet with
Argon/CO2 automatic welding process and the suction tube shall be made of PVC
material. All extinguishers shall carry instructions for operation and maintenance in
English and Arabic.
c) The Dry powder fire extinguishers: The product should have at least been certified
by two independent Certification Organizations from International Testing
Laboratories & Accredited Certification Bodies as LPCB Approval / BSI KITE mark
approval and or UL listed/FM Approved.
d) Multipurpose Dry Chemical Extinguishers (Class A, Class B, and Class C Fires and
Electrical Fires).

Dubai Municipality
e) The extinguishers are recommended with the capacities and minimum fire rating as
follows:
SL # Capacity Fire Rating
1 1 Kg ABC Dry Powder 8A & 34B
7 25kg Dry powder Mobile 34A I B
8 50kg Dry powder Mobile 34A II B
9 100kg Dry powder Mobile 34A III B
10 150kg Dry powder Mobile 34A IV B
20.1.3.1.3.Carbon Dioxide Fire Extinguisher
a) Carbon dioxide fire extinguishers shall be manufactured in accordance with BS EN

3 (portable) and BS EN 1866 (mobile) and shall be operated by means of a lever
/squeeze handle operated valve provided with a safety pin which shall avoid
inadvertent operation and the valve shall be capable for controlling partial
discharge.
b) The cylinder shall be made of high grade seamless carbon steel pipe or aluminium
alloy and It must be coated externally by electrostatic polyester powder quoting and
oven baking to resist corrosion. The cylinders shall be free from leakage during
hydrostatically pressure tested to 250bar. The temperature shall range from -20° to
60° C.
c) The suction tube shall be Aluminium. All extinguishers shall carry instructions for
operation and maintenance in English and Arabic.
d) Typical applications are electrical & electronic equipment, food preparation areas,
laboratories, and printing or duplicating areas, telephone equipment Rooms, Engine
Rooms, Control Rooms, Paint spray Booths, Flammable liquid storage areas etc.,.
Since the agent is discharged in the form of a gas/snow cloud, it has a relatively

Dubai Municipality
short range of 3 ft. to 8 ft. (1 m to 2.4 m). This type of fire extinguisher is not
recommended for outdoor use where windy conditions prevail, or for indoor use in
locations that are subject to strong air currents because the agent can rapidly
dissipate and prevent extinguishment. The concentration needed for fire
extinguishment reduces the amount of oxygen (air) needed for life safety when the
discharge is in a confined area (space).
e) The CO2 extinguishers are recommended with the capacities and minimum fire
rating as follows:
1 2 Kg CO2 55B
2 5 Kg CO2 55B
3 10Kg CO2 Mobile Min 70B
4 20kg CO2 Mobile Min 89B
5 30kg CO2 Mobile Min 113B
6 50Kg CO2 Mobile Min 144B
20.1.3.1.4.Water Fire Extinguisher
a) Water type Fire extinguisher shall manufactured in accordance to BS EN 3

(portable) and BS EN 1866 (mobile) and shall be operated by means of a lever
operated self-closing control valve to enable the discharge to be interrupted
temporarily and provided with a safety pin. The cylinder shall have minimum
working pressure of 14bar. The temperature shall range from +5° to 60°C.
b) The extinguisher must have a plastic base. It must be coated inside by electrostatic
PVC resin to resist corrosion. The cylinder shall be made special cold rolled steel
sheet with Argon/CO2 welding process and the suction tube shall be made of Rigid
PVC with filter. The water type fire extinguisher capacity shall be of 9 Litres stored
pressure type or 2-1/2 Gallon. All extinguishers shall carry instructions for use in
English and Arabic.
c) The capacity of the extinguisher shall be of 9Lts and 2 ½” Gallon shall have a
minimum fire rating of 13A as per BS EN3.
d) The water extinguishers are recommended with the capacities and minimum fire
rating as follows:

Dubai Municipality
1 6 ltr Water 13A
2 9 ltr Water 21A
3 20 Liter Mobile Min 13A
4 25 Liter Mobile Min 13A
5 45Liter Mobile Min 13A
20.1.3.1.5.Foam Fire Extinguisher
a) Foam type Fire extinguisher shall manufactured in accordance to BS EN 3

(portable) and BS EN 1866 (mobile) and shall be operated by means of a lever
operated self-closing control valve to enable the discharge to be interrupted
temporarily and provided with a safety pin. The cylinder shall have minimum
working pressure of 14bar. The temperature shall range from +5° to 60°C.
b) The extinguisher must have a plastic base. It must be coated inside by electrostatic
PVC resin to resist corrosion. The cylinder shall be made special cold rolled steel
sheet with Argon/CO2 welding process and the suction tube shall be made of Rigid
PVC with filter. The Foam type fire extinguisher capacity shall be of 9 litres stored
pressure type or 2-1/2 Gallon. All extinguishers shall carry instructions for use in
English and Arabic.
c) The capacity of the extinguisher shall be of 9Lts and 2-1/2Gallon shall have a fire
rating of 21A & 183B as per BS EN3.
d) The Foam extinguishers are recommended with the capacities and fire rating as
follows:
1 6 ltr Foam 21 A & 144B

Dubai Municipality
2 9 ltr Foam 21A & 183B
3 20 Liter Foam Mobile Min 13A I B
4 25 Liter Foam Mobile Min 13A I B
5 45Liter Foam Mobile Min 13A II B
6 50Liter Foam Mobile Min 13A II B
7 90Liter Foam Mobile Min 13A III B
8 100Liter Foam Mobile Min 13A III B
9 135Liter Foam Mobile Min 13A IV B
20.1.3.1.6.Wet Chemical Fire Extinguisher
a) The Wet Chemical Fire Extinguishers shall have LPCB/BSI KITE mark approved
and comply with BS EN3 standards. The cylinder shall be tested to 30 bars and
shall have minimum pressure of 10 bars. The capacity shall be of 3 litres 25F/13A &
6 litres with 75F/13A ratings. They shall be provided in all the kitchens. The
temperature shall range from +5° to 60°C.
b) The Wet Chemical extinguishers are recommended with the capacities and fire
rating as follows:
1 3 ltr Wet Chemical 13A & 25F
2 6 ltr Wet Chemical 13A & 75F
20.1.3.1.7.Installation
a) Fire extinguishers shall be conspicuously located where they will be readily

accessible and immediately available in the event of fire. Preferably they shall be
located along normal paths of travel, including exits from areas.
b) Fire extinguishers shall not be obstructed or obscured from view.
c) Portable fire extinguishers other than wheeled types shall be securely installed on
the hanger or in the bracket supplied or placed in cabinets or wall recesses. The
hanger or bracket shall be securely and properly anchored to the mounting surface

Dubai Municipality
in accordance with the manufacturer’s instructions. Wheeled-type fire extinguishers

shall be located in a designated location.
d) Fire extinguishers having a gross weight not exceeding 40 lb (18.14 kg) shall be
installed so that the top of the fire extinguisher is not more than 5 ft. (1.53 m) above
the floor. Fire extinguishers having a gross weight greater than 40 lb (18.14 kg)
(except wheeled types) shall be so installed that the top of the fire extinguisher is
not more than 31/2 ft (1.07 m) above the floor. In no case shall the clearance
between the bottom of the fire extinguisher and the floor be less than 4 in. (10.2
cm).
e) Fire extinguishers shall be installed in a 1.2 mm thick, stainless steel, polished finish
cabinets where required in finished rooms / office areas and as shown on the
drawings and shall be confirmed with the Architect.
20.1.3.2. Fire Hose Reels- Automatic Type
a) The hose reel drum shall be made of electro galvanized steel sheet or stainless
sheet and the cabinet shall be supported with reinforced support arm and swing
through 180 degrees. Welding of any part on cabinet front shall not be allowed. The
middle piece of the hose reel shall be not less than 200mm diameter.
b) The reels shall comply with BS EN 671-1 and comprise a reinforced semi rigid hose.
The semi rigid hose use for the hose-reel shall be LPCB/BSI Kite mark and or
having Local Civil Defence approved in conformance to BS EN 694. The semi rigid
hose shall be 25mm or 19mm diameter x 30m long, coiled on a revolving drum. The
outer end of a hose shall be fitted with a “jet / spray / shut-off” control nozzle. The
inner end of the hose shall be connected through the reel to the water supply.
c) All water passage must be brass chrome plated and plastic parts are not permitted.
The product should have at least been certified by two independent Certification
Bodies as LPCB approval/KITE mark approval.
d) In case of automatic hose reels, the reels shall incorporate a valve that
automatically turns on the water supply when approximately 3 metre of hose is
unreeled, and shut off again when the hose is re-wound onto the reel. A manual
shut-off valve of the wheel type shall also be installed on the service pipe to each
hose reel.
e) The hose nozzle shall be (JET/SPRAY/SHUT OFF) type nozzle.
f) Each hose reel shall be installed and tested to BS 5306 and shall deliver not less
than 0.4 l/s when the two top-most reels are in use simultaneously providing a jet of
approximately 6 metre in length. Pressure reducing devices shall be provided
whenever necessary to limit the pressure as per local authority remotest point
requirement.
g) Brief operating instructions should be clearly displayed on or by each hose reel in

both English & Arabic languages

Dubai Municipality
h) The hose reels shall be suitable for working pressures up to 12 bar (175psi) and
shall be installed in accordance with the manufacturer’s instructions.
20.1.3.3. Fire Hose Rack
a) Fire hose rack assembly shall be UL/FM approved. The hose rack shall be of size of
1.5 inch x 30 metre or 2.5 inch x 30 metre.
b) Brief operating instructions shall be clearly displayed on the unit.
c) The hose rack assembly shall be semi-automatic type and suitable for the working
pressure of 150Psi and shall be installed in accordance with the manufacturer’s
instructions.
20.1.3.4. Fire Blankets
a) Provide fire blankets in Kitchens. Fire blanket shall be good quality with silicon
coating provided on both sides. The size shall be 4 feet x 4 feet, 4 Feet x 6 feet and
6 feet x 6 feet.
b) The product should have at least been certified by two independent Certification
Bodies as LPCB/KITE mark approved.
20.1.3.5. Standpipe and Hose Systems
20.1.3.5.1.Fire Hose & Nozzle
a) The product should have at least been certified by two independent Certification
Bodies as LPCB approval/BSI KITE mark approval and or UL listed/FM Approved.
b) Fire hose shall be of synthetic reinforced rubber lined, 65 mm diameter and 30 m

long equipped with brass chrome plated male coupling for the connection with the
landing valve, and female coupling for the connection 65 mm chrome plated
adjustable diffuser nozzle. The fire hose unit shall include the landing valve
specified above, and shall have minimum working pressure of 15 Bar and bursting
pressure of minimum 45 Bar.
20.1.3.5.2.Landing Valves (Pressure Reducing & Resisting Devices)
a) Landing valves shall be of pressure reducing and restricting type devises

acceptable to the Fire Brigade use inside buildings. This device shall have 65mm
inlet diameter bore fitted with 65 mm. instantaneous female coupling conforming to
BS 336 and a blank cap secured by a suitable length of chain. The product should
have at least been certified by two independent Certification Organizations from
International Testing Laboratories & Accredited Certification Bodies as LPCB
approval/BSI KITE mark approval and or UL listed/FM Approved.
b) The valve shall be of brass / Gunmetal construction with approved finish. If the
landing valve is UL listed then the outlet coupling must be quick instantaneous with

Dubai Municipality
local fire services. The installation of the coupling should be done by an authorized
installer.
c) Landing valves shall be installed inside the cabinet, at a height above floor level
between 750 mm and 1100 mm. The outlet shall be installed to give clearances of
not less than 150 mm on both sides and below the valve and not less than 200 mm
clearance above the hand wheel.
20.1.3.5.3.Hose Reel Cabinets
a) The hose reel cabinet shall be either wall-mounted type or recessed type. The
cabinet can be single or double to accommodate fire hose reel in the upper
compartment and other fire equipment including fire extinguishers in the bottom
compartment.
b) The cabinet has to be made of minimum 1.2mm thickness electro-galvanized steel

sheet or stainless steel as per design requirement. The door can be different type
like wood to steel finish, marble finish, MDF wooden door, clear glass or wired
glass. The stainless steel cabinets shall be polished finish type, the finish shall be
decided upon the approval of the architect.
c) The Double fire hose reel cabinet in different locations of the building shall have
following specified fire equipment:
i. Automatic or manual Fire Hose Reel

ii. Fire Hose and Nozzle or fire hose rack assembly
iii. 5 kg CO2 Fire Extinguisher
iv. 6 kg DCP Fire Extinguisher
20.1.3.5.4.Fire Breeching Inlet Valve
a) The unit shall be of BSI kitemark / LPCB approved and or UL Listed/FM approved.
b) The inlet breeching piece shall be of horizontal pattern having a 150 mm flanged
outlet and four 65 mm instantaneous male inlets complete with blank caps and
chains. A non-return (check) valve shall protect the inlet. The coupling shall comply
with BS 336. The inlet connections shall be of suitable type of local fire brigade
department.
c) The breaching piece shall be equipped with a 25 mm drain valve to drain the riser.
d) All parts including valve body, chain and caps shall be brass / gunmetal if it is UL
Listed and valves body shall be made of DI body with Brass Inlet Valves polished
chrome plated if it is BSI kitemark/LPCB approved. The product should have at least
been certified by two independent Certification Organizations from International
Testing Laboratories & Accredited Certification Bodies as LPCB approval/KITE
mark approval and or UL listed/FM Approved.

Dubai Municipality
20.1.3.5.5.Fire Breeching Inlet Valve Cabinet
a) The unit shall be BSI kitemark/LPCB approved. The product should have at least
been certified by two independent Certification Organizations from International
Testing Laboratories & Accredited Certification Bodies as LPCB/BSI Kitemark
approved and shall be accepted by DCD..
b) The inlet breeching unit shall be housed in an steel flush box painted by polyester
powder coated with wired glass glazed front panel as per BS 5041-5 standard and:
c) Conspicuously indicated by the words: “Dry Riser Inlet, Sprinkler Inlet, Wet Riser
Inlet” in block letters on the inner face of the glass, depending on the project type.
d) Fastened only by means of a spring lock, which can also be operated from the
inside without the aid of a key after the glass has been broken.
e) Made large enough for hose to be connected to inlets even if the door cannot be
opened and the only means of access is by breaking the glass.
20.1.3.5.6.Execution/Installation
a) Standpipe and hose systems shall be installed in accordance with NFPA-14 and
Authority having jurisdiction requirements and as shown on the drawing.
b) The Fire protection contractor shall be responsible to co-ordinate his work with all
other trades and shall be completely familiar with and shall make allowance for
conditions which affect the fire protection installation.
c) The Fire hose cabinets shall be mounted securely in the concrete block walls
shimmying the back box and mortaring tightly in place.
d) Provide a pressure gauge with an isolation cock with inspectors test plug on top and
bottom of the each stand pipe risers.
e) Chrome plated nipples shall be provided in between the landing valve and hose
connection. Chrome plated escutcheons shall be provided where pipes penetrate
the cabinet.
f) A water flow switch shall be provided in each standpipe riser and interfaced to fire
alarm system for monitoring and to locate the section of water flow during
firefighting operation.
g) A drain valve and piping, located at the lowest point of the standpipe piping
downstream of the isolation valve, shall be arranged to discharge water at an
approved location.

Dubai Municipality
20.1.3.5.7.Cleaning and Testing
a) Tubes and all items of equipment shall be delivered, stored and maintained in
closed storage with their open ends effectively plugged, capped or sealed. All
fittings, valves and sundry items shall be stored in clean bins or bagged and stowed
in suitable racks. All such stored items shall be maintained under weatherproofed
cover to be supplied by the MEP sub-contractor until they are ready for
incorporation in the works. Particular care shall be taken to ensure that electrical
equipment and components are kept clean and dry.
b) Before installations are handed over or subjected to the inspection and tests, the
entire installation shall be thoroughly cleaned, both internally and externally.
c) All fire protection installations shall be flushed out with clean water. During the
flushing out, provision shall be made to exclude any items of plant, which could be
damaged by the cleaning operation. The entire operation shall be carried out to the
d) The fire protection system shall be tested in accordance with the NFPA codes and
the relevant standards, with particular reference the requirements set forth in this
section:
e) All testing shall be performed under the work of this section. All services required for
testing shall be a responsibility of the work of this section. The MEP sub-Contractor
shall notify the Engineer of all tests, 48 hours prior to testing.
f) If the systems are tested in sections, the connection to the previously tested section
shall be included.
g) All tests that may be required by the local fire authorities shall be performed under
the work of this section, in the presence of their representative, if so required.
h) All leaks shall be corrected and the system re-tested until no leaks are found, at no
cost to the client.
i) Functional tests of all water flow alarms are a responsibility of the works of this
Section.
j) When the various systems are completed, operation tests shall be run on all
equipment to demonstrate proper operating conditions. These tests shall be run
under the observation of the inspector and the client’s operating engineer. The
client’s operators shall be instructed during this period. Operation tests shall be
performed under the work of this section.
k) Should any piece of equipment or apparatus of any material or work fail in any of
these tests, it shall be immediately removed and replaced by a perfect material, and
the portion of the work replaces shall again be tested under the work of this Section.

Dubai Municipality
20.1.4. FIRE PUMP SETS

20.1.4.1. General
i. 1 Electric Main Fire pump

ii. 1 Diesel Stand By Fire pump
iii. 1 jockey pump
a) Each system shall be design to insure the maximum pumping capacity even if 1
pump fails.
b) The total supplying of all the necessary equipment for the firewater production
(including pumps, engines driven, controllers, instrumentation, piping, valves, relief
valves) shall be deemed included.
c) The supplying and installation of the day fuel tank of the engines is included in the
Contractor’s scope.
d) The fuel tank (and all the fuel installation) shall be in accordance with NFPA
standards.
e) The air supply system of the diesel engines drive (automatic opening, venting
panels,) is included in the Contractor’s scope.
f) The fire pumps, motor, engine and electric pump controllers and diesel pump
controllers shall be UL listed or FM approved, built in the country where the
agreement is made. Unit responsibility must be submitted from the manufacturer.
g) The fire pumps and engine driven shall be in accordance with NPFA 20 (curves,
starting, protection,).
h) The problem of surge (hammer effect) shall be taken into account in the design. A
surge analysis shall be conducted and specific surge pressure control system shall
be installed.
i) Over-pressure system shall also be installed.
j) The contractor shall provide fully certified hydraulic calculations for exact sizing of
the pumps.
k) The pumps shall be furnished with a full set of bench test certificates proving
acceptability for the design points of this installation.

Dubai Municipality
20.1.4.2. Products
20.1.4.2.1.Fire Pumps
a) Fire pumps shall be UL or FM approved. Each pump shall have a capacity as

shown in pump schedule, adjusted as necessary to suit the hydraulic calculations.
b) The pumping unit or package shall meet all requirements complying with NFPA 20
c) The pumps shall also deliver not less than 150% of rated capacity at a pressure of
not less than 65% of rated pressure. The shutoff pressure shall not exceed 140% of
the rated pressure at rated capacity.
20.1.4.2.2.Fire Pump Type
a) Each fire pump shall be of horizontal split case centrifugal single stage or multistage
construction, specifically labelled for fire service and capable of providing the
required flow and pressure of the entire development.
b) The pump shall be connected to the combined sprinkler/standpipe system. The

suction supply for the fire pump shall be from a storage tank at a maximum pressure
of 20 kPa and a minimum pressure of 0 kPa. The pump casing shall be cast iron
and rated to withstand twice the working pressure.
20.1.4.2.3.Pump Construction
a) The pump construction shall be cast iron casing, Bronze impeller, Stainless Steel
shaft and gland packing.
b) The pump shall also deliver not less than 150 % of the rated capacity at a pressure
of not less than 65 % of the rated pressure. The shut off pressure shall not exceed
140 % of the rated pressure at rated capacity.
20.1.4.2.4.Pump Discharge and Head
a) The pump discharge & head shown on the drawing schedule is an estimate. The fire
protection contractor shall select a pump discharge and head to satisfy the fire
protection system requirements resulting from the system hydraulic calculations.
20.1.4.2.5.Fire Pump Accessories
a) The Fire and Sprinkler Pumps shall include the following accessories, as required
by NFPA standards:
i. Flow Metering Device, shall be of the Venturi type. Pilot and annubar devices
will not be acceptable - One metering device shall be provided for each
pump or as shown on the drawings. Pipe water back to the storage tank.

Dubai Municipality
ii. Discharge tee.

iii. Necessary isolating valves with supervisory switches.
iv. Air release valve and fittings.
v. Discharge pressure gauge.
vi. Main relief valve, pilot operated, enclosed relief valve overflow cone and
discharge tee with elbow (diesel drive only).
vii. Main relief valve with discharge pipes to water tank.
viii. Pump casing relief valve.
20.1.4.2.6.Electrical Motor Drive
a) On installations where the Fire Pump is to be operated electrically, the electric

motor shall be a horizontal, open drip-proof type U/L listed, wound for 400 V, 3
phase, 50 Hz (cycle) current The motor shall be of such capacity that 115% of the
full-load ampere rating shall not be exceeded at any condition of the pump load for
UL Listed fire pump.
b) With an ambient temperature not exceeding 50 deg. C, the motor shall be designed
for a temperature rise not exceeding 60 deg. C when carrying fully rated-load
continuously, and shall be capable of operating continuously with an overload of
15% without stress or excessive rise in temperature. The locked rotor current shall
not exceed the values specified in NFPA Pamphlet No. 20.
c) Bearings shall be anti-friction ball or roller type.
d) The Fire Pump motor control shall be UL listed and FM Approved. It shall be
completely assembled, wired and tested by the control manufacturer before
shipment from factory, and shall be labelled 'Fire Pump Controller". The controller
shall be located as practical and within the sight of the motor.
e) The controller shall be so located or protected that it will not be injured by water
escaping from the pump or connection. The controller shall be of the combined
manual and automatic star & delta type. and shall be complete with:
i. Disconnect switch - externally operable, quick-break type.

ii. Circuit breaker - time delay type with trips in all phases set for 300% of the
motor full load current-
iii. Motor starter, capable of being energized automatically through the pressure
switch or manually by means of an externally operable handle. Motor starter
shall be of the autotransformer type.
iv. Pressure switch, of adjustable type.
v. Running period timer - set to keep motor in operation, when started
automatically, for a minimum period of one minute for each 10 HP motor
rating, but not to exceed 7 minutes.

Dubai Municipality
vi. Pilot lamp - to indicate circuit breaker closed and power available.
vii. Ammeter test link and voltmeter test studs.
viii. Alarm relay - to energize an audible or visible alarm through an independent
source of power to indicate circuit breaker open or power failure.
ix. Manual selection station - a two position station shall be provided on the
enclosure marked "Automatic" and Non-automatic".
x. Means shall be provided on the Controller to operate an alarm signal
continuously while the pump is running.
xi. Provisions for power supply at 220 V for diesel pump battery chargers.
xii. Control equipment shall meet all requirements of NFPA20 & NFPA72.
20.1.4.2.7.Diesel Engine Drive
a) Diesel engine shall be UL listed and FM approved for fire protection service.
b) The engine shall be of the self-contained open type, mounted on a suitable base
with the following minimum plus any others that may be necessary by NFPA-20 and
local CD requirements.
i. Dual battery set sized to NFPA -20 requirements with electrolyte shipped in
separate containers, rack and cables.
ii. Dual battery charger of proper type for batteries used (included in UL Listed /
FM Approved controller). Power to battery charger shall be supplied from
electric pump control panel. Wiring from control panel to battery chargers
shall be by the contractor.
iii. Electric starter with suitable generator and voltage regulator.
iv. Engine water pump.
v. Heat exchanger cooling system.
vi. Water cooled or ceramic blanketed exhaust manifold.
vii. Lubricating oil pump and filter.
viii. Fuel injection system.
ix. Air cleaner.
x. Proper instrument panel, complete with engine run warning light, water
temperature gauge, oil pressure gauge, voltmeter, totalizing type tachometer
and hour meter.
xi. Residential Grade Muffler.
xii. Cooling water line for the engine heat exchanger assembly.
xiii. Flexible exhaust connectors.
c) All engine wiring for automatic operation shall terminate in a proper junction box to
permit connection to control panel.

Dubai Municipality
d) A suitable fuel system for the diesel engine shall be furnished. It must be in
accordance with NFPA Pamphlet No.20 and shall include above surface day
storage tank, flexible hose connectors, combination vent, flesh arrestor and fill cap.
e) The silencer shall be for turbo-charged engines, sized and selected to

accommodate the allowable pressure drop of the engine.
f) The silencer shall provide an average attenuation of 20-25 dBA.
g) The silencer shall be designed by HEAVY DUTY APPLICATIONS, with noise

attenuation across the entire audible range of the frequency spectrum 63 through
8000 Hz. The silencer shall consist of a series of chambers connected by non-
resonant tubes. The entire silencer shall be manufactured from plate steel and be
of a completely welded design. The heavy plate ensures longer silencer life and
better resistance to damage. The heavy plate shall prevent shell radiated noise.
There shall be no spot welds or press fits used.
h) Silencer inlet and discharge shall be flanged, manufactured from minimum 10mm
thick plate and drilled to ANSI 70 kg. Silencers shall be either and in/end out and
side in/end out configurations to suit installation.
i) Provide 12mm drain connections. Prior to shipping, the silencers shall be

thoroughly cleaned and coated in a high temperature 650ºC aluminium paint.
j) The automatic engine control panel shall be UL/FM approved for fire pump service
and meet the requirements of NFPA20. The panel shall be of the floor mounted
type, and enclosed in moisture and dust tight housing. A combination manual and
automatic type controller with “Manual-Off-Automatic” selector shall be provided and
a 240 volt single phase power failure relay or a pressure switch, which will ( when
the system pressure drops ) activate all electric circuits to automatically start the
engine.
k) Should the engine fail to start after the required cranking cycles, the controller shall
disconnect the starting circuit and activate an alarm system using lights and buzzer
or bell. “Low oil pressure” and “high jacket-water temperature” shall also be
indicated by a suitable alarm system. The engine shall not shut down if either of
these conditions occurs during an operating cycle.
l) The engine shall be started automatically by the Controller at least once a week,
adjustable, and operate a minimum of 30 minutes (adjustable). An appropriate
timing arrangement shall determine the day and hour of this test.
m) Pressure recorder (7 day drive) shall be provided within the control panel.
n) Fire Pump Controller shall be a diesel engine type, Controller approved and listed
by the Underwriters Laboratories for fire pump service, carry the labels of both
UL/FM and meet the requirements of the NFPA20.
o) Each charger shall be completely independent of the other charger and equipped
with its own individual power transformer, rated for a maximum continuous charge

Dubai Municipality
current of 10A. The charger shall be of solid state electronic design, with semi-
conductor type rectifier, and include the following supervisory and safety features.
i. Current limiting in every charging mode

ii. Over current shut-off
iii. Automatic selection of bulk or charge by sensing battery voltage
iv. Trickle charge limited to less than 500MA
v. Reverse voltage shut-off
vi. Dead cell detection
vii. Over and under voltage alarm
p) In case of battery failure, the charger shall initiate an alarm and provide a signal to
prevent the use of the defective battery during the start attempt cycle.
q) All relays shall be equipped with manual test buttons, status “ON” – “OFF”
indicators, be of the plug in type and shall meet all voltage and current
requirements.
r) A total of five ( 5 ) standard alarm contacts shall be provided for Remote Alarm
Circuit, rated at 10 A, 125 V shall be provided and wired to the field terminal block,
to indicate the following engine conditions :
i. SPDT contact : Engine Running

ii. 1 N/O contact : Contact shall close when main switch in Auto-position
iii. 1 N/O contact: Contract shall close when main switch is in OFF or Manual
position.
iv. SPDT contact: Engine trouble. This shall be a common alarm contact
indicating the following conditions. Engine over-speed, engines fail to start,
low oil pressure, high coolant temperature.
s) A four positions main switch shall provide selection of three starting method and one
OFF position.
i. OFF position shall shut down engine and alarms under any condition.
ii. AUTO position - a water pressure switch mounted inside the controller shall
provide the engine start on water pressure drop. The automatic starting
circuit shall alternate the two storage batteries after each start attempt. The
attempt to start cycle shall consist of six cranks and five rest periods of 15
seconds duration. In the event of one battery failure, the starting cycle shall
lock itself to the remaining battery. In case of engine failure, the controller
shall stop any further cranking and energize the ENGINE FAIL TO START
alarm. A manual stop pushbutton shall enable engine shut down, but only
after all starting causes have returned to normal. The automatic Weekly
Exercise cycle shall also be operational in the auto-position. This cycle shall
be programmed on the 7 day time clock. A short opening of the water
solenoid valve shall create a momentary pressure drop and cause automatic
engine start. At the end of the programmed Exercise cycle, engine shall shut

Dubai Municipality
down automatically. A manual test switch located on the time clock shall
allow for manual test operation of the weekly exercise cycle. The 7 day time
clock shall hold its time on A/C power failure and not require resetting.
iii. TEST Position - Engine shall start in the same manner as the above exercise
cycle start. Turning main switch to Auto or Off position shall shut down
engine.
iv. MANUAL Position - Start pushbutton “Battery 1” or “Battery 2”, shall override
all automatic starting circuits, and allow for direct manual engine start.
v. Safety Shut Down - Engine over-speed condition shall shut down engine
without time delay and lock out until manually reset.
t) The controller shall provide the following additional safety features Engine shut
down in case of low oil pressure or high coolant temperature during exercise, test or
optional AC failure operation only.
u) The diesel engine driven pump set shall be complete with all piping works their
protection, support and fuel system including double skinned day tank, fuel transfer
pumps, support etc. complete.
20.1.4.2.8.Jockey Pump
a) The Jockey pump capacity and pressure shall be as indicated in the pump schedule
on the drawings.
b) Pump shall be constructed as follows:
i. Type : Vertical multi-stage motor driven,

ii. Rotation : Counter-clockwise, viewed down
iii. Motor : TEFC
iv. Motor bracket : Cast type, connecting motor to pump
v. Diffuser cases : Pressure containing, flow directing
vi. Impellers : Stainless steel
vii. Shaft, l : Stainless steel,
viii. Pump discharge : Flanged type
ix. Control : Definite purpose type, magnetic starter In NEMA
II enclosure, with reset button
c) Pump controller shall be factory pre-wired and tested. Pressure switch shall sense
low pressure in the fire pump system. Set cut-in pressure 5 PSI above main fire
pump cut-in pressure. Set cut-out pressure at system pressure. Provide minimum
run timer to operate the pump for a minimum of 3 minutes.
d) Across the fine start, H-O-A selector switch.

Dubai Municipality
e) Control panel to contain a fusible 3-pole disconnect switch, magnetic motor

contractor and thermal overload relays with external reset Enclosure to be wall
mounted with hinged door.
20.1.5. Fire Hydrant

20.1.5.1. Dry Barrel Fire Hydrant
a) Fire hydrants shall be manufactured to comply with AWWA Standard C502. Fire
hydrants shall meet all requirements of UL/FM.
b) Fire hydrants shall be rated for a minimum working pressure of 150 Psi (1034 kPa).
c) Fire hydrants shall have a main valve which shall provide complete closing of the
drains after 4 to 5 turns of the operating nut in the opening direction.
d) The drain ring assembly shall be replaceable without removing the hydrant from the
connecting pipe or having to dig.
e) Fire hydrants shall be three-way in design, having one pumper nozzle (size as
specified) and two 2-1/2” hose nozzle (side outlet). Nozzle thread type shall be as
specified by the end user.
f) The operating nut shall be a one piece design, manufactured of Bronze. It shall be
pentagon in shape and the nut dimensions shall be as specified by the end user.
g) An arrow shall be cast on the bonnet flange to indicate the specified opening
direction.
h) Hydrants shall be a “traffic-model” having upper and lower barrels joined at the
ground line by a separate and breakable “swivel” flange providing 3600 rotation of
upper barrel for proper nozzle facing.
i) The lower barrel shall be an integrally cast unit. The use of threaded on or
mechanically attached flanges is deemed unacceptable.
j) All ferrous part shall be epoxy coated, the lower barrel shall be bitumen coated.
k) Hydrants shall be internally coated by Epoxy to avoid corrosion
l) A bury line shall be marked on the lower barrel below the break flange to indicate
proper installation depth.
m) Hydrant Inlet shall flanged and the size shall be minimum 6”
20.1.5.2. Wet Barrel Fire Hydrant
a) Fire hydrants shall be manufactured to comply with AWWA Standard C503. Fire
hydrants shall meet all requirements UL/FM. Coupling must be quick coupling as
per Civil Defence requirements where coupling must be Listed & Certified.

Dubai Municipality
b) Fire hydrants shall be rated for a working pressure of 200 Psig.
c) Hydrant Body shall be Ductile Iron, Stainless Steel, or Bronze as specified.
d) All ferrous part shall be Internally & Externally Epoxy coated.
20.1.5.3. Under Ground Hydrants
a) Under ground fire hydrant valves shall be of screw down type and are suitable for a
maximum working pressure of 16 bar. The Inlet shall be flange type and the Outlet
of this hydrant shall be round threaded 2 ½” size to BS 336 Standard.
b) Under ground fire hydrants are manufactured to comply with BS 750:2006 &
EN14339:2005 and shall be BSI KITE Mark Approved.
c) Body material shall be made of Grey cast iron or Ductile Iron as per BS standard.
Material of spindle shall be made of Stainless steel to BS EN 10088-1. Material for
the screwed outlet is made of High tensile brass to BS 12163. Spindle sealing (two
seals) is of the toroidal sealing ring (‘O’ ring) type. Design of the spindle cap in
accordance with BS 5163. A Wiper ring is positioned above the spindle sealing to
prevent the ingress of foreign matter.
d) The Hydrant shall be compactable against resistance to disinfection products.
e) Maximum operating torque value (MOT) 105 N-m, Minimum strength torque value
(mST) 210 N-m
f) All Ferrous components liable to corrosion shall be shot blasted (inside & outside) to
SA 2-1/2 standard.
g) Each hydrant should be painted from inside a 3 Coat epoxy paint system including
primer, intermediate & Top coat
h) Hydrant draining system is by self-operating frost valve, the maximum allowable

volume of retained water shall be 80ml and time of draining~3 min. 20 Sec.
i) Flow co-efficient Kv equal 120 m3/hr @ 1.7 bar
20.1.6. Sprinkler System

20.1.6.1. General
a) The sprinkler system shall be designed as per NFPA-13 Installation of Sprinkler

System requirements. Spacing of sprinklers shall suit the hazard of the occupancy.
b) All sprinklers shall be of UL listed / FM Approved.
c) The sprinkler heads shall be of the spray pattern installed in an upright position or
pendant position as may be required. Sprinkler in false ceilings shall be concealed
to ceiling and to architect approval.

Dubai Municipality
d) The design Criteria for all sprinklers such as K-factor, type and operating
temperature shall be submitted for approval.
e) A set of spare sprinkler heads shall be provided and located in a cabinet in the fire
pump room together with sprinkler spanners for use in removing and installation of
the heads as recommended in NFPA-13 and local authority requirements.
f) The sprinklers and lines shall not be spaced too close together in order to prevent
an operating sprinkler from wetting and hereby delaying operation of adjacent
sprinklers.
g) In locations where sprinkler heads are liable to be operated or damaged by

accidental blows, stout metal guards should protect them; care being taken to
ensure that the normal operation of the sprinkler head in the event of fire is not
thereby impeded.
h) The contractor shall supply set of spare sprinkler heads in each type / temperature
range and located in a cabinet in the fire pump room together with sprinkler
spanners for use in removing and installation of the heads as recommended in
NFPA-13 and local authority requirements.
i) Finish of sprinklers shall be to the approval of the architect.
20.1.6.2. Sprinkler Control Valves
20.1.6.2.1.Alarm Valves
a) It should be UL listed conforming to NFPA-13. Retarding device of approved design

to obviate false alarms due to mains pressure variations where necessary or where
indicated.
b) .Alarm valves shall be complete with Water Motor Alarm Gong, all required auxiliary
valves and drains and with pressure switch for wiring into the building electric alarm
system.
c) Alarm check valves shall be iron body bronze trim for minimum 175psig (12bar)
working pressure complete with electric pressure switches, test and alarm bell
connections, Pressure gauges and all other ancillaries.
20.1.6.2.2. Water Motor Alarms
a) The sprinkler system shall be fitted with an approved water motor alarm, which shall
be located at a distance not exceeding 21m from the alarm valve, and at a height
not to exceed 6m above the alarm valve.
b) The pipe work and fittings used shall be galvanized and to the sizes determined by
the NFPA-13.
c) The pipe work shall be arranged to drain through a fitting having an orifice not
exceeding 3 mm in diameter. The orifice plate may form an integral part of the fitting

Dubai Municipality
but shall be manufactured from a non-ferrous material to prevent the hole from
becoming blocked by corrosion or foreign matter.
d) A 15 mm test valve shall be installed on the installation side of each alarm valve.
20.1.6.2.3. Electric Alarm Pressure Switches
a) The electric alarm pressure switch should be UL 753 Listed. It shall be installed in
the system as per NFPA 13 and they shall be mounted on a vertical branch pipe at
least 300 mm long.
b) The pressure switch shall be sufficiently sensitive to operate when only one
sprinkler is discharging. The pressure switch shall be provided with volt free
contracts to facilitate monitoring by a Building Management System, and wired to
the main fire alarm panel.
20.1.6.2.4.Pressure Gauges
a) Pressure gauges shall be fitted to meet the requirements of the LPCB. Pressure
gauges shall conform to BS 1780 or equivalent International Standards. The
maximum reading of the scale shall be 150% of the maximum system pressure and
each scale shall have divisions not exceeding 0.2bar.
20.1.6.2.5.Automatic Zone Check / Zone Control Valve Assembly
a) A zone control valve set shall UL listed, FM Approved and it is to be provided for
each sprinkler system zone and shall comprise of :
b) Butterfly valve shall be UL listed. It shall be fitted with factory installed UL listed FM
approved tamper switch.
c) Flow alarm switch shall be UL listed and FM approved for the size of the pipe in
which it is installed as a paddle type water flow indicator. Shall be fixed after the
butterfly valve, on the main supply pipe and before any connection is taken off.
d) Inspector test and drain connections.
e) Dial pressure gauges suitable for the water pressures shall be fitted so arranged
that it can be easily removed for testing and checking without shutting down the
water supply.
f) Provide UL listed automatic zone check assembly to support monitoring, controlling,

inspection, testing & maintenance of each zone in sprinkler system, where shown in
the drawing as sprinkler zone control valve assembly or automatic zone check
assembly.
g) They consist of following:

Dubai Municipality
1. Two sets of valve, elbows and pipes to facilitate the circulation of the water
around water flow monitoring switch.
2. Vane-type water flow monitoring switch (WFMS).
3. Electrical box enabling control of motor and monitor of WFMS, local /

remote as required.
h) When actuated they shall perform the following:
1. Test mode actuation: When activated in test mode, the pump shall circulate
the water, within the sprinkler riser, around WFMS to stimulate the flow of
one sprinkler head in operation. The electrical box shall control and
monitor, motor and WFMS respectively, as required.
2. Fire mode actuation: When fire occurs, the sprinkler burst and water starts
flowing to control / extinguish the fire. This leads to flow equal to or more
than one sprinkler through the WFMS actuating it. The fire alarm panel /
flow monitoring panel performs monitors / controls required in the fire
condition when the WFMS actuation signal reach them.
i) They shall have following features in the system:
1. Insure the testing of WFMS as per the requirements of BS5306 Part-2 &
NFPA 25 without activating the fire pump and opening of test/drain
valve.
2. Installed in such a way that the test shall be conducted from a central
control room, through single push button and the individual WFMS
status can be read from main fire alarm panel or separate flow
monitoring panel.
3. Have the future (contacts and relays) facilitating the connection to BMS,
for automatic actuation, once in 3 months which records the status as
required.
20.1.6.2.6.Isolating Valves OS and Y type
a) Isolating valves shall be UL Listed and shall be fitted to the installation in order to
shut the valve, the spindle must turn clockwise. The hand wheels of all stop valves
shall be clearly marked to indicate which direction the wheel is to be turned to close
the valve.
b) An indication shall also be provided which shows whether the valve is open or shut.
c) Each main stop valves shall be installed with a tamper / supervisory switch and
interconnected to the building fire alarm system or secured open by a padlock or
riveted strap.

Dubai Municipality
20.1.6.2.7.Drain Lines
a) All drain lines from test valves, drain down points etc. shall discharge over suitable
and proper drain vent. Each drain vent shall be connected to a 50 mm galvanized
steel drain line, which shall discharge over a suitable gully.
b) All drain-vent, pipe fittings, and support clips used for the drain lines shall be
galvanized.
20.1.6.2.8.Execution / Installation
a) The “Protection Area of Coverage” per sprinkler shall be determined as the

multiplication of the distance between sprinklers upstream and downstream, and the
perpendicular distance between a sprinkler and another on the adjacent branch line.
b) Installation for hydraulically calculated system with concealed pendent and upright
sprinklers shall be, according to NFPA 13 latest edition and local authority
requirements.
c) Complete Sprinkler system shall be installed in accordance with NFPA-13 and

authority having jurisdiction requirements and as shown on the drawing.
d) The Fire protection contractor shall be responsible to co-ordinate his work with all
other trades and shall be completely familiar with and shall make allowance for
conditions which affect the fire protection installation.
e) The Zone control valve assembly locations and access panels shall be mounted
securely and provided with proper sign boards.
f) Provide a pressure gauge with a isolation cock with inspectors test plug on top of
the each sprinkler pipe risers.
20.1.6.2.9.Cleaning and Testing
a) Tubes and all items of equipment shall be delivered, stored and maintained in
closed storage with their open ends effectively plugged, capped or sealed. All
fittings, valves and sundry items shall be stored in clean bins or bagged and stowed
in suitable racks. All such stored items shall be maintained under weatherproofed
cover to be supplied by the MEP sub-contractor until they are ready for
incorporation in the works. Particular care shall be taken to ensure that electrical
equipment and components are kept clean and dry.
b) Before installations are handed over or subjected to the inspection and tests, the
entire installation shall be thoroughly cleaned, both internally and externally.
c) All fire protection installations shall be flushed out with clean water. During the
flushing out, provision shall be made to exclude any items of plant, which could be
damaged by the cleaning operation. The entire operation shall be carried out to the

Dubai Municipality
d) The fire protection system shall be tested in accordance with the NFPA codes and
the relevant standards, with particular reference the requirements set forth in this
section:
e) All testing shall be performed under the work of this section. All services required for
testing shall be a responsibility of the work of this section.
f) The fire protection piping System shall be tested hydrostatically for not less than 2
hours and at one time of the system pressure without any leaks or as directed by
the local fire department.
g) If the systems are tested in sections, the connection to the previously tested section
shall be included.
h) All tests that may be required by the local fire authorities shall be performed under
the work of this section, in the presence of their representative, if so required.
i) All leaks shall be corrected and the system re-tested until no leaks are found, at no
cost to the client.
j) Functional tests of all water flow alarms are a responsibility of the works of this
Section.
k) When the various systems are completed, operation tests shall be run on all
equipment to demonstrate proper operating conditions. These tests shall be run
under the observation of the inspector and the client’s operating engineer. The
client’s operators shall be instructed during this period. Operation tests shall be
performed under the work of this section.
l) Should any piece of equipment or apparatus of any material or work fail in any of
these tests, it shall be immediately removed and replaced by a perfect material, and
the portion of the work replaces shall again be tested under the work of this Section.
m) Cost to repair any damages to the building construction occasioned by pipe leaks or
defective materials shall be become under the works of this section, at no cost to
the client. All corrective work shall commence immediately after damage occurs.
20.1.7. CLEAN AGENT FIRE SUPPRESSION SYSTEM (FM-200 / HFC-

227ea)
20.1.7.1. General
a) This specification outlines the requirements for a “Total Flooding” Clean Agent Fire
Suppression System with automatic detection and control. The work described in
this specification includes all engineering, labour, materials, equipment and services
necessary, and required to complete and test the suppression system.
b) The manufacturer of the Suppression System hardware and detection components

shall have a minimum of 10 years’ experience in the design and manufacture of
similar types of suppression systems and who can refer to similar installations
providing satisfactory service.

Dubai Municipality
c) The name of the manufacturer, part numbers and serial numbers shall appear on all
major components.
d) All devices, components and equipment shall be new, standard products of the
manufacturer’s latest design and suitable to perform the functions intended.
e) All equipment shall be UL listed and/or FM approved.
f) The Clean Agent System materials and equipment shall be standard products of the
supplier's latest design and suitable to perform the functions intended.
20.1.7.1.1.Clean Agent System Description and Operation
a) The system shall be a Total Flood Clean Agent Suppression System supplied &
installed by an Authorised by the manufacturer.
b) The system shall provide minimum design concentration of 7.0%, by volume, in all
areas and/or protected spaces, at the minimum anticipated temperature within the
protected area. System design shall not exceed the NOAEL value of 9.0%, adjusted
for maximum space temperature anticipated, unless provisions for room evacuation,
before agent release, are provided.
c) The system shall be complete in all ways. It shall include all mechanical and
electrical installation, all detection and control equipment, agent storage containers,
FM 200 agent, discharge nozzles, pipe and fittings, manual release and abort
stations, audible and visual alarm devices, auxiliary devices and controls,
shutdowns, alarm interface, caution/ advisory signs, functional checkout and testing,
training and all other operations necessary for a functional, U.L. Listed and/or F.M.
approved FM 200 Clean Agent Suppression System.
d) Provide two (2) inspections during the first year of service. Inspections shall be
made at 6 month intervals commencing when the system is first placed into normal
service.
e) The contractor shall be responsible for sealing and securing the protected spaces
against agent loss and/or leakage during the 10 minute "hold" period.
f) The system(s) shall be actuated by cross zoned photoelectric detectors installed at

a maximum spacing of 250 sq. ft. (23.2 sq. m) per detector, in both the room,
underfloor and above ceiling protected spaces. If the air flow is one air change per
minute, photoelectric detectors shall be installed at a spacing not to exceed 125 sq.
ft. (11.6 sq. m) per detector. (Ref. NFPA No. 72 - current edition).
g) Detectors shall be wired in Sequential Detection method of operation, standard

Cross-Zoned detection, or Single Detector Release, using either a Class "A" or
Class "B" wiring arrangement. No other detection / wiring arrangements will be
acceptable.
h) Automatic operation of each protected area shall be as follows:
1) Actuation of one (1) detector, within the system, shall:


Dubai Municipality
i. Illuminate the "ALARM" lamp on the control panel face.

ii. Energize an alarm bell and/or an optional visual indicator.
iii. Transfer sets of 5 Amp rated auxiliary contacts which can perform auxiliary
system functions such as:
- Operate door holder/closures on access doors.
- Transmit a signal to a fire alarm system.
-Shutdown HVAC equipment.
iv. Light an individual lamp on an optional graphic annunciator.
2) Actuation of a 2nd detector, within the system, shall:
i. Illuminate the "PRE-DISCHARGE" lamp on the control panel face.
ii. Energize a pre-discharge horn or horn/strobe device.
iii. Shut down the HVAC system and/or close dampers.
iv. Start time-delay sequence (not to exceed 60 seconds). System abort
sequence is enabled at this time.
v. Light an individual lamp on an optional graphic annunciator.
3) After completion of the time-delay sequence, the HFC-227ea Clean Agent
system shall discharge and the following shall occur:
i. Illuminate a "SYSTEM FIRED" lamp on the control panel face.
ii. Shutdown of all power to high-voltage equipment
iii. Energize a visual indicator(s) outside the hazard in which the discharge
occurred.
iv. Energize a "System Fired" audible device.
4) The system shall be capable of being actuated by manual discharge devices
located at each hazard exit. Operation of a manual device shall duplicate the sequence
description above except that the time delay and abort functions SHALL be bypassed.
The manual discharge station shall be of the electrical actuation type and shall be
supervised at the main control panel.
20.1.7.1.2.Clean Agent System and Distribution
a) Each system shall have its own supply of GX-20 FM200 clean agent.
b) The system design can be modular, central storage, or a combination of both design
criteria.
c) Systems shall be designed in accordance with the GX-20 FM200 manufacturer's

guidelines
d) Each supply GX-20 container shall be located within the hazard area, or as near as
possible, to reduce the amount of pipe and fittings required installing the system.
e) FM-200 is stored in steel GX20 containers at 25 bar at 21 °C (360 psig at 70 °F), as

a liquid with nitrogen added to improve the discharge characteristics. When

Dubai Municipality
discharged, the FM-200 liquid vaporises at the discharge nozzles and is uniformly
distributed as it enters the fire area.
f) Clean agent containers with an FM200 GX20 valve can be actuated by the following
methods:
Method 1: Electric actuation

Method 2: Manual Activation
Method 2: Electric & Pneumatic actuation
g) Each GX-20 container shall have a pressure gauge and low pressure switch to
provide visual and electrical supervision of the container pressure. The low
pressure switch shall be wired to the control panel to provide an audible and visual
"Supervisory" alarm in the event the container pressure drops below 305 psi . The
pressure gauge shall be colour coded to provide an easy, visual indication of
container pressure.
h) Each GX-20 container shall have a burst disc provision that automatically operates
when the internal temperature exceeds 150oF. (66oC).
i) Engineered discharge nozzles shall be provided, within the GX-20 FM200

manufacturers guidelines, to distribute the clean agent throughout the protected
spaces. The nozzles shall be designed to provide proper agent quantity and
distribution.
j) GX-20 Fm200 Nozzles shall be available in pipe sizes 1/2” thru 2.0” (BPS 15mm
thru 50mm). Each size shall be available in 180o and 360o distribution patterns.
k) Distribution piping, and fittings, shall be installed in accordance with the GX-20
FM200 manufacturer's requirements, NFPA 2001 and approved piping standards
and guidelines. All distribution piping shall be installed by qualified individuals using
good, accepted practices and quality procedures. All piping shall be adequately
supported and anchored at all directional changes and nozzle locations.
l) All piping shall be reamed, blown clear and swabbed with suitable solvents to
remove burrs, mill varnish and cutting oils before assembly.
m) All pipe threads shall be sealed with Teflon tape pipe sealant applied to the male
thread only.
20.1.7.1.3.Control Panel
a) The control panel shall be Fire Beta Extinguishing Control Panel.
b) The Fire Beta Extinguishing Control System, and its components, shall be UL listed
and FM approved for releasing service and is suitable for clean Agent release
service.
c) The Fire Beta Extinguishing Control System shall perform all functions necessary to
operate the system detection, actuation and auxiliary functions, as outlined.

Dubai Municipality
d) The Fire Beta Extinguishing Control System shall be capable of providing 7AH
Battery standby power supplies.
e) The Fire Beta Extinguishing Control System shall be microprocessor based with
hardware and software integration designed to guarantee reliability.
f) The Fire Beta Extinguishing Control System shall support Cross Zoned, Sequential,
Single Detector Release and Manual Release detection/actuation methods.
g) The Fire Beta Extinguishing Control System shall provide the following capabilities
and functions:
i. Three (3) Class B (Style Y) indicating appliance circuits rated for 2.0 amps @
24 VDC.
ii. Four (4) Class B (Style A) initiating circuits.
iii. Optional Class A (Style D) module for initiating circuits.
iv. Eight (8) Status LEDs plus alpha-numeric display for troubleshooting: AC
normal; alarm; pre-discharge; release; supervisory; trouble; alarms silenced
and system abort.
v. Programmable pre-discharge and discharge timers.
vi. Resettable and continuous auxiliary output power.
vii. Five (5) optional Abort types.
viii. Intelligent Transistor protection to prevent noise spikes and microprocessor
failure from inadvertently activating release outputs
ix. A dedicated Disarm switch for release outputs
x. Dedicated alarm and trouble contacts programmable for alarm, trouble, pre-
discharge, discharge, abort, supervisory or water flow functions, depending
on panel configuration.
xi. Two (2) Form “C” relays, rated at 5 amps, are provided on the
EXTINGUISHING panel board. Installation of the optional SRM4 Relay
Module (P/N 10-2176) will provide four (4) additional 5 amp relays.
xii. Multiple input power source - 120 VAC or 208/220 VAC @ 50/60 Hz
xiii. 2.6 amps @ 24 VDC power supply to operate high current draw horns and
strobes. Capable of allowing expansion to 8 amp external power supply for a
total of 10.6 amps of available power.
xiv. Available in either Red or Grey finish.
20.1.7.2. Optical Smoke Detector
a) The optical smoke detector shall continuously measure the smoke level in the air
and gives a proportional output. It shall comply with the requirements of EN54 part
7.
b) The detector shall be an optical light scattering type sensitive to visible smoke and
be stable under all environmental conditions. The internal test and calibration

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circuits shall use the same optical elements as the smoke sensing circuits, to
ensure reliability.
c) A light emitting diode (LED) on the base must illuminate when a detector is in alarm.
20.1.7.3. Manual Release (Electric)
a) The electric manual release switch shall be a dual action device which provides a
means of manually discharging the Suppression System when used in conjunction
with the SHP Control System.
b) Manual actuation shall bypass the time delay and abort functions, shall cause the
system to discharge, and shall cause all release and shutdown devices to operate in
the same manner as if the system had operated automatically.
c) A Manual Release switch shall be located at each exit from the protected hazard
and shall have an advisory sign, provided at each location.
20.1.7.4. Abort Station
a) The optional Abort Station shall be located next to each manual switch.
b) The Abort Station shall be supervised and shall indicate a trouble condition at the
Fire Beta Extinguishing Control Panel, if depressed, and no alarm condition exists.
c) "Locking" or "Keyed" abort stations shall not be permitted.
d) The Abort Station shall be located adjacent to each manual station.
20.1.7.5. Audible Visual Alarms
a) Alarm audible and visual signal devices shall operate from the Fire Beta
Extinguishing Control Panel.
b) The Alarm Bell, Alarm Horn and Horn/Strobe devices shall operate on 24 volts Dc
power to allow supervision of the circuit wires.
c) The alarm bell and horn shall deliver a minimum sound level of 92 decibels at a
distance of 3m.
d) Horn and strobe light are to operate simultaneous from one power supply with flash
rate of 1-3 flashes per second minimum over the listed input voltage range.
e) A Strobe device shall be placed outside, and above, each exit door from the
protected space. Provide an advisory sign at each light location.
20.1.7.6. Caution and Advisory Signs
a) Provide signs, as required, to comply with NFPA 2001:
i. Entrance sign: (1) required at each entrance to a protected space.

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ii. Manual Discharge sign: (1) required at each manual discharge station.
iii. Flashing Light sign: (1) required at each flashing light over each exit from a
protected space.
20.1.7.7. System and Control Wiring
a) All system wiring shall be furnished and installed by the contractor.
b) All wiring shall be installed in surface clipped or metallic conduit and must be
installed and kept separate from all other building wiring.
c) All system components shall be securely supported independent of the wiring.

Runs of conduit and wiring shall be straight, neatly arranged, properly supported,
and installed parallel and perpendicular to walls and partitions.
d) The sizes of the conductors shall be those specified by the manufacturer. Colour
coded wire shall be used. All wires shall be tagged at all junction points and shall
be free from shorts, earth connections (unless so noted on the system drawings),
and crosses between conductors. Final terminations between the Fire Beta
Extinguishing Control Panel and the system field wiring shall be made under the
direct supervision of a factory trained representative.
e) All wiring shall be installed by qualified individuals, in a neat and workmanlike

manner, to conform to the National Electrical Code, Article 725, and Article 760,
except as otherwise permitted for limited energy circuits, as described in NFPA 72 -
current edition. Wiring installation shall meet all local, state, province and/or country
codes.
f) The complete system electrical installation, and all auxiliary components, shall be
connected to earth ground in accordance with the National Electrical Code.
20.1.7.8. Acceptance Tests
a) At the time "As-Built" drawings and maintenance/operations manuals are submitted,

the installing contractor shall submit a "Test Plan" describing procedures to be used
to test the control system(s). The Test Plan shall include a step-by-step description
of all tests to be performed and shall indicate the type and location of test apparatus
to be employed. The tests shall demonstrate that the operational and installation
requirements of this specification have been met. All tests shall be conducted in the
presence of the owner and shall not be conducted until the Test Plan has been
approved.
b) The tests shall demonstrate that the entire control system functions as designed
and intended. All circuits shall be tested: automatic actuation, solenoid and manual
actuation, HVAC and power shutdowns, audible and visual alarm devices and
manual override of abort functions. Supervision of all panel circuits, including AC
power and battery power supplies, shall be tested and qualified.
c) A room pressurization test shall be conducted, in each protected space, to

determine the presence of openings which would affect the agent system
concentration levels. The test(s) shall be conducted using the Fire Safety

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Technology or equivalent, with integrated computer program. All testing shall be in

accordance with NFPA 2001.
d) If room pressurization testing indicates that openings exist which would result in
leakage and/or loss of the Extinguishing agent, the installing contractor shall be
responsible for coordinating the proper sealing of the protected space(s) by the
contractor or his sub-contractor or agent. The contractor shall be responsible for
adequately sealing all protected space(s) against agent loss or leakage. The
installing contractor shall inspect all work to ascertain that the protected space(s)
have been adequately and properly sealed. THE SUPPRESSION SYSTEM
INSTALLING CONTRACTOR SHALL BE RESPONSIBLE FOR THE SUCCESS OF
THE ROOM PRESSURIZATION TESTS. If the first room pressurization test is not
successful, in accordance with these specifications, the installing contractor shall
direct the contractor to determine, and correct, the cause of the test failure. The
installing contractor shall conduct additional room pressurization tests, at no
additional cost to the owner, until a successful test is obtained. Copies of
successful test results shall be submitted to the owner for record.
e) Upon acceptance by the owner, the completed system(s) shall be placed into
service
20.1.8. FIRE ALARM AND VOICE EVACUATION

20.1.8.1. General
a) The System shall comprise of a range of analogue addressable, microprocessor

based fire alarm control equipment to offer flexibility in both design and operation.
The System shall be of modular concept for easy tailoring of system design, to meet
the full requirements of this Project.
b) The System shall be designed to provide early warning smoke detection, to quickly
identify the location of fire and provide user definable text informing the occupants
of the building of potential smoke spread. Simultaneously, the System shall alert
and evacuate the occupants, and control all necessary auxiliary command functions
such as elevator control, air handling shut down, gas shut off & damper control, as
per the cause and effects requirements of the building.
c) The complete facility shall be protected by a fully Analogue Addressable Fire Alarm
System. A range of smoke, heat, multi-sensor detectors, manual call point and
sounders shall be installed in the building.

Dubai Municipality
d) The addressable type fire detection and alarm system shall be designed installed
and commissioned with all the necessary equipment and accessories in accordance
with LPCB, UL or VDS standards.
e) The fire detection and alarm system shall comprise of Automatic Soft Addressable
Modular design main fire alarm control panels, optical smoke and heat, multi
Sensor, manual call points, electronic wall mounted Alarm sounder/flasher/
combined devices, The system shall be fully programmed to accommodate fire
alarm zones. The system shall be configured to allow on site modifications with the
minimum of disruption using the PC based software to facilitate future changes or
alterations to existing buildings/network on site.
f) The complete Analogue Addressable Fire Detection System shall be located in the
Control Room on the Ground Floor. The Main Control Panel will be equipped with
sufficient loop cards to meet the need of the entire project. There shall be sufficient
spare capacity to cater for at least the full requirement plus 20% spare.
g) The system will be capable of providing fire, fault, action, supervisory, disable and
monitoring facilities.
h) In the event of a fire alarm the FACP unit shall operate the alarm signal throughout
the building in accordance with the cause and effects and any additional
requirements laid down by the Civil Defence:
- Signal the local authority fire brigade via Auto Dialler
- Activate all control by event function related to the alarm
- Signal to graphic monitoring station
- Release door with hold
- Operate fire dampers, shutdown HVAC, and general exhaust fan.
- Signal to elevator
20.1.8.2. Fire Alarm Control Panel
a) The FACP shall incorporate a number of features to allow easy operation through a
user-friendly menu. It shall have a Graphical OLCD display and non-tactile
membrane type switches/keypad in durable plastic. For reliability it shall have its
own on-board circuit protection and multiprocessor architecture. The keypad shall
include means to enter of two minimum level passwords to prevent unauthorized
manual control. The system shall be on and off-site programmable by using the
keypad and, also by connecting a PC to the communication port on the main
processor/display board.
b) Analogue addressable detectors shall be with variable sensitivity settings and

automatic sensitivity control. The detectors should be equipped with SWITCH
address for the address settings; soft addressable sensors will not be acceptable.
c) All the proposed devices should be UL listed.


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d) The FACP shall have a minimum capacity of up to 2000 addressable initiating

devices
e) Each loop shall be capable of addressing minimum 250 initiating devices of any
combination
f) Isolator sensor bases shall be proposed per every 20 initiating devices.
g) The system shall be capable of expanding up to 12000 addressable device with

single network control panel by networking other FACP’S.
h) Network shall be expandable up to 396 Nodes (FACP’s) and Network shall support
17000 Feet distance between Nodes using 24 AWG cable.
i) Accessing the Fire Alarm Panel thru LAN/WAN/Internet and capability to Generating
e-mail automatically by the panel to report Alarm and System related Trouble
massages. Also facilitate the access of Panel Information thru Internet Browser
such as Internet Explorer.
j) The FACP shall be fully configurable and expandable at the owner’s site without the
need for handheld programmer. All the configurations shall be done by the control
panel.
k) The FACP shall be of modular construction, capable of monitoring 10 monitored

detection loops and shall have repeated code facility to learn if the loop have
duplicated address. Each loop shall be capable to accommodate a minimum of 250
addressable devices.
l) Each loop length maximum 1.2Km.
m) Detectors (Smoke, heat, flame), manual call points, modules, sounder strobe shall
be connected on the same two wire loop.
n) Each device and zone shall have its own 40 character text message allocation; also
each device shall be linked to a software zone. Can be edited the device detailed
and type, sensitivity and address on the control panel.
o) The FACP shall be capable of minimum zone indications per panel and have 3
common 1-amp rated sounder circuits and 2 common 1-amps rated auxiliary relay
contacts. The panel shall have an internal event printer; this shall be mounted within
the same enclosure. The printer shall have the facility to be programmed to print
alarms only; failure of the printer must not affect any other part of the system.
p) The FACP shall have a one man walk test facility to periodically test the detectors
without having to continually manually reset from the panel. The test feature shall
have silent mode option.
q) The MFACP-VCC shall have all fire alarm and voice evacuation components built-in
within the same panel, i.e. master controller for minimum 2000 devices, Audio
controllers, selector switches, Fire operator panel with interface for HVAC

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equipment, master Fire telephone, paging microphone with push to talk, amplifiers,
expansion cards etc.to form a complete system.
r) The FACP shall automatically program to switch the sounders to Day/Night mode
whereby any alarm condition is recognised outside normal hours shall provide an
evacuation signal throughout the entire premises.
s) The FACP shall have internal memory lock to prevent unauthorised data entry and
shall also have 1200-memory event log for system information and shall be stored
in non-volatile memory.
t) The FACP shall have the facility to networking on RS485 to other panels and
repeaters, while communication to colour graphics shall be via RS232.
u) Alarm and faults shall be indicated as for a fire alarm via the LCD along with an
associated LED and printer. A buzzer shall sound in the event of an alarm, pre-
warning of fault.
v) The FACP shall have verification facility to delay acceptance of alarms until they
can be confirmed, and shall meet the applicable standard. All the devices in the
zone can be configuring for verification through the panel. Manual call point or
contact devices connected to a loop will be separated and will not be verified.
w) The Batteries and charger shall maintain the entire system, plus 20% for a minimum
period of 24 hours stand-by in the event of mains failure. After 24 hours has elapsed
the system shall be capable of initiating a full global alert and evacuate for a
minimum period of 30 minutes.
x) The network shall be peer to peer with each panel generating command to other
panel as required. The network shall be class A wiring up to 1.2Km between two
panels.
y) Each control panel shall operate independently by performing its own specific
control, alarm supervision and history gathering. The system which requires master
or slave is not acceptable.
20.1.8.3. Repeater Panels
a) Repeater panels shall be connected via panel RS485 repeater output and installed
at each fireman’s entrance (2 No.). The repeater panel shall have basic control, and
have a LCD large display. The repeater panels shall be installed in slim line,
aesthetically pleasing enclosures.
20.1.8.4. Fire Operators Control Switches
a) Firemen’s smoke control, provide a manual station switches based on mechanical

smoke control/zone which shall be an integral part of Main Control Panel. This shall
include but not be limited to the switches for “Automatic” and “Manual Override” of
each fan and/or damper that need be controlled as per smoke management
requirement of particular zone/s.

Dubai Municipality
b) Where a BMS system is specified the system shall be integrated with the Building
Management System (BMS) through Bacnet open protocol to operate and
“graphically” annunciate the status of the various fans and dampers. The manual
control station shall be “Listed” by Underwriter’s Laboratory, Inc. (UL) for use as
such under Smoke Control System Equipment (UUKL). As part of this contract, this
contractor and the fire alarm system manufacturer’s authorized distributor shall
coordinate the interconnections between this system and the mechanical system
with the BMS contractor as applicable. This shall include a complete test of the
integrated system by all said contractors and distributors.
20.1.8.5. Graphical Monitoring Centre
a) A colour graphic command centre shall be installed in control room. When a fire
alarm status changes, colour graphics shall display an indication of the type of
alarm or other activity and its location. The operator then uses the mouse control to
access a more detailed view of the alarmed zone or device. With proper access
code, the operator shall be able to acknowledge alarm conditions, silence audible
alarms and extinguish visible notification appliances, and perform system reset
directly from the colour graphic screens.
b) GCC shall accommodate up to 4 network card and each network capable of

accommodating up to 99 nodes. The graphic command centre shall use IBM
compatible PC the PC shall have an Intel® Core™ i7-4980HQ Processor (6M
Cache, up to 4.00 GHz), 500GB HDD and a 17" OLED monitor with graphics
hardware acceleration. It shall provide history logging up to 400,000 historical
events, on line A4 laser printer capable of printing at a speed of at least 10ppm.
20.1.8.6. Intelligent Duct Smoke Sensors
a) Duct smoke sensors: Provide where indicated on the plans, Duct Housings with
True Alarm sensors. The sensors shall meet the requirements of UL Standard 268A
and shall be documented compatible with the control equipment to which they are
connected.
b) The addressable duct smoke sensors shall operate on the light-scattering, photo-
diode principle, and shall communicate actual smoke chamber values to the system
control. The sensors shall not have a self-contained smoke sensitivity setting and
shall automatically compensate for environmental changes. The sensor's
electronics shall be completely shielded to protect against false alarms from EMI
and RFI.
c) The duct housing shall contain a red LED which shall pulse to indicate power-on
and glow continuously to indicate an alarm or a sensor trouble condition. It shall
also contain a SPDT auxiliary relay rated at 2 amps @ 230VAC or @ 24VDC for
unit shut down or external control of other airflow devices. The detectors shall be
installed by the Mechanical Contractor, wired and connected to the fire alarm control
panel by the Electrical Contractor.

Dubai Municipality
20.1.8.7. Intelligent Photoelectric Smoke Sensor
a) The system control panel must be capable of communicating with the types of
addressable devices specified below. The system shall identify when a smoke
sensor becomes too dirty to operate properly. It shall also identify sensors which are
almost dirty which need cleaning before they drift beyond their selected sensitivity.
In short, a review of the front panel display or the printed status report quickly
identify sensor that need cleaning. Sensor shall have only sensing part of the device
without electronic analysing part on device base..
b) Sensitivity of the sensor shall a programmable; photoelectric shall be variable from

0.2 to 3.7 percent and ionisation sensitivity from 0.5 to 1.7 percent. It shall also be
possible to programme for timed, automatic sensitivity selection such as less
sensitive during working hours and more sensitive when quite.
c) Address of the device shall be set in the base using dip switches so that removal or
replacement of the sensor head will not affect the operation of the system. Device
addressed through software or address set in the sensor head are not acceptable.
Soft addressable sensors are also will be acceptable subject to compliance with
other requirements of the specifications.
20.1.8.8. Intelligent Heat Sensor
a) The Heat Sensor shall incorporate a highly linear thermistor circuit. A voltage is
produced proportional to temperature which shall be scaled, linearized and
transmitted as an analogue value.
b) Where required the heat sensor shall be a combination rate-of-rise and rate
compensated fixed temperature sensor of which both operations are self-restoring.
The sensor's small thermal mass shall allow an accurate up-to-date temperature
reading of each sensor to be logged at the control panel. The rate of rise operation
shall be selectable in either a 15 degree per minute or a 20 degree per minute rate
of temperature rise. The fixed temperature principle shall operate entirely
independent of the rate of rise principle and shall be selectable for either 47 degrees
or 60 degrees Celsius.
c) The detector shall be capable of the features like Rate of Rise or Fixed temperature
20.1.8.9. Intelligent Flame Sensor
a) The Flame Sensor shall incorporate a highly accurate electronics and be capable of
monitoring a flame with a surface area of 30mm at a distance of 12 meters within a
maximum of 10 seconds. A voltage is produced proportional to flame which shall be
scaled, linearized and transmitted as an analogue value. The sensors software shall
allow the device to operate quickly and accurately to a naked flame. The
addressable code for the device shall be stored in the sensor and be non-volatile.
20.1.8.10. Intelligent Combustible Gas Sensors
a) The Gas Sensor shall incorporate a highly accurate electronics and be capable of
monitoring Liquid Petroleum Gas. The sensor shall have two stages of alarm, which

Dubai Municipality
shall be adjustable. A voltage is produced proportional to gas, which shall be

scaled, linearized and transmitted as an analogue value. The sensors software shall
allow the device to operate quickly and accurately to a gas leak. The addressable
code for the device shall be stored in the sensor and be non-volatile specification.
20.1.8.11. Intelligent Beam Sensors
a) The Beam Sensor shall incorporate a highly accurate electronics and be capable of
monitoring smoke spread. The sensor shall comprise of an emitter and receiver.
The emitter shall generate an infrared beam of light that can be monitored by the
receiver. When this light source is deflected by the obscuration of smoke the
receiver shall generate an alarm. The sensor shall be fully adjustable. Each device
shall be adjusted by a qualified engineer, for optimum performance. The
addressable code for the device shall be stored in the sensor and be non-volatile.
20.1.8.12. Manual Call Points
a) Provide where shown on the drawings Addressable Manual Call Points. Stations
shall be constructed of high impact red Lexan and shall operate with or without
glass rod. Station shall contain a key lock keyed identical to the control panel to be
used for resetting the station. Manual stations shall be suitable for semi-flush or
surface mounting as indicated on the drawings. Where stations are to be surface
mounted, the enclosures shall be provided by the manufacturer.
20.1.8.13. Addressable Monitor Module
a) Addressable Circuit Interface Modules: Arrange to monitor one or more system

components
b) that are not otherwise equipped for addressable communication. Modules shall be
used for monitoring of water flow, valve tamper, non-addressable devices, and for
control of evacuation indicating appliances and AHU systems.
c) All modules shall be line powered and used for individual equipment. Multiple input
with Locally powered modules are not acceptable
20.1.8.14. Addressable Interface Module
a) All Circuit Interface Module shall be supervised and uniquely identified by the
control unit. Module identification shall be transmitted to the control unit for
processing according to the program instructions. Modules shall have an on-board
LED to provide an indication that the module is powered and communicating with
the FACP. The LEDs shall provide a troubleshooting aid since the LED blinks on
poll whenever the peripheral is powered and communicating.
b) The intelligent interface shall be installed at the commissioning stage. The

addressable code for the device shall be electronically programmed and stored in
the sensor and be non-volatile. The programming of this code shall be facilitated by
a digital electronic hand held device.

Dubai Municipality
20.1.8.15. Circuit Isolator
a) The short Circuit Isolator shall be installed at least every twenty devices and or each
separate fire zone and between floors. The circuit isolator shall be used to protect
the installation wiring in the event of a short in the cables. Should a fault occur the
isolator shall automatically disconnect the loop either side of the short, the control
panel shall recognize this disconnection and shall communicate in both directions.
This process will enable a limited number of devices to be off line whilst the fault is
being investigated and repaired. Once the short is removed the isolators shall
automatically reinstate the loop connection. The isolator shall incorporate an LED,
which illuminates when the short is detected on the loop circuit.
20.1.8.16. Addressable Remote Sensor Indicator
a) Remote Indicators shall be installed as shown on the drawings. The remote

indicators shall be addressable linked to any number of detectors within the given
location. The remote indicator shall be installed in a clearly identifiable location. The
remote indicator shall fit onto a standard electrical accessory box.
20.1.8.17. Sounder Base
a) The sounder shall be powered using separate 24V for safety and circuit integrity in
the event of circuit loop isolation/failure. The unit shall neatly be incorporated within
the sensor to ensure aesthetics are maintained. The sounder shall be rated 89dBA
at 1 meter and 30-40 units per loop. The addressable code for the device shall be
stored in the sounder base and be non-volatile. The programming of this code shall
be facilitated by binary switches.
20.1.8.18. Sensor Base
a) The addressable sensor bases shall contain integral addressable electronics that
constantly monitor the status of the detachable photoelectric, ionization or heat
sensors. Each sensors output shall be digitized and transmitted to the control panel
every four seconds.
b) When the control panel determines that a sensor is in an alarm or trouble condition,
the control panel shall command the LED on that sensor's base to turn on steady
indicating the abnormal condition. Each sensor shall contain a magnetically
actuated test switch to provide for easy alarm testing at the sensor location. Each
sensor shall be scanned by the control panel for its type identification to prevent
inadvertent substitution of another sensor type.
c) The control panel shall operate with the installed device but shall initiate a "Wrong
Device" trouble condition until the proper type is installed or the programmed sensor
type is changed. The sensor's electronics shall be immune from false alarms
caused by EMI and RFI.

Dubai Municipality
20.1.8.19. Sounder and Strobe
a) The sounder and strobe shall be sited on separate circuits. It shall be surface
mounted. The sounder shall be rated 85 dBA at 3 meter and 30 units in a circuit.
The addressable code for the device shall be stored in the panel and be non-
volatile. Weather resistant version should be utilized for external applications
20.1.8.20. Sounder and Strobe Separate
a) The sounder and strobe shall be surface mounted and shall incorporate a zone
address. The circuit shall be addressable from the main fire alarm control panel.
Weather resistant version should be utilised for external applications
20.1.8.21. Flashing Beacons Separate
a) Visible only units: Provide where shown on drawings Xenon Strobe Visible Units.
Xenon strobe light shall produce a 4.75 candela flash at a rate of 45 (+/- 20 percent)
flashes per minute. The strobe lights shall incorporate a controlled flash rate which
keeps the flash rate consistent with strobes connected on the same circuit thereby
preventing seizures in photosensitive epileptics.
b) The lens shall be tamper resistant, and the lamp assembly shall also be shock
resistant. The lens shall be white with the word "FIRE" printed in red. All units shall
be muti-candela 15, 30 & 75 with provision to select a site
20.1.8.22. Fire Fighters Telephone
a) Telephone Hand Sets: High-impact plastic handset, heavy-duty coil cord, and hook
switch; connected to the FACP by means of dedicated, supervised communication
lines. Handsets have a dynamic receiver and a carbon transmitter, operating on
24VDC.
b) A black master telephone handset with flexible-coiled self-winding five (5) foot cord
shall be provided and recessed within a protective unit-mounted enclosure at the
command centre. The specialist shall determine how many distributed power
supplies shall be required.
20.1.8.23. BMS Integration
a) Fire Alarm System shall be software integrated with BMS for status monitoring of
all devices to BMS, if BMS is specified in the contract. In addition volt free contacts
shall be provided for DCD 24x7 interfaces.
20.1.8.24. Electrical Installation
a) The Fire Alarm system shall use fire rated cable. The fire rated cable shall be a
minimum of 1.5 mm and shall be red Low Smoke and Fume (LSF) outer sheaf. The
Fire rated capable shall be clipped directly to the building fabric for single and
double cable runs. The Clips shall be fire rated metal with a LSF Coated Red finish.
The clips shall be fixed suitably and shall be no greater than 300mm between
fixings. Where there are more than 2 cables, the cables shall be installed on

Dubai Municipality
suitable galvanised tray or in trunking. Where cables run below 2.4 meters from
finished floor level then all cables shall be installed within galvanised conduit.
b) Correct corresponding termination devices and boxes shall be used. All devices
shall be terminated using a compression lock gland coloured red manufactured in
LSF material. Where devices are fixed surface a suitable LSF shroud shall be used.
c) Before any devices are connected the contractor must fully demonstrate and prove
the quality of the installation for loop integrity, continuity, resistance and
capacitance.
d) The system specialist shall install all devices; this shall include 2nd fix and 3rd fix.
Prior to completion of the project the system specialist must demonstrate the entire
system to the approval of the Consultant. The entire system shall have been 100%
tested independently prior to the demonstration to the Owner/Consultant. Should
any items fail during the test a new and complete 100% re-test shall be carried. The
specialist will be responsible for any costs involved with re-testing of the system.
e) The system specialist will be responsible for providing complete and detailed
manuals for the entire system. The manuals shall be fully detailed and shall
describe the operation and function of each part of the system.
20.1.8.25. System programming
a) The specialist shall completely programme the entire integrated system to meet the
full needs of the specification. This shall be done off site and proven to the
Consultant.
20.1.9. EMERGENCY LIGHTING SYSTEM

20.1.9.1. General
a) The emergency lighting system & all its components shall be designed & installed to
meet the local UAE Fire Code requirements & the respective NFPA, DIN/VDE 0108
& BS5266 standards applicable to this project and shall bear the CE certification for
Electro-Magnetic compatibility. The product shall have local Civil defence approval.
The entire system including associated Substations/ Emergency distribution panels/
Emergency and Exit lights shall be manufactured by a specialist manufacturer from
one range of product. Mixing of different brands of the manufacturer to form an
Emergency lighting package shall not be permissible.
b) The manufacturer shall have major working installations with over 1000Nos
Emergency and Exit lights in the region for atleast 5 years. Where Distribution
Boards are supplied instead of Substation panels, these shall be manufactured by
the specialist manufacturer at his factory and shall bear a specific civil defence
approval for the same model.
c) All products proposed/used shall be listed in DCD certificate of respective suppliers.

Products not listed will not be acceptable

Dubai Municipality
d) The Emergency lighting equipment shall be designed and manufactured as per

relevant BS, EN, standards. The contractor shall ensure that the final system shall
include the following design requirements in addition to that shown on the tender
drawings:
i. Escape routes up to 2m wide and permanently unobstructed shall be

illuminated to a minimum as per local authority requirements.
ii. Escape routes up to 2m wide with risk of being obstructed shall be
illuminated to a minimum as per local authority requirements.
iii. Escape routes wider than 2m wide shall considered as open areas.
iv. Open areas shall be illuminated as per local authority requirements.
v. High risk work areas shall be illuminated as per local authority requirements.
vi. In addition emergency luminaries shall be sited as follows:
vii. Near changes of level
viii. Near each change of direction
ix. To illuminate Exit doors and safety signs
x. Near firefighting equipment and call points
xi. Near every final Exit
xii. Near each first aid point
xiii. Near each intersection of corridors
e) All Exit and converted luminaries shall be maintained type, and Emergency / Safety
luminaries shall of non-maintained type. The battery capacity shall be calculated to
provide a minimum of 3 hours operation at 100% light output. Where indicated on
the drawings, local lighting circuits shall be monitored for failure via sub-circuit
monitoring / changeover relays.
20.1.9.2. Central Battery
a) The battery housing shall be sheet steel, powder coated housing IP20 with hinged
doors to provide complete access to the batteries. The electronics section shall
have IP20 sheet steel enclosure with hinged door and transparent polycarbonate
window for all central systems & substations. The status LED for all the components
including each changeover devices within each panel shall be seen from the
outside.
b) The electronic compartment shall have large cabling compartments with cable
entries from top via four or more undrilled removable metal flange plates. All
incoming cables & looping circuits shall be connected on dedicated terminal blocks,
2.5sqmm, provided at the top of the cabinet.
c) The electronic compartment shall have large cabling compartments with cable
entries from top via four or more undrilled removable metal flange plates. All

Dubai Municipality
incoming cables & looping circuits shall be connected on dedicated terminal blocks,
2.5sqmm, provided at the top of the cabinet.
d) The system shall be built up in a modular format with all modules being slide-in-type
design. The outgoing circuits shall be fed through changeover modules. One
module shall be used for each separate switchable outgoing circuits with maximum
load of 6Amps as per DIN/VDE 0108. The following changeover modules shall be
used.
e) The system shall be built up in a modular format with all modules being slide-in-type
design. The outgoing circuits shall be fed through changeover modules. One
module shall be used for each separate switchable outgoing circuits with maximum
load of 6Amps as per DIN/VDE 0108. The following changeover modules shall be
used:
i. 230V AC/220V DC 4x2A

ii. 230V AC/220V DC 2x4A
iii. 230V AC/220V DC 1x6A
iv. 24V DC 2x3A
v. 230V AC/220V DC DER lights
f) Each circuit shall be protected within the system for mains & battery operation via
screw-in type cartridge fuses on each module. The fuses shall be accessible via
front plate of the module. The mains supply & battery mains cables shall be
protected by knife edge/ screw-in type fuses. The changeover modules shall have
facility for 230V AC/ 220V DC as well as 24V DC outputs. Where 24V DC output
changeover modules are used, Class A wiring should be available.
20.1.9.3. Control module
a) The control module shall be composed of a microprocessor based TFT display unit,
plain text display with multiple (minimum 4 line) display of operative states &
luminaire failures including text location of individual luminaries. LED shall indicate
mains operation, Mains failure, Battery operation and Summation fault. USB
Interface for the connection of standard printers/keyboard shall be provided on the
front of the control module.
b) As a standard Manual reset and Time delay of Mains return shall be available.
Download to program the configuration of the panel and upload to retrieve system
status as well as log book functions shall be possible on this control module using a
standard USB link device.
c) Where applicable, individual battery block Voltage and block temperature shall be
displayed on the TFT screen in conjunction with the internally wired battery
management system. These Voltage and Temp readings on each block shall be
stored in internal logbook of the control module. Earth leakage failure tests shall be
conducted for the outgoings and any failure shall be indicated on the Control
module and the Central monitoring PC.

Dubai Municipality
d) The Control module shall enable possibility to connect 24V output substations, 24V
output group supply systems for LED emergency lights, Directional dynamic escape
routing lights 230V output substation systems etc. and the monitoring shall be
carried out via the same single data-line without the need for separate data-lines for
24V and 230V systems.
20.1.9.4. Charger
a) Charger module shall be plug-in type 3A or 7.5A rating, microprocessor

controlled module with temperature controlled voltage charging to IU characteristics.
Automatic boost charging facility shall be built in to the system depending on the
required total battery capacity. It shall have charging & supervising method for
failure indication of battery circuits as well as battery charger as per EN50171. The
charger shall be designed for a 80% recharge of a fully discharged battery set within
12 hours. The Charger shall be equipped with adequate ventilation facility in the
form of a ventilation fan and shall be provided with isolation breaker and battery
fuse. Slave type booster chargers are not allowed for safety reasons.
20.1.9.5. Change over Module
a) Each changeover module shall be slide-in type, programmable to suit maintained,

non-maintained and switch maintained type of luminaires on each outgoing circuit.
Individual lamp monitoring shall be included in the changeover module. Each
changeover module shall have LED indications for Circuit On & Lamp failure & shall
be fit to monitor up to 20 luminaires maximum. The LED’s shall be visible to visual
inspection via the clear polycarbonate window on the Electronic cabinet cover of
the panel. The changeover modules shall be 230VAC/220VDC as well as 24V DC
output without additional data-line for monitoring each light.
20.1.9.6. BMS Interface:
a) Each ECBS panel shall have three potential free contacts to indicate panel
operation/Mains failure, common fault and system OK. These contacts shall be
hardwired to BMS, where required.
20.1.9.7. Batteries
a) Batteries shall be maintenance free, sealed leak proof 220V lead acid gas
recombination type battery with following system features, extremely low gas
generation, requiring no special ventilation with service life of ten years at 25degree
centigrade. Batteries shall be sized for 100% of light output from each emergency
lamp, for a duration of 3 hours.
b) Battery Management : Where required, Batteries shall also be provided with Battery
Management System which is internally wired to the control module in the panel.
The control module displays and logs the individual battery block Voltage and
Temperature with a minimum of 1000entries. This also ensures that when individual
block temperature exceed safe limits, the charging function can be automatically
swithed off to prevent battery damage/explosion.

Dubai Municipality
20.1.9.8. Emergency/ Exit Luminaries
20.1.9.8.1. General
a) All Exit luminaires shall have pictogram legends as per DIN 4844/CEN TC 169 or
markings as per local Fire Department requirements with viewing distance based on
the length of the corridor. The exit luminaries shall comply with EN60598-2-22, EMC
55015, supply voltage 230V+/-10%, AC/220V+/-20% DC.
b) The contractor shall comply to the local UAE Fire codes to achieve the Lux level
specified in the codes. The wattages of lamps given above are indicative and based
on the site fixing conditions, the contractor shall, where required, increase the
wattage of the fittings to achieve the desired lux levels specified in the codes.
20.1.9.8.2. Ceiling Surface Mounted - Stairs/ Electrical Rooms
a) It shall be non-maintained type slave luminaire with 8W fl lamp, addressable HF

electronic gear. Luminaire housing shall be IP65 Polycarbonate with clear structured
polycarbonate diffuser.
20.1.9.8.3. Ceiling Surface Mounted – Plant Rooms / Mechanical Rooms
a) It shall be non-maintained type slave luminaire with 11W fl lamp, addressable HF

electronic gear. Luminaire housing shall be IP65 Polycarbonate with clear structured
polycarbonate diffuser.
20.1.9.8.4. Ceiling Recess Mounted – Office areas
a) The recessed mounting luminaire shall be of sheet steel trip RAL shaded to white.
The Trim shall be slim 80mm dia with 3mm thickness of the sheet steel plate. The
fitting shall be IP20. Fittings with polycarbonate trims are not acceptable.
20.1.9.8.5. Exit : Wall mounted/ Ceiling suspended – Weatherproof areas/ Warehouse areas
a) It shall be maintained type slave luminaire with 8W fl lamp, addressable HF

electronic gear. Luminaire housing shall be IP65 high quality stainless steel with
clear structured polycarbonate diffuser. The viewing distance shall be 35m. The
fitting shall be suitable for wall or ceiling suspended mounting.
20.1.9.8.6. Exit : Wall mounted/ Ceiling mounted – Back of House areas

electronic gear. Luminaire housing shall be IP65 polycarbonate with clear structured
polycarbonate diffuser. The viewing distance shall be 23m. The fitting shall be
suitable for wall or ceiling mounting.
20.1.9.8.7. Edgelit decorative Exit lights – Public areas

electronic gear. Luminaire housing shall be sheet steel with white metal trim & with
double or single sided acrylic legend panel marked EXIT in Running Man and

Dubai Municipality
directional Arrow. Minimum viewing Distance shall be 30Mtrs. The luminaire shall
have facility for various mounting operation like recessed, wall mounted, pendulum
suspended and parallel to wall and cantilever type. Except recess mounted, the
other options shall have aluminum profile slim housing.
20.1.9.9. Location of panels
a) The emergency central battery system shall use maintenance free, gas
recombination type, sealed lead acid batteries. The central batteries shall be located
in air conditioned room with room temperature of 25deg.C. The room shall be air-
conditioned using a recirculation air-conditioning system without any special battery
room ventilation requirements. The battery shall feed the emergency and exit
luminaires. In large systems the battery shall feed satellite or substations. The
substations shall be installed in areas with a maximum room temperature of
30deg.C. The substations shall be located based on the requirements of the lighting
loads and optimizing the field wiring. All substations shall be connected to the
central station for central group monitoring.
20.1.9.10. Automatic Cyclinic Mode
a) An automatic monitoring and testing facility shall be installed with permanent cyclic
charger and battery monitor at intervals of five minutes or less with daily/weekly
function test of the complete load supplied from the battery, charger, wiring,
luminaires, registration and logging of tests and results. A manually operated test
feature shall also be provided in addition to the automatically operated testing
feature. The monitoring system and data transfer shall be carried out based on a
current multiplexer system in DC mode.
20.1.9.11. Central Monitoring Unit
a) Central Monitoring shall be carried out by IP addressing each panel. Entire data
from each individual panel, including end luminaire status with text location, shall be
available at the central monitoring PC. The central monitoring software shall be a
non-proprietary, easy to install and access, to ensure that any future maintenance/
upgrade on the central PC is easy. Log book facility as per the relevant EN
standards shall be available at the central monitoring PC. The PC shall be with
latest configuration at the time of delivery of materials to site and shall include a 17”
OLED monitor.
b) It shall be possible to connect any Building Automation or Management System in

the same Central monitoring network so that the information available on the
dedicated central monitoring PC of the Emergency lighting system is available also
at the Building Automation PC. The protocol to enable this shall be Modbus over IP
and shall be open protocol. The BMS PC as well as the Central Monitoring PC shall
be working in parallel so that failure of one shall still enable the same data available
at the other.
20.1.9.12. Wiring
a) All wiring of the Emergency Lighting and Monitoring system shall be done using fire
resistant cabling approved by the Civil Defence .The diameter of the cable shall be
selected as per the estimated loading of each circuit.

Dubai Municipality
b) The cables necessary for the system shall generally be provided as recommended
by the specialist supplier and in accordance with the local civil defence regulations.
Wiring between central battery, substation panels and luminaires shall be carried
out in fire resistant cables with cable sizes as per local authority requirements. 3
core fire resistant cables with earth wire shall be provided to feed substation from
central battery panels. The cable selection details must be provided based on the
electrical load of each substation. Cable sizing calculations to meet the local
authority requirements as well BS5266 standards to be submitted for approval.
c) The control module shall be composed of a microprocessor based TFT display unit,
plain text display with multiple (minimum 4 line) display of operative states &
luminaire failures including text location of individual luminaries. LED shall indicate
mains operation, Mains failure, Battery operation and Summation fault. USB
Interface for the connection of standard printers/keyboard shall be provided on the
front of the control module
d) As a standard Manual reset and Time delay of Mains return shall be available.
Download to program the configuration of the panel and upload to retrieve system
status as well as log book functions shall be possible on this control module using a
standard USB link device.
e) Where applicable, individual battery block Voltage and block temperature shall be
displayed on the OLED screen in conjunction with the internally wired battery
management system. These Voltage and Temp readings on each block shall be
stored in internal logbook of the control module. Earth leakage failure tests shall be
conducted for the outgoings and any failure shall be indicated on the Control
module and the Central monitoring PC.
f) The Control module shall enable possibility to connect 24V output substations, 24V
output group supply systems for OLED emergency lights, Directional dynamic
escape routing lights 230V output substation systems etc. and the monitoring shall
be carried out via the same single data-line without the need for separate data-lines
for 24V and 230V systems.
20.1.10. Fire Door

a) Design and construction of Fire door assemblies shall be in accordance to NFPA
80, UL10B, UL10C or BS 476 part 22
20.1.10.1. Rating
a) As per NFPA guidelines all fire door & frames shall have fire rating to resist
combustion in the event of a fire. A fire door will typically shall have 3/4 of the rating
of the surrounding wall. The duration of a fire rating can range from 20 minutes to 3
hours, though 20-minute doors are designed to block smoke rather than flames.
Hourly rating shall include 3hours (180min), 1 ½ hours (90min), 1 hour (60min), ¾
hours (45min) and 1/3 hours (20min).
20.1.10.2. Labels
a) All fire-rated doors and frames must be equipped with a label indicating the model
no listed by certifying authority. The approving authority shall be Underwriters

Dubai Municipality
Laboratory or Local Civil defence and the labels may be embossed or mechanically
fastened. Labels must indicate the door's duration (such as 90 minutes) and may
not be painted over or tampered with in any way.
20.1.10.3. Door & Frame requirements
a) Wooden fire doors must have a solid wood or mineral core, while steel doors will
typically have a honeycombed or insulated core. The door should be prepared at
the factory so that there is no more than 10mm clearance between the bottom of the
door and the finished floor. No holes larger than 1 inch in diameter may be drilled in
the field without voiding the fire rating, and pairs of doors must be equipped with an
astragal. Frames must be made from at least 16-gauge steel and should be
prepared at the factory for easy assembly.
20.1.10.4. Hardware
a) All fire doors must be self-closing and self-latching. This means that in the event of
a fire, all of these doors will be closed and latched without manual intervention. This
is accomplished through the use of a closer or spring hinge and a fire-rated lockset
or exit device. Fire doors can never be held open with a door stop or any other
device than a magnetic hold. The magnetic hold must be tied to the fire alarm so
that the door will close automatically during a fire. Electric locks used on fire doors
must be fail-safe, never fail-secure (door will be automatically unlocked during a fire
to save lives rather than locked to protect property).
20.1.10.5. Accessories
a) Louvers are permitted in fire doors only if they are labelled by a certified agency.
The louver must have a fusible link so that it closes to prevent smoke from
spreading during a fire. Glass windows are also allowed, but may not be used in
combination with a louver.
20.1.11. Pipes, Fittings and Supports

20.1.11.1. General
a) These specifications shall be read in conjunction with the relevant specifications in

section 4’ pipes, pipework, manholes and chamber of the specifications.
20.1.11.2. Pipes
a) Pipes and fittings shall be in conformance with the following specifications unless
specified otherwise by the Authority having jurisdiction. Obtain approval of local
Authorities before proceeding with the work.
b) Pipe shall be seamless UL, factory galvanized steel to ASTM A53 grade B,
schedule 40.
c) When pipes are assembled by screwed fitting or by roll-grooved / cut-grooved, the

minimum thickness for a pressure up to 20.7 bars.

Dubai Municipality
d) Diameters minimum diameter is DN25
e) Pipes bending:
i. Schedule 40 Steel pipes bending is allowed if bending are executed with no

defaults, no diameter reduction and no significant deviation in the pipes circle
symmetry.
ii. The bending minimum radius must be:
 6 pipe diameters for a diameter < 2 ‘’, and
 5 pipe diameters for a diameter > 2 ½ ’’.
f) Pipes marking and identification
i. Firewater pipes in galvanised steel shall be marked to indicate its

destination.
g) Pipes Drainage
i. For sprinkler system, pipe drainage shall be accomplished by sloping pipe to

low point with auxiliary drain as per NFPA13.
h) Special Requirements
i. Full flanges or plugs, according to the diameter shall be installed on the

collector’s extremities to flushing rinsing of the pipes.
20.1.11.3. Pipe Fittings
a) Fittings for piping 50mm and small shall be UL listed and FM approved. The fittings
shall be suitable for 300 psi working pressure. Fittings shall be ductile iron or cast
iron in black or hot dipped factory galvanized finish.
b) Fittings for piping larger than 50 mm shall be hot dipped factory galvanised
mechanical grooved fittings and mechanical joints. Fittings, gaskets and mechanical
couplings shall be UL listed and FM approved. The fittings shall be suitable for 300
psi working pressure.
c) Pipes welding shall not be carried out on site.
d) The galvanised steel fittings shall be UL Listed and FM approved.
e) Unions and Couplings
i. Screwed unions shall not be used for pipe greater than DN40. For pipes
above, flanges will be used.
f) Reducers and male/female reducers
i. One piece reduced fitting must be used for each pipe diameter change.
ii. Reduced sleeve for the pipe continuity, and

Dubai Municipality
iii. Male/female reducer for a direction change with reduction (T shape +

reducer)
20.1.11.4. Pipe Hangers and Supports
a) Pipe hangers and supports must be in accordance to NFPA13.
b) Pipes supports shall be designed to maintain their integrity in case of fire exposure.
c) All underground piping / valves shall be supported with Concrete Anchor Thrust
blocks as recommended by the manufacturer. Provide calculation for the Engineers
approval.
d) All Above ground piping / equipment hangers, supports and sway braces shall be
fabricated in accordance with ANSI B 31.1. The Hangers, rod supports and
supporting devices and accessories shall be capable of supporting at least twice the
live loads of the product being supported. All hangers, supports and accessories
shall be UL listed and or FM approved.
e) Hangers shall be adjustable clevis type, of yoke and lower U strap design with cross
bolt and manufactured from galvanised steel. Cross bolt shall have double locking
nuts. Vertical adjustable supporting rod shall have a load nut below the yoke and a
locking nut above the yoke.
f) Concrete anchors shall be factory made cadmium plated alloy steel expansion
shield type.
a) Concrete inserts shall be factory made galvanised malleable iron, poured in place
type, screwed or toggle style.
b) Riser clamps shall be galvanised steel bands shaped to tightly fit O.D. of the pipe,
secured with bolts and nuts.
c) Piercing of load supporting system is not permitted.
d) The supporting structure can be directly attached to equipment if the equipment

supplier certifies this supporting feasibility.
e) The welding of pipes on the supports on the pipes is not permitted.
f) Pipes supporting system must be reinforced in order to reduce any movements

resulting from nozzles reaction and therefore preserve the system performance and
integrity if battering ram is used.
g) The maximum length for a non-supported DN 25 pipe is 0.8 meter.
h) When possible, loop-type clamps will be used
i) If spring hangers are used, they shall be installed and located in accordance with
NFPA 13 specifications.

Dubai Municipality
j) The Contractor shall take into account the problem of dilatation (of his systems but
also of the buildings) and shall make the coordination with the others Contractors to
solve the support problems.
20.1.12. HDPE Pipe

20.1.12.1. General
a) These specifications shall be read in conjunction with the relevant specifications in

section 4’ PIPES, PIPEWORK, MANHOLES AND CHAMBERS’ of the
specifications.
20.1.12.2. Under Ground Pipes and Fittings (UPTO 11 BAR) FM approved
a) High density Polyethylene Pipes and fittings (HDPE) PE100 Manufactured for
underground fire protection lines, FM approved and listed to be used for fire
underground main, Class 200, confirm to AWWA C 906 and NFPA 24.
b) Pipes and fittings to be from one manufacturer to meet above standards.
c) Welding to be butt fusion only, suitable for pipe pressure ratings, and each joint
should have separate report showing full details on joint and welding process and
result.
20.1.12.3. Under Ground Pipes (UPTO 16 BAR) FM approved
a) High density Polyethylene Pipes & fittings (HDPE) PE 100 FM approved

manufactured for underground fire protection lines, FM approved and listed to ISO
4427 – SDR 7.4 to be used for fire underground main.
b) Pipes and fittings to be from one Manufacturer to meet above standards.
c) Welding to be butt fusion only, suitable for pipe pressure ratings and each joint
should have separate report showing full details on joint and welding process and
result.
20.1.13. Accessories
The Tenderer shall supply and install where specified the items listed below:
a) FIRST AID BOX - wall mounted first aid box marked with a red crescent and
containing:
i. 40 No. individually wrapped adhesive dressings

ii. 2 No. sterile eye pads and bandages
iii. 2 No. sterile triangular bandages
iv. 6 No. safety pins
v. 6 No. sterile unmedicated dressings No. 8
vi. 6 No. sterile unmedicated dressings No. 9
vii. 2 No. sterile unmedicated dressings extra large
viii. 1 No. roll elastic bandage 2 inch

Dubai Municipality
ix. 1 No. pair scissors

x. 1 No. eyebath
xi. 1 No. bottle eye wash solution
xii. 25 g cotton wool
xiii. 1 No. bottle antiseptic
xiv. 1 No. card or booklet giving simple instructions
b) ELECTRIC SHOCK FIRST AID INSTRUCTION - Instructions in both English and

Arabic for the treatment of persons suffering from electric shock. The instructions
shall be printed on a substantial wall mounted plate with a wipe clean surface.
c) DANGER NOTICE - Danger notices inscribed “DANGER DO NOT OPERATE -

MAN WORKING ON EQUIPMENT” in both English and Arabic. The plates shall be
of laminated plastic with white letters on a red background and arranged to hang on
isolator handles.
d) RUBBER GLOVES - One pair of heavy duty insulating rubber gloves. The gloves
are to be stamped with their date of manufacture and shelf life.
20.1.14. APPROVED SCHEDULE OF MANUFACTURERS:

a) All materials supplied under this contract shall be from one of the manufacturers
listed below. No alternate makes shall be accepted unless all the makers are
unavailable. Materials proposed from listed makes also must fully comply with the
detailed specifications, country of origin, where listed, must be complied.
b) All Materials should have at least been certified by two independent Certification
Bodies as LPCB/ BSI Kitemark /VDs and or UL/FM.
Item Make
Seamless / Galvanised Steel Pipes - UL Listed a) Sumitomo

b) Shield
c) Nippon
d) Universal

Dubai Municipality
Item Make
Galvanized threaded fittings (UL listed and or FM a) Crane

Approved).
b) BIS
c) Anvil
d) Grinell
e) Shield
Grooved Fittings (UL listed and or FM Approved). a) Fluid

b) National
c) Victaulic
d) Grinell
e) Shield
HDPE pipes & fittings a) Hepworth

b) George Fischer
d) ISCO
e) Shield
Hangers & Accessories a) Flamco

b) Diamond Pipe Supports
c) Shield
d) PHD
Sprinkler heads and accessories (UL listed and a) Angus

or FM Approved)
b) Fluid
c) Viking
d) Kidde
e) Automatic Sprinkler
Corporation
f) Shield
g) Central / Spraysafe

Dubai Municipality
Item Make
Special Valves (Alarm valve, pre-action valve) a) Angus

b) Viking
c) Kidde
d) Automatic Sprinkler
Corporation
e) Shield
f) Central / Spraysafe
Valves (OS & Y, Butterfly & Check Valves) a) Fluid

Seismic Connector – UL Listed and or FM b) NIBCO
approved
c) AVK
d) Automatic Sprinkler
Corporation
e) Shield
f) Central / Spraysafe
g) Mueller
Fire Hose Reel, Fire Hose, Nozzle, Landing a) Angus

Valve, Cabinets and accessories (LPCB,
b) SFFECO
BSI/Kitemark/ UL listed and or FM Approved).
c) Chubb
d) Naffco
e) Shield
Fire Hydrant – UL Listed a) AVK

b) Naffco
c) Mueller
d) Kennedy
Fire Department connection (LPCB, a) Angus

BSI/Kitemark/ UL listed and or FM approved).
b) SFFECO
c) Chubb
d) Naffco
e) Shield

Dubai Municipality
Item Make
Fire Extinguisher (LPCB, BSI/Kite Mark/ UL listed a) Kidde / Badger

and or FM Approved).
b) Naffco
c) Shield
Fire Pumps (UL Listed and or FM Approved) a) Armstrong

b) R-B Pumps
c) Peerless
d) ITT
e) Naffco
Diesel Engine (UL Listed and or FM Approved) a) Armstrong

b) Caterpillar
c) Clarks
d) Cummins
e) Firedriver
Fire Pumps Controller (UL Listed and or FM a) Tornatech

approved)
b) NAFFCO
c) Firetrol
d) Cutler Hammer
e) Joslyn clark
Clean Agent Fire Suppression(FM- a) Kidde Fire Protection UK

200/HFC227ea) System equipment (UL Listed
b) Chemetron
and or FM Approved)
c) Pyrochem
d) NAFFCO
e) Figgie Fire Protection
Products
f) Fike
g) Siemens

Dubai Municipality
Item Make
Fire Alarm System (UL Listed and or FM a) Simplex

Approved) & Voice Evacuation System
b) Notifier-USA
c) Autocall
d) Ziton
e) Fike
f) Siemens
g) Shield
h) Esser
Emergency & Exit Lighting system (Addressable a) Sibca

Central Battery)
b) ClearLight
c) Thorn Lighting
d) Ceag
e) Siemens
f) Shield
g) Megalights
Fire resistant cable and accessories a) Pirelli (FP 200)

b) Delta Cables
c) Polycab
d) Firecel
e) Shield
Foam System & Equipment a) National Foam

All Foam Concentrate b) Viking
c) Chemguard
d) Naffco
Passive Fire a) Magma

b) SVT
Fire Door a) Grandeur

b) Task (CECO Doors)
c) Indica
d) Naffco

Dubai Municipality
Item Make
Fire/Smoke Damper a) Aerovac

b) TUF
c) ISONE

DUBAI MUNICIPALITY
DEPARTMENT
SECTION 21
GEOTECHNICAL INVESTIGATION WORKS
DM/SRPD Section 21 Geotechnical Investigation Rev 00 June 2016

Dubai Municipality
DM/SRPD Section 21 Geotechnical Investigation Rev 00 June 2016 Page i of iii

Dubai Municipality
SECTION 21 – GEOTECHNICAL INVESTIGATION WORKS
CONTENTS
21 GEOTECHNICAL INVESTIGATION WORKS ...................................................... 1
21.1 SCOPE OF GUIDELINES ..................................................................................... 1
21.1.1 DOCUMENT DESCRIPTION .......................................................................... 1
21.1.2 HEALTH AND SAFETY .................................................................................. 2
21.1.3 QUALITY MANAGEMENT .............................................................................. 2
21.1.4 REFERENCE STANDARDS ........................................................................... 3
21.2 PRELIMINARY CONSIDERATIONS .................................................................... 3
21.2.1 INTRODUCTION ............................................................................................ 3
21.2.2 OBJECTIVES OF SITE INVESTIGATION ...................................................... 4
21.2.3 STAGES OF SITE INVESTIGATION .............................................................. 4
21.2.4 CONTRACTUAL ISSUES ............................................................................... 8
21.2.5 SUBMITTAL .................................................................................................. 10
21.2.6 METHOD STATEMENT ................................................................................ 11
21.2.7 STAFF ORGANIZATION .............................................................................. 12
21.2.8 HEALTH AND SAFETY ................................................................................ 12
21.2.9 CONTRACTOR’S EQUIPMENT ................................................................... 14
21.2.10 CONTRACTORS WORKING AREA ............................................................. 15
21.2.11 ENVIRONMENT IMPACT ............................................................................. 16
21.3 GROUND INVESTIGATION - PLANNING.......................................................... 17
21.3.1 INTRODUCTION .......................................................................................... 17
21.3.2 SCOPE AND EXTENT OF GROUND INVESTIGATION .............................. 18
21.3.3 SETTING OUT .............................................................................................. 19
21.3.4 MAINTAINING AND SUPPORTING SERVICES AND STRUCTURES ........ 20
21.3.5 CONTRACTOR’S SUPERVISION ................................................................ 20
21.3.6 REPORTING REQUIREMENTS ................................................................... 21
21.4 EXPLORATORY EXCAVATION......................................................................... 21
21.4.1 INTRODUCTION .......................................................................................... 21
21.4.2 TRIAL PITS ................................................................................................... 21
21.4.3 BOREHOLES................................................................................................ 23
21.4.4 SAMPLING ................................................................................................... 30
21.4.5 DESCRIPTION AND LOGGING OF SOILS AND ROCKS ........................... 34
21.4.6 GROUNDWATER LEVEL ............................................................................. 34
21.5 FIELD TESTING ................................................................................................. 35
21.5.1 GENERAL ..................................................................................................... 36
21.5.2 SIMPLE LOGGING TESTS .......................................................................... 36
21.5.3 TESTS IN BOREHOLES .............................................................................. 37
21.5.4 PUMPING TESTS ......................................................................................... 40
21.5.5 CONE PENETRATION TEST / STATIC PROBING ..................................... 41
21.5.6 DYNAMIC PROBING .................................................................................... 42
21.5.7 FIELD DENSITY ........................................................................................... 43
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21.5.8 P AND S SUSPENSION LOGGING ............................................................. 43

21.5.9 PLATE BEARING TEST ............................................................................... 45
21.5.10 IN-SITU CALIFORNIA BEARING RATIO TEST (CBR) ................................ 46
21.6 LABORATORY TESTS....................................................................................... 46
21.6.1 INTRODUCTION .......................................................................................... 46
21.6.2 SAMPLES ..................................................................................................... 47
21.6.3 QUALITY CONTROL .................................................................................... 47
21.6.4 REPORTING OF RESULTS ......................................................................... 47
21.6.5 SCHEDULE OF TESTS ................................................................................ 47
21.6.6 TESTING PROCEDURES ............................................................................ 48
21.7 REPORTING ....................................................................................................... 53
21.7.1 GENERAL ..................................................................................................... 53
21.7.2 DAILY REPORT............................................................................................ 54
21.7.3 PRELIMINARY RECORDS OF EXPLORATORY HOLES ........................... 55
21.7.4 LABORATORY TEST RESULTS .................................................................. 55
21.7.5 PRELIMINARY GROUND INVESTIGATION FACTUAL REPORT............... 56
21.7.6 FINAL GROUND INVESTIGATION FACTUAL REPORT ............................. 56
21.7.7 INTERPRETATIVE REPORT ....................................................................... 56
21.7.8 DIGITAL DATA ............................................................................................. 60
21.7.9 COPYRIGHT................................................................................................. 60
21.8 GEOPHYSICS ..................................................................................................... 60
21.8.1 GEOPHYSICAL SURVEYING ...................................................................... 60
21.8.2 QUALIFICATIONS ........................................................................................ 62
21.8.3 INCEPTION REPORT .................................................................................. 62
21.8.4 SEISMIC METHOD....................................................................................... 62
21.8.5 RESISTIVITY SURVEY ................................................................................ 63
21.8.6 TOPOGRAPHICAL SURVEY FOR RESISTIVITY SURVEY ........................ 63
21.8.7 BORINGS FOR GEOPHYSICAL SURVEYS ................................................ 64
21.8.8 PROGRESS REPORT .................................................................................. 64
21.8.9 DELIVERABLES ........................................................................................... 64
21.8.10 GEOPHYSICAL INVESTIGATION REPORT ............................................... 65
APPENDIX 2.1 - BORE HOLE LOGS ................................................................................... 67
APPENDIX 2.2 - WATER MONITORING DETAIL ................................................................ 68
APPENDIX 2.4 - REFERENCES ........................................................................................... 70
END OF SECTION................................................................................................................. 73
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21 GEOTECHNICAL INVESTIGATION WORKS
21.1 SCOPE OF GUIDELINES
21.1.1 DOCUMENT DESCRIPTION

a) This document, titled “Geotechnical Investigation Guidelines”, is made of
nine sections numbered from 21.1 to 21.9.
b) The guide deals with the technical specification requirements for site
investigations. It sets out guidelines for assessing the suitability of particular
sites in the Emirate of Dubai for the design and construction of civil
engineering works. It also describes the testing and interpretation methods of
obtaining reliable geotechnical parameters needed for design purpose.
c) This guide should be considered a reference tool. The requirements and
practices described within are not intended to be definitive in scope or to
provide detailed guidance on every type of subsurface investigation in every
condition.
d) The guide is based on good engineering practice and internationally
accepted standards. As such these standards and practices are to be
followed as the minimum and more details, standards or specifications may
be required dependent on the specifics of the project.
e) In this document two expressions have been used to differentiate between
the various stages of investigation. The expressions are defined as follows:
i. Site investigation refers to all the stages of assessment of the

suitability of the site. It includes desk study, reconnaissance,
sinking of exploratory holes, and interpretation of field and
laboratory test results, geotechnical designs and possibly further field
and laboratory testing.
ii. Ground investigation refers solely to the works undertaken to excavate
exploratory holes, extract representative samples and to carry out
field and laboratory tests.
f) This guide is made up of a further eight sections. A brief description of each

section is given below:
i. Section 21.2 “Preliminary considerations” deals with initial stages of site

assessment and information gathering. It also covers technical, legal,
economical, safety and environmental issues that influence the choice
of site.
ii. Section 21.3 “Ground investigation - planning” highlights the scope of the
field and laboratory works required to provide geotechnical parameters
representative of the existing ground of the area under investigation.
iii. Section 21.4 “Exploratory excavation” discusses the scope of
sinking boreholes and excavation of trial pits and obtaining
representative samples.
iv. Section 21.5 “Field testing” explains the methods and frequency of
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in-situ tests.
v. Section 21.6 “Laboratory testing” discusses the scope, type and
frequency of laboratory testing on representative samples.
vi. Section 21.7 “Reporting” sets out the procedure and the format of
reporting all the discovered factual data and the interpretation of
the information into the required soil parameters for design and
analysis purpose.
vii. Section 21.8 “Geophysics” sets out the procedure and format of
deliverables for geophysical investigation and surveying.
viii. Section 21.9 Appendices
21.1.2 HEALTH AND SAFETY

a) The contractor shall prepare and submit health and safety documentation to
the satisfaction of DM. Those responsible for health and safety will be
clearly identified on the contractors organization chart submitted for the
works.
b) The contractor’s health and safety procedures shall be in compliance with
the guidelines in these sections.
21.1.3 QUALITY MANAGEMENT

a) The contractor shall document, implement and maintain a Q.A. system in full
compliance with the requirements of ISO 9001. The Q.A. system shall be
sufficient to ensure that the results of the site investigation are submitted
within the required standards for accuracy and presentation, as defined in
the specifications, and the contractor shall produce documentary evidence to
demonstrate the adequacy of his Q.A. system in this respect, when
requested to do so by DM.
b) The contractor shall ensure that all sub-contractors working on the project,
whether nominated, appointed by himself or appointed by his own sub-
contractors, shall be subject to the full requirements of his own Q.A. system,
without exception.
c) The contractor shall allow for the regular audit of this Q.A. system, by
representatives of DM, at times defined by DM and shall rectify any
deficiencies reported to him, as a result of such audits.
d) The contractor shall prepare and submit a project Quality Plan to DM for the
approval within 7 calendar days of first taking possession of all or part of the
Site. The Quality Plan shall contain as a minimum a description of the
contractor's overall and site management organisations, and all procedures
that will be applied by the contractor to achieve the quality requirements of
this Contract.
e) Prior to the preparation and submission of his Quality Plan to DM, the
contractor shall liaise with DM to ensure that his Q.A. system shall correlate
and interface with DM’s Q.A. system, such that items of mutual responsibility
or concern can be adequately coordinated and incorporated within his
Quality Plan.
f) All equipment requiring calibration and certification as per relevant standards
shall be periodically maintained and records of the same produced in the QA

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Plan.
g) When requested by DM, the contractor shall produce additional information

to update, augment or revise the Quality Plan, to properly reflect the Contract
Conditions.
h) The QA Plan shall include:
i. A quality document consisting of a series of written procedures

covering some or all of the components of the site investigation,
relevant observation sheets, report formats, specimen calculation
sheets and check lists. All proposed test equipment, procedures,
calculations and reporting formats should be in accordance with
applicable internationally acceptable standards and practices.
ii. Equipment list with the standard of maintenance, frequency of check
on performance, frequency of calibration, etc.
iii. Records of Calibration and inspection of drilling equipment.
iv. Records of equipment that is mandatory to be calibrated by the
relevant local authority.
i) Records of personnel detailing their qualifications, training and experience

appropriate to their duties who are associated in the works.
21.1.4 REFERENCE STANDARDS

a) All works shall be in accordance with the applicable International Standards
and as specified in these specifications and as detailed in the approved
method statements. DM may vary the work requirements depending on
actual ground conditions encountered. The contractor shall confirm his
acknowledgement of the amended requirements.
b) Workmanship and work performance in compliance with reference Codes
and Standards under against the agreed / approved quality management
plan for the project.
21.2 PRELIMINARY CONSIDERATIONS

21.2.1 INTRODUCTION
a) Site investigation is essential to the design and construction of civil
engineering projects. The purpose of site investigation is to examine the
general soil and ground water conditions of the proposed construction site by
undertaking field works and laboratory testing. The interpretation of the
results will assist the designer in producing robust and cost effective design.
It also assists in identifying problematic ground conditions prior to the
preliminary design stage.
b) This section also covers relevant contractual, environmental and site issues
which need to be considered prior to commencement of work.

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21.2.2 OBJECTIVES OF SITE INVESTIGATION

a) The main objectives of site investigation are; to assess the suitability of the
site for the proposed construction scheme, to enable safe and economic
design, to plan the most appropriate stages and methods of construction and
to identify techniques of ground improvement wherever needed.
b) Site investigation should be undertaken to achieve the following objectives:

i. Examination of all available soil / rock data.
ii. Identification of soil / rock and groundwater conditions of the site.
iii. Identification of areas of exceptionally weak ground.
iv. Highlighting any soil instabilities such as slope failures or geological
structures such as; faults, folds etc.
v. Indication of any long term instabilities such as ground water
problem, solution features, buried channels and cavities.
c) The investigations will also, dependent on the project, provide information

that would assist in selecting the most suitable location for work and
development. For instance, when an excavation has to be carried out,
knowledge of the subsurface strata and groundwater conditions should
indicate, for example:
i. Ease of removal of material.
ii. Stability of the side of the excavation and support requirements.
iii. Dewatering requirements and special precautions.
iv. Changes in the nature of the excavated material.
v. Suitability of the excavated materials for re-uses as backfill and
requirement for special controls on excavation, movement, disposal,
and additional safety measures.
vi. Environmental or ecological considerations that might impose any
constraints on the scope of the new works.
d) For design purpose, it is necessary to assess such considerations as bearing

capacity and settlement of foundations, stability of pipe trenches, earth
pressures on supporting structures, and the effect of any chemically
aggressive or hazardous ground conditions.
e) The nature and the size of the proposed project will determine the extent and
the type of investigation. Any site investigation should be phased in the
following sequence; desk study and site reconnaissance, detailed ground
investigation with topographic and hydro-geological survey. Further ground
investigation may be required during the detailed design stages.
f) Generally the capital costs of site investigations are low in relation to the total
cost of the construction project. Involvement of a geotechnical engineer at
early stages of design will help in formulating efficient and economical plan,
and to assist with interpretation of results at a later stage.
21.2.3 STAGES OF SITE INVESTIGATION
a) Ideal site investigation should be carried out in the following sequence:

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i. Stage 1 - Desk study associated with site reconnaissance.

ii. Stage 2 - Detailed ground investigation with topographic and hydro-
geological survey in addition to specific studies as required.
iii. Stage 3 - Additional investigations and design review during
construction.
b) A schematic presentation of site investigation stages is shown in Figure

2.2.3.
c) The Desk Study stage is discussed in this section, whereas stages 2 and 3
will be covered in later sections of this document.
21.2.3.1 Desk Study and Site Reconnaissance

a) The primary objectives of the desk study are to evaluate the ground
conditions based upon available information on geology and ground water
conditions, both locally and regionally, in order to plan the extent of
subsequent stages of ground investigation. During the desk study stage, the
information may be collected from published literature such as:
i. Geological maps.
ii. Geological memoirs.
iii. Flooding, erosion, landslide and subsidence history.
iv. Data held by central and local authorities.
v. Construction and investigation records of adjacent sites.
vi. Aerial photographs and other remote sensing data.
vii. Site boundaries and outlines of the proposed construction area.
viii. Ground contours and natural drainage features.
ix. Location and ease of access to the site.
x. Ecological considerations and potential contamination as well as
any restrictions imposed by local authorities and other service
agencies.
xi. Previous reports on studies carried out by others.
b) To verify the available information site reconnaissance is necessary at this

stage. Examination of the site and its surroundings must be carried out by an
experienced engineer with predefined objectives.
c) Topographical features should be noted and any subsurface strata
exposures in pits, quarries trenches and road cuttings should also be
recorded. Note should be made on signs of instability or soil creep,
particularly of sloping sites with Alluvium cover.
d) Evidence of surface and groundwater features or courses should also be
noted and described.
e) The investigation should cover all ground in which significant temporary or
permanent changes may occur as a result of the construction works. These
changes include: changes in stress and associated strain; changes in
moisture content and associated volume changes; changes in groundwater
level and flow pattern; and changes in properties of the ground, such as
strength and compressibility. Materials placed in the ground may deteriorate,
especially in landfill and contaminated former industrial sites. It is therefore

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necessary to provide information from which an estimate of the corrosivity of

the ground can be made.
f) For design purpose, it is necessary to assess such considerations as bearing
capacity and settlement of foundations, stability of pipe trenches, need for
dewatering of excavations, feasibility of trenchless technology solutions,
earth pressures on supporting structures, and the effect of any chemically
aggressive or hazardous ground conditions.
g) In cases of large or extended areas, preliminary investigation is necessary in
order to plan the main site investigation and obtain more accurate results.
The detailed investigation obtains the bulk of the information required, but it
may be necessary to carry out supplementary investigations for more
detailed information related to specific problems.
h) Sometimes additional investigation, during project works, may be necessary.
In tunnelling, for example, probing ahead of the face may be required to give
warning of hazards or changes in ground conditions. The properties of the
ground and also the groundwater levels may vary with seasons. In planning
the investigation, consideration should be given to predicting the ground
conditions at different times of the year.
i) It is essential that there should be adequate direction and supervision of the
work by a competent person with appropriate knowledge, training,
experience and authority to decide on variations to the ground investigation
when required.

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Figure 2.2.3 - General Sequence of Site Investigation Stages

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21.2.4 CONTRACTUAL ISSUES
21.2.4.1 Notice of Intent and Approvals
a) Issue formal ‘Notice of Intent’ to all concerned parties and authorities to

obtain information on location of existing underground services and ‘no
objection’ to executing the Work. A sample of Notice of Intent Model Form is
given in this guide.
b) The contractor is required to send notices of intent of the works, including
maps and drawings to the relevant authorities, service provider or other
parties having jurisdiction over such matters. Notices should be sent in
duplicate.
c) On receipt of responses from all interested parties the contractor must
comply with all conditions of approval, stipulated or implied.
d) DM are not responsible for pursuing or obtaining licenses, permits or no-
objection certificates. All such documents must be obtained prior to the
commencement of work on the site.
e) A copy of all licenses permits or no-objection certificates must be held at the
site for the duration of the investigation, and the contractor must be able to
make them available to the DM representative or other interested parties
upon request.
f) If a license, permit or no-objection certificate proves difficult to obtain DM
may be approached for assistance, although the responsibility remains with
the contractor.
21.2.4.2 Public Notice of Starting Work

a) Provide and distribute to all occupants along the streets or other alignments
affected by the Works, a full A4 page size printed notice, with wording
approved by DM, indicating the nature of the proposed works and the
inconveniences likely to be caused thereby.
b) Notice to include the name, designation and address of the contractor's
Agent or Representative who should be contacted in an emergency.
c) The notice shall be in both Arabic and English languages.
21.2.4.3 Protection of Existing Structures, Furniture and Tracks
a) The contractor shall take all measures necessary to protect existing roads,
structures, fences, gates, walls and other site features from damage during
the currency of the Contract and shall be responsible for making good any
damage caused by him directly or arising indirectly from anything done or
omitted to be done.
b) The contractor shall deal promptly with any complaints by the owners or
occupiers of such properties.
c) The contractor shall carry out all temporary works and any other measures
as necessary to provide adequate protection.

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d) Any damage shall be notified immediately to DM.

e) The contractor with DM shall take, at the start and finish of the Contract,
suitable photographs of any existing road, structure, fence, gate, wall, etc. to
determine whether any damage has been caused by the contractor during
the period of the Contract.
f) On completion of the work, the contractor shall thoroughly clean the whole of
the Works. The contractor shall remove from Site all plant, rubbish and
temporary works of all kinds provided by him and leave the whole site in a
clean and workmanlike condition.
21.2.4.4 Compensation for Damage to Property
a) Reinstate all public and private property if affected by the Works, Temporary
Works, constructional plant, labour, materials and transport to a condition at
least equal to that existing before first entry onto them.
b) Failure to reinstate adequately and promptly, DM reserves the right to :
i. Carry out the reinstatement.

ii. Arrange for it to be carried out by others.
iii. Pay compensation to the owners and occupiers, if required.
c) All such costs incurred to be deducted from payments due to the contractor
by DM.
21.2.4.5 Site Access

a) The contractor shall demonstrate that his chosen access is acceptable with
regard to engineering and environmental concerns.
b) The contractor shall acquaint himself and comply with any load restrictions,
which apply and shall avoid peak traffic. If it is unavoidable that the
contractor has to drive tracked vehicles along the existing roads, he must
take all necessary precautions to prevent damage thereto. Such
precautions shall not however relieve him of his responsibility for reinstating
any damage caused to the existing roads. The contractor is also to ensure
that existing roads are kept clear of site materials and debris at all times.
c) The contractor shall inform his sub-contractors of all restrictions relating to
access and ensure that the sub-contractors comply with them.
d) The contractor shall allow for all other necessary items relating to his access
to the Works.
e) The contractor shall be responsible for making his own arrangements for
establishing his plant and equipment in the investigation area and for
transporting personnel to and from the Site during the Contract Period.
f) The contractor is permitted access to the Site for the sole use of carrying out
the works. The contractor shall be responsible for ensuring that all roads
and bridges and sea vessels en route to the Site are suitable for
transporting materials and plant required under the Contract.

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21.2.5 SUBMITTAL
21.2.5.1 Procedures
a) The contractor shall submit within two weeks after signing Agreement a list of
all submittals showing the forecast date for submission of each item.
b) No work represented by required submittals shall be commenced until the
applicable submittal has been approved.
c) Drawings and data shall be submitted to meet the time schedules stipulated
in these specifications or the approved programme.
d) Allow a minimum of two weeks for the review of submittals by DM.
e) Submittal copies shall be neatly bound and shall have an index listing the
contents
f) Submit by means of dated, signed and sequence numbered transmittals with
Company letterhead. Identify as to initial or re-submittal status, and fully
describe the submittal contents.
g) State the Drawing numbers and Specification Sections, articles and
paragraphs to which the submittal pertains; other information to fully describe
the item, and supplementary information as may be required for approval.
h) Unless otherwise specified, each submittal shall include three sets of copies.
One copy of the submittal will be returned marked with one of the following
categories:
A : "Approved" subject to contract requirements.

B : "Approved except as noted" resubmission not required.
C : "Disapproved" pending corrections, resubmission required.
D : Rejected not to specification.
E : Incomplete.
Proceed with related works for categories A and B only.
i) Apply stamp, signature or initial certifying that review, approval, verification of

field dimensions, adjacent Work, and coordination of information is in
accordance with the requirements of the Work and Contract Documents.
j) Identify variations from Contract Documents which may be detrimental to
successful performance of the completed Work.
k) Provide space for writing Engineer’s view only and review stamps.
l) Distribute copies of reviewed submittals as appropriate and as directed by
DM. Request parties to promptly report any inability to comply with
requirements.
m) Make all required corrections and resubmit the required number of corrected
submittals until approved. Direct specific attention in writing to revisions other
than the corrections called for on previous submittals.
n) Check submittals returned for correction and ascertain if the corrections
result in extra cost above that included under the Contract Documents. Give
written notice to DM within five days if such extra cost results from
corrections. By failing to notify DM or by starting any Work covered by a

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submittal, all claims for extra costs resulting from required corrections are
waived.
o) Whenever a variation causes a change to the information contained in
previously approved submittals, submit information and data corresponding
to the changed requirements for approval.
p) Revised submittals shall be submitted following the procedures required for
previously approved submittals.
q) All final ground investigation reports including drawings must also be
submitted in electronic forms, and as further elaborated in Section 21.7.8.
21.2.5.2 Drawing Submittal Requirements
All generic terms shall be used on drawings as per latest DM CAD

Manual format to ensure nomenclature parallel with the Specification
Section. In addition any interpretation required may be referred to this
Drawing Coordination Section.
21.2.6 METHOD STATEMENT

Prior to commencing any subsurface investigation the contractor shall
prepare and submit to DM a detailed method statement. This should
include a description of how all aspects of the work will be carried out;
provide details of the equipment to be used and techniques to be employed.
The following is a suggested contents list for a method statement. This

should be modified and amplified according to the scope of the works and
the guidance and requirements of relevant standards, local procedures and
requirements of this guide, detailed in this and other sections.
a) Fieldwork
i. Equipment
i. Staffing and qualifications
ii. Schedules
iii. Boring and coring techniques
iv. Trial pit excavation methods, including stabilization methods.
v. Groundwater measurement
vi. Details of any installations
vii. Sample storage, labeling and preservation
viii. In-situ testing and sampling methods
ix. Backfilling
x. Quality procedures
xi. Health and safety plan
xii. Calibration certificates for equipment to be used
b) Testing
i. In-situ, on site and laboratory testing procedures and techniques

ii. Laboratory equipment
iii. Calibration certificates for equipment to be used

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iv. Schedules
v. Staffing and qualifications
c) Reporting
i. Forms
ii. Log sheets
iii. Diaries
iv. Journals
v. Report formats
Standard description and classification system used
21.2.7 STAFF ORGANIZATION
21.2.7.1 Layout Organization Plan

a) Prior to mobilizing the contractor shall prepare and submit to DM for approval
a Site Layout Organization Plan and any modifications thereafter showing
the proposed layout of facilities on the site.
b) The Site Layout Organization Plan shall include, but not be limited to, the
following:
i. Temporary facilities including accommodation.
ii. Plant, storage areas.
iii. Access for other contractors, Employer's staff, visitors etc
21.2.7.2 Contractor's Site Staff Organization.

a) No later than two weeks from the start of the mobilisation period(s) and
before commencement of Works on site, submit a full listing of his proposed
site staff for the organization, management and supervision of the Works.
The list shall include all personnel from Project Manager through to foreman
level and shall amplify and reflect the details already given by the contractor
in the Bidder's Schedule of Data submitted with his Bid and incorporated in
the Contract. Such listing shall be supported by authenticated details of the
qualifications and experience of such personnel, for review by DM and
approval by DM.
b) Before being approved DM shall have the right to interview any of the
contractor's proposed staff and notwithstanding their approval DM retains the
right to instruct the removal of any person employed by the contractor in or
about the Works, who, in their opinion, misconducts himself, or is
incompetent or negligent in the proper performance of his duties, or whose
employment is otherwise considered to be undesirable.
c) The contractor’s staff selected to work on the project will have sufficient
suitable experience as further detailed in Section 21.3.
21.2.8 HEALTH AND SAFETY

21.2.8.1 General
a) The contractor shall submit his Health and Safety Policy Document to DM for
review which shall include as a minimum.

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i. Company Health and Safety Policy Statement, signed by the

authorised signatory of the Company.
ii. Details of the Company’s safety organisation, including curriculum
vitae of Company safety officers.
iii. Safety responsibilities of all Company staff.
iv. Details of the Company health and safety procedures.
21.2.8.2 Site Working Conditions

a) The contractor shall ensure that he and his subcontractor comply fully with all
health and safety legislation current and relevant to the scope of works.
b) The contractor shall, throughout the progress of the Works, comply with the
health and safety requirements of the Specification and with the health and
safety recommendations for building and civil engineering work published by
the International Labour Organisation and the specific requirements of all
other authorities having jurisdiction over such matters.
c) The contractor shall be responsible for acquainting his employees with the
potential hazards and shall institute positive measures, as necessary to
ensure both the safety of his employees and that his own activities cause no
additional hazards.
d) The contractor shall be responsible for carrying out the works in a safe and
sound manner to avoid risk or danger to all people employed on the Site,
whether or not employed by the contractor, and the General Public.
e) The contractor shall make his own arrangements for the first aid treatment of
casualties on Site and for transporting the injured to hospital or their home.
This shall be at the contractor’s expense.
f) The contractor shall appoint a responsible person from his staff to undertake
the duties of Safety Officer and Safety Supervisor on Site. The contractor
shall inform DM in writing prior to commencement of any work on the
Contract of the nominated Safety Officer’s name and relevant qualifications,
experience and documentation for formal approval.
21.2.8.3 Personal Protective Equipment (PPE)

a) The contractor shall ensure that all of his staff are provided with suitable
PPE.
b) The contractor shall also maintain PPE on site for use by DM
representatives.
21.2.8.4 First Aid

a) The contractor shall provide a qualified first-aider, and supply and maintain at
each main area of the Site a set of first-aid equipment. Each unit shall
comprise stretcher equipment and a container holding dressings and
medicaments.
b) A list of all first aiders and the location of first aid kits shall be provided to DM
in advance of the commencement of the Works. Such provision does not
relieve the Contractor of his duties to brief his employees and Subcontractors
of the same.

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21.2.8.5 Emergency Arrangements

Before commencement of any of the Works the contractor shall submit his
proposed emergency procedures to DM for approval. In any case, DM
must be informed as soon as is reasonably practicable of any
emergency situation, which develops on Site.
21.2.8.6 Tidiness of Site

a) Throughout the period of construction of the Works, the contractor shall
maintain the whole area of his operations in a clean, tidy and safe condition.
b) All rubbish, waste materials, debris and the like shall be systematically
cleared off the working areas as they accumulate and, if not removed directly
off the Site, shall be temporarily deposited at general collecting points agreed
with by DM, pending removal from the site.
c) The contractor shall keep the working areas and the site and access roads
clear of mud, water, silt and other materials at all times.
d) The contractor shall clean all vehicles and plant before they leave the Site to
ensure that they deposit no earth, mud or other objectionable matter on
roads. If earth, mud or other objectionable matter is deposited on roads, the
contractor shall provide sufficient labour, plant, equipment etc. as is
necessary and as required by DM to ensure that deposits are immediately
removed.
e) Following completion of the fieldworks the contractor and DM will conduct a
joint site visit through the site to ensure that all public and private properties
are restored to their original condition and that any potentially hazardous
situations created by the investigation have been rectified.
21.2.9 CONTRACTOR’S EQUIPMENT
21.2.9.1 General
a) The contractor shall provide and maintain in good order all the construction
equipment required for the successful execution of the Works.
b) All Plant and equipment used on the performance of the works shall be of
such type, size and of such method of working as DM approves. If for any
reason whatsoever DM shall be of the opinion that any machine or appliance
employed or proposed to be employed by the contractor for the purpose of
the Works shall not be used, or that any such machine or appliance as
aforesaid is unsuitable for use on the Works or any part of them, then such
equipment shall be immediately withdrawn from use.
c) In particular DM shall prohibit or suspend the use of machinery which in his
opinion is likely to damage or render unstable any structure, or any other
property or work of any kind.
d) All machines and equipment must be calibrated and tested for compliance to
the manufacturer’s specifications and DM should approve before use in the
site. Tests should be repeated at DM’s request without any extra cost or
time. All certificates and calibration sheets shall be provided to DM.

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21.2.9.2 Noise Control

All plant and equipment supplied by the contractor for use on the Works
shall be effectively "sound reduced" by means of silencers, mufflers,
acoustic linings or shields, acoustic sheds or screens, etc., as necessary to
fulfill the requirements of the Building Permit and current editions of all
Regulations applicable to noise control on construction and demolition sites.
21.2.9.3 Disposal of Plant, Equipment And Materials

All plant and equipment shall be removed by the contractor from the Site at
the completion of the Works.
21.2.9.4 Disposal of Construction Waste

The contractor shall be responsible for the safe disposal of all waste
produced as a result of the Works and he shall provide details of his
proposed disposal arrangements to DM. Under no circumstances will
disposal of any waste be permitted on or adjacent to the Site. And reinstate
the site as before handover the site
21.2.9.5 Avoidance of Nuisance

The contractor shall ensure at all times that spillage does not occur of grout,
drilling mud, contaminated soils into any new or existing drainage, duct
system or water course. Nevertheless, should any drainage or duct system
or water course be fouled by such materials the contractor shall clean the
drainage or duct system or water course at his own expense, to the
satisfaction of DM.
21.2.10 CONTRACTORS WORKING AREA
21.2.10.1 General
a) The contractor shall be responsible for temporary drainage, security fencing,
temporary roads, all other necessary works, maintaining, clearing away and
reinstating the area when no longer required.
b) The contractor shall be responsible for maintaining and cleaning all site
facilities as detailed in this section.
c) The contractor shall submit to DM details of any working compound / area he
proposes for review before any work is carried out therein.
d) The contractor shall note that no land will be available outside of the Site and
that if this is insufficient for his requirements then he shall be
responsible for acquiring such additional areas of land off the Site as he may
require to accommodate his needs, paying all charges and taking all
responsibilities in connection therewith.
e) The contractor shall note that no temporary labour camps will be permitted at
the Site unless otherwise specifically advised in advance, in writing by the
Employer.
f) The contractor shall arrange for all his own water, electricity and

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telecommunications services for the performance of the Contract including

the provision of any cables, pipes, valves, meters, storage tanks, etc. The
contractor shall be responsible for obtaining all permissions and consents
from the relevant supply or service authorities for the use of their respective
supplies or services.
21.2.10.2 Toilet and Washing Facilities

a) The contractor shall provide on the Site suitable hygienic toilet and washing
facilities for the use of his own workforce.
b) The contractor must exercise strict supervision of all persons employed by
him to avoid nuisance or contamination of the Works.
21.2.10.3 Site Electricity Supply
a) The contractor shall make his own arrangements for the temporary supply of
any electricity required for the execution of the Works and he shall issue all
notices and pay all fees, dues, charges and other costs in respect thereof.
b) The contractor shall be responsible for providing and maintaining the whole
of the temporary electrical installation and in relation thereto shall take all
reasonable precautions to ensure the safety of every person on the Site. DM
may require the disconnection or alteration of any parts which he considers
may be dangerous.
c) The whole of the contractor's temporary electrical installation shall comply
with all statutory requirements of BS 7375: 1996 Code of practice for
distribution of electricity on construction and building Sites.
d) Electric heaters or radiators having exposed heating coils or elements shall
not be used on the Site.
e) As soon as any part or the whole of the contractor's temporary electrical
installation is no longer required for the carrying out of the Works, the
contractor shall disconnect and remove the same.
f) The Employer shall not be responsible for any loss or delays incurred by the
contractor due to interruption of supply of electricity.
21.2.11 ENVIRONMENT IMPACT
21.2.11.1 Water Control

a) Grade site to drain to maintain excavations free of water. Provide, operate,
and maintain pumping equipment.
b) Protect site from ponding or running water. Provide water barriers as
required to protect site from soil erosion.
21.2.11.2 Dust Control
a) Minimize raising dust while executing works using appropriate methods.
b) Provide positive means to prevent air-borne dust from dispersing into
atmosphere.

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21.2.11.3 Noise Control
Refer to clause 21.2.8.2.
21.2.11.4 Pollution Control

Provide methods, means, and facilities to prevent contamination of soil,
water, and atmosphere from discharge of noxious, toxic substances, and
pollutants produced by construction operations.
21.2.11.5 Plantations and Trees

a) Inform DM if any plantation, tree or grass is conflicting with the works. DM
shall approach the Director, Town Planning for realignment of the concerned
work.
b) Removal of any plantations, tree or grass is prohibited.
c) Maintain all greenery, plantations and the existing irrigation system within
the area of the Contract limits.
d) Protect plants and grass from excavation, spoils or other construction
materials, throughout the period of contract except for those green areas and
plantations shown on the Drawings to be removed or altered as directed by
DM with prior approval of the authority concerned.
21.2.11.6 Post Investigation Site Visit

On completion of the investigation works a joint site visit and inspection shall
be undertaken by the contractor, DM and if required an DM
representative. The contractor shall be required to demonstrate that the site
has been restored to its previous condition, that no hazardous situations have
been created and that any damage caused during the investigation has been
corrected.
21.3 GROUND INVESTIGATION - PLANNING
21.3.1 INTRODUCTION
a) The objective of the ground investigation is to obtain reliable information

on engineering properties of the subsurface materials in order to
produce economical and safe design and to assess any potential
hazards associated with the ground particularly for new projects.
b) The ground investigation should cover all areas in which significant

temporary or permanent changes may occur as a result of the proposed
works. These changes include: changes in stress and associated strain;
changes in moisture content and associated volume changes; changes
in groundwater level and flow pattern; and changes in properties of the
ground such as strength and compressibility.

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21.3.2 SCOPE AND EXTENT OF GROUND INVESTIGATION
a) Depending on the results of the desk study and the complexity of the project,
it may be advisable to carry out the investigation in phases. The initial stage
might involve widely spaced boreholes, widely spaced geophysical survey
lines, trial pits and probing designed to establish the general geology and
ground conditions of the site.
b) This preliminary investigation will assist in setting out an effective programme
for the detailed investigation.
c) Geotechnical Investigation shall include but not be limited to the following
major items:-
i. Drilling boreholes and conducting in-situ tests in boreholes;

Standard Penetration Tests shall be conducted in every borehole.
ii. Excavation of Trial Pits.
iii. Collection and preservation of soil, rock and ground water samples.
iv. Conducting Field shear tests in boreholes (Vane shear).
v. Permeability tests in select boreholes.
vi. Static Cone penetration tests.
vii. Pressuremeter tests.
viii. In situ density test.
ix. Field well pumping tests.
x. Measuring and monitoring groundwater levels.
xi. Plate bearing tests.
xii. Seismic suspension logging.
xiii. Geophysical surveying if required.
xiv. Regime of laboratory tests on selected samples.
xv. Submission of Ground investigation reports.
d) Employment of Nominated Specialist Subcontractors to carry out

geophysical survey works shall be agreed with DM. Works specifications are
to be defined by DM.
e) The contractor’s and nominated sub-contractor’s attention is drawn to the
requirements of Clauses 6(4), 37, 38 and 86 of the Conditions of Contract
and the Supplementary Conditions and to the Nominated Subcontract
Agreement, Part one.
f) Normally, exploration should be extended below all deposits that may not be
suitable for foundation purposes, e.g. made ground and weak compressible
soils, including weak strata overlain by a layer of higher strength.
g) Cavities are commonly found within 20m depth below ground surface in
several areas throughout the Emirate of Dubai and therefore it is
recommended that any detailed investigation should include for this
possibility.
h) It is normal practice for an appointed geotechnical engineer or specialist
consultancy to scope and plan the investigation based on the known design

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and construction requirements. However, when such an appointment is not

available the contractor may use the following guidelines regarding the
extent of exploration below ground surface depending on the existing
geology of the area and the purpose of the investigation:
i) Structures; the depth of exploration should be at least one and a half times
the width of the loaded area, unless the area contains compressive strata or
contains cavities.
j) Embankments; the depth of the exploration should be sufficient to check
possible shear failure through the foundation strata and to assess the likely
amount of any settlement due to compressible strata.
k) Cutting, quarries and open-cast mines; the depth of exploration should be
sufficient to permit assessment of stability of the slopes; this may require
proving the full depth of any relatively weak strata.
l) Roads and airfields; the depth of exploration should be sufficient to
determine the strength of possible sub-grade and the drainage conditions.
m) Pipelines; for small shallow pipelines, it is generally sufficient to take
exploration to 5 m below the invert level. For deeper pipelines the depth of
exploration should be sufficient to provide information for the design of de-
watering and to identify the presence of any adverse strata or cavities with
the depth stress stressed by the pipeline.
n) Tunnels; it is important to take the exploration to an adequate depth below
the proposed invert level for the same reasons indicated in item m).
21.3.3 SETTING OUT
a) The contractor is to provide to DM valid certificates of calibration for all

survey instruments to be used prior to the commencement of the survey
works.
b) The exploratory hole locations shall be surveyed using the co-ordinates as
c) The contractor shall be responsible for setting up any permanent or
temporary survey station required to accurately set out the works. The
contractor shall employ the services of an experienced surveying specialist
for this purpose if necessary.
d) The contractor shall at the commencement of the Works check the
consistency of existing survey stations and report any discrepancies to DM.
e) The contractor shall give DM reasonable notice (7 days minimum) of his
intention to set out or take levels for any part of the Works so that
arrangements may be made for checking the work. The accuracy of setting
out and leveling shall be within the tolerances specified in BS 5606: 1990 or
as called for in the Specification. In the course of setting out if DM finds the
locations to be unsuitable and location of exploration needs to be relocated
then the contractor shall determine the co-ordinates and the elevations of the
new locations.
f) The checking of setting out or leveling by DM shall not relieve the contractor
of his duties or responsibilities under the Contract. The contractor shall be

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responsible for Setting Out works in their entirety.
21.3.4 MAINTAINING AND SUPPORTING SERVICES AND STRUCTURES
a) The contractor shall take all measures necessary to protect existing roads,
structures, sewers, fences, gates, walls and other site features from damage
during the currency of the Contract and shall be responsible for making good
any damage caused by him directly or arising indirectly from anything done
or omitted to be done.
b) Any damage shall be notified immediately to DM.
If the proposed method of working will damage, expose or affect these in any
way, obtain written acceptance from the appropriate Authority and DM for
this method of working before commencing work. Such acceptance will in no
way relieve the contractor from any of his responsibilities under the Contract.
c) In areas where utilities are likely to be encountered the contractor shall
ascertain the actual locations of all existing services and obstructions before
commencing any part of the Works and submit to DM detailed drawings
showing the services and proposed excavation method.
d) The contractor shall carry out all temporary works and any other measures
as necessary to provide adequate protection to services and structures
present on site.
21.3.5 CONTRACTOR’S SUPERVISION
a) The contractor will be expected to provide a very high standard of

management and technical supervision of the works. The contractor shall
employ on site sufficient personnel with extensive experience of similar
works to enable the Contract to be completed to programme and in full
accordance with the Contract Document.
b) A senior member of the contractor’s staff who can demonstrate a minimum of
10 years relevant experience in high quality investigation contracts shall
carry out the overall direction of the work. He will be expected to promote
and maintain the high standard of work required, to regularly inform DM
concerning the technical progress of the works including reporting and to
propose variations in technique as required.
c) The contractor shall be represented on site at all times during working hours
by an experienced supervisor who shall be a skilled and experienced
geotechnical engineer or engineering geologist and can demonstrate a
minimum of 5 years relevant experience.
d) The supervisor will be responsible for controlling and coordinating the site
works and carry out the various items within the Contract in an efficient and
competent manner. He will be expected to maintain close liaison with DM.
e) The supervisor shall be capable of setting out the works accurately and
identifying immediately and positively the strata penetrated in order that the

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decisions regarding sampling, laboratory testing, changes in method of

advancing the exploratory hole and the hole termination can be made. He
shall be fully conversant with the theory and techniques of the field and
laboratory testing covered by this Contract. He shall always be present
during sampling operations and shall be capable of producing the borehole
logs and directing the crew in matters of technique and so as to ensure that
the highest quality of sampling and testing is achieved.
f) In addition to the supervision described above, the contractor shall employ
foreman and surveyors, and all other staff necessary and experienced in the
works covered by the Contract.
g) If at any time during the Contract DM is not satisfied with the competence of
any of the personnel providing technical direction or supervision, he will
inform the contractor in writing and the contractor shall provide a
replacement to the approval of DM within 7 days of notification.
h) The contractor shall be represented in the laboratory at all times during the
testing of sample and cores by an experienced supervisor who will be
responsible for the control of the laboratory testing.
i) The contractor shall nominate supervisory staff and provide CVs for them as
part of his Tender Offer.
j) DM reserves the right to have full representation on site for the duration (or
part duration) of the works and the contractor shall afford full co-operation to
representatives requirements.
21.3.6 REPORTING REQUIREMENTS

Reporting shall be in accordance with Section 21.7.
21.4 EXPLORATORY EXCAVATION

21.4.1 INTRODUCTION
a) Ground investigation is a combination of various methods employed to cover
the technical requirements and a range of ground conditions that are
expected to be encountered.
b) The range of methods includes intrusive methods such as excavation,
boreholes and probing and geophysical survey.
21.4.2 TRIAL PITS
a) The contractor shall excavate trial pits by hand or machine to permit in situ
examination, sampling and testing as required. The contractor shall provide
all necessary compressors and breakers and other plant as necessary for
breaking out concrete or other hard material at the commencing surface.
The plan area of any trial pit shall not be less than 2 sq.meters.
b) Trial Pits shall be excavated in accordance with BS5930, 1999 by hand
pitting or by mechanical excavator. The contractor shall supply, fix and
remove on completion sufficient support to the sides of the excavation to
protect anyone entering and working in the hole. The material used for this
support shall be to the approval of DM.
c) The contractor shall keep the excavation free of water by pumping or other

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means to permit continuous work in so far as the rate of inflow of water does
not make control unreasonably difficult.
d) Shallow trial pits permit the in-situ condition of the ground to be examined in
detail both laterally and vertically; they also provide a means of determining
the orientation of discontinuities in the ground. The field record should
include a plan giving the location and orientation of the pit with details of
which face(s) was logged, and a dimensioned section of each side and the
floor.
e) Tube samplers can be driven into the floor of the pit, using a jarring link and
drill rods, and then extracted by the excavator similarly block samples can be
also be cut out at required depths. In-situ testing, such as the vane shear
strength test, can also be carried out.
f) Shallow pits without side support can be used for making a rapid check on
the condition of the ground by drawing a ground profile working from ground
surface supplemented by collection of bulk and undisturbed samples.
g) Trial pits may be extended laterally to form Trial Trenches to examine the
lateral variation in ground conditions and or to determine the extent of
features observed.
h) Trial pits on potentially contaminated land shall be excavated by machine. All
safety precautions as detailed in the Contract shall be followed. Ground from
potentially contaminated material shall be described by an environmental
specialist as appropriate.
i) Pits that are unsupported may collapse soon after being dug, so any logging,
sampling and in-situ testing should be carried out immediately after the pit
has been dug. It is advisable to backfill pits as soon as possible after logging,
sampling and testing have been completed, since open pits can be a hazard
to the general public. Entry by personnel into unsupported pits deeper than
1.2 m is not allowed for health and safety reasons. The stability of the pit is
solely the responsibility of the contractor.
j) The field record should include a plan giving the location and orientation of
the pit with details of which face is logged. The record should include
photographs.
k) Photographs shall clearly show the details of the ground conditions in the pit
or trench with any support in place and shall contain a graduated scale.
Photographs are required for each face of the excavation and the excavation
base. The photographs shall be collected using a digital camera with a
resolution of not less than 5 mega-pixels.
l) Trial Pits may also be excavated as Inspection pits for the location of
underground services. Inspection pits shall be excavated manually unless
otherwise agreed by DM.
m) Backfilling of the pits and trenches shall be carried out as soon as practicable
with material replaced at similar depths as encountered. The backfilling shall
be compacted in such a manner, and in layers not exceeding 0.5m, as to
minimize any subsequent depression at the ground surface. If the top soil is
rich in humus the same shall be stacked separately during excavation and
shall be replaced in its same position during back fill.

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21.4.3 BOREHOLES
a) The following methods are generally adopted for advancement of boreholes:
i. Light cable percussion.

ii. Auger boring.
iii. Rotary open hole drilling.
iv. Rotary core drilling.
b) The method of advancement and the diameter of a borehole shall be such

that the coring and boring is completed to the scheduled depth and SPT
samples are obtained as well as in situ testing carried out and
instrumentation installed.
21.4.3.1 General
a) The contractor shall bring in to the site all necessary boring or drilling
equipment to carry out the boreholes.
b) Boring/drilling shall not commence until the contractor has obtained the
necessary permits to work and notified DM.
c) The contractor shall provide adequate operatives, supervisors and plant to
ensure that satisfactory standards of workmanship are maintained
throughout.
d) The sequence of boreholes shall be agreed with DM.
e) The sequence of sampling and in situ testing shall be agreed in writing with
DM for each borehole prior to the start of boring/drilling.
f) All boreholes shall be vertical or within a tolerance of 1 in 100.
g) Unnatural obstructions shall be reported immediately to DM.
h) If cavities are encountered the depth of the top and bottom of each cavity
shall be recorded.
i) The contractor shall ensure that his plant and method of working are in all
respects suitable for carrying out the work in the conditions to be found in the
investigation areas. The contractor shall be deemed to be fully conversant
with the ground conditions prevailing at the site.
j) Boreholes are required to extend to the required depths as indicated in the
contract unless otherwise instructed by DM. DM’s decision with respect to
the final borehole depth will be dependent on the ground conditions
encountered.
k) All boring/drilling in soils shall be carried out by a method which minimises
the disturbances to the soil to be sampled or tested below the base of the
borehole. The method shall be to the approval of DM.
l) Where caprock or bedrock in layers is encountered and cable percussive
boring/drilling or sampling/testing is required below the caprock/bedrock the
borehole shall be enlarged using non-coring methods to enable
boring/drilling or sampling/testing to continue using cable percussion/ drilling
techniques, unless agreed otherwise by DM.

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21.4.3.2 Re-Entry To Boreholes

The contractor shall provide suitable equipment at each borehole position to
enable the borehole to be relocated, recentred and redrilled or sealed in the
event of the drilling plant having to move off location prior to completion of
the hole. Details of the equipment shall be provided to DM prior to
commencement of works.
21.4.3.3 Light Cable Percussion

a) General
i. Light cable Percussion shall be conducted in accordance with BS

5930, 1999. Advancing the holes in soils may be carried out by use
of shell or clay cutter.
ii. The contractor must be represented full-time by his geologist /
geotechnical engineer during cable percussion in order that clear
and appropriate instructions can be passed to the drillers in terms
of sampling and in-situ testing as the borehole progresses.
b) Use of Clay Cutters

Where the use of clay cutters may cause critical disturbance of the soils to
be sampled the contractor shall adopt a sequence of sampling and boring
previously agreed with DM.
c) Diameter of the borehole
i. The minimum diameter of borings or internal diameter of casing

shall be 150mm. However, the contractor shall bore or provide
casings of sufficient diameter to ensure completion of the hole to
the required depth. Should any boring prove abortive because of
the contractor's failure to begin operations with a sufficiently large
diameter boring, then the contractor shall be liable for any
necessary re-exploration at his own expense.
ii. The diameter of wash boring/open holing shall be sufficient to take
the required samples and to continue with rock coring of the
required diameter as necessary.
d) Support of Borehole
i. All boreholes shall be suitably lined with casings which shall extend
from ground level to a depth below which the sides of the borehole
will be self- supporting for the full depth for the period of
investigation at the borehole.
ii. The diameter of the casing will be sufficiently larger than the boring
diameter to prevent suction and undue disturbance of the
investigated materials.
e) Addition of Water to Borings
i. The contractor shall not advance the boring by adding water,

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except in the case of dry granular soils and stiff clays or where
approved by DM. For conditions where the addition of water is
permitted, the contractor shall use the minimum amount of water
necessary for advancing the bore.
ii. Where borings reveal soft alluvial soils or where sub-artesian
ground water loosens granular soils, the contractor is required to
add, and maintain, a head of water during boring and sampling in
order to counteract the disturbance caused by the removal of
overburden. In addition, where adverse hydraulic heads are
encountered and a shell is used, the contractor shall use a shell of
a diameter at least 25mm less than that of the borehole casing to
minimise disturbance due to suction.
iii. The water level in the boreholes shall at all times be maintained at
or above groundwater level.
f) Termination of Percussion Boring
If using percussion boring, a hard stratum is encountered, through which

percussion boring cannot progress, the contractor shall consult and agree
with DM the use of the following alternatives:
i. Continue the percussion boring using a chisel. Should percussion

boring be required at a greater depth, the contractor shall break out
the obstruction or use rotary drilling methods at a diameter sufficient
to enable boring, in situ testing and sampling to proceed.
ii. Abandon the exploratory hole or commence another exploratory
hole nearby.
iii. Prove hard stratum by two consecutive standard penetration tests
at 0.5m centres meeting refusal and continue the exploratory hole
by rotary drilling.
g) Sampling and In Situ Testing in Percussion Boreholes or wash boring holes
i. Undisturbed samples shall be taken in cohesive soils and standard

penetration tests (using the split spoon sampler) SPTs all be carried
out in cohesionless soils unless otherwise specified. S may also be
required in cohesive soils and weak rocks. SPTs shall be
conducted to n > 100 in weak cemented material, for which a solid
cone (60) should be adopted.
ii. The depths from which all samples are taken and at which all in situ
tests are carried out shall be measured using a device to be
approved by DM and the limits of the sample or tested zone
recorded.
h) Backfill to Boreholes
i. A borehole acts as seepage path, and if connected to an aquifer,

can cause pollution of the aquifer. Care should be taken to prevent
such connectivity by completely sealing the borehole using cement:
Bentonite slurry in accordance with BS 5930, 1999.
ii. Boreholes shall be properly backfilled to preclude any future

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surface settlement, internal soil erosion or contamination of the

groundwater. The following guidance shall be followed:
 Green areas – Boreholes to be backfilled to 300mm from the

surface and then filled with appropriate natural material.
 Tiled areas – Boreholes backfilled to the level of the tile base
and the tile reinstated flush.
 Asphalt areas – Borehole backfilled to the level of the top of the
base course, a tack coat applied to the exposed surfaces and
then filled with asphalt to the level of the wearing course.
iii. Backfill shall be with site arisings, or cement/bentonite grout as

deemed appropriate by DM.
21.4.3.4 Auger Boring

a) Auger boring will not normally be accepted as a suitable method of
advancing a borehole, except in conditions where explicit approval has been
given by DM.
b) Mechanical augers for advancing through soil strata may be used in
accordance with BS 5930, 1999.. However, the use of hollow-stemmed
augers in cohesionless soils often presents practical problems because it
may be difficult to prevent material from flowing into the hollow stem on
removal of the plug.
c) When rock is encountered, boring can be extended by core-drilling through
the hollow stem. Typically, augers with hollow stems of approximately 75 mm
and 125 mm diameter produce boreholes of about 150 mm and 250 mm
diameter respectively.
d) Arisings from auger boring operations are brought to the surface by auger
flights and give only a very rough indication of the nature of the strata. A
precise intermittent identification of the strata may only be obtained from
drive samples taken through the hollow stem of the auger.
e) In self-supporting strata, solid rods and a suitable auger tool can be used,
the auger tool being drawn up to the ground surface each time it has to be
emptied. Drive sampling and testing can be carried out in the borehole.
21.4.3.5 Rotary Open Hole Drilling

a) Rotary open hole drilling may be used in soils and weak rocks as a rapid and
economical means of drilling exploratory holes to recover disturbed samples,
carry out in-situ tests, install instruments to carry out grouting and ground
stabilisation etc. The technique may also be used to probe voids and
cavities.
b) The excavated material constitutes very low quality samples and it is not to
be used to detect a change in strata.
21.4.3.6 Rotary Core Drilling

c) General
i. Core drilling comprises an annular bit, fixed to the bottom of the

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outer rotating tube of a core barrel which cuts a core, which is

recovered within the innermost tube of the core barrel assembly
and brought to the surface for examination and testing.
ii. Rotary drilling including core recovery will be required through the
caprock and any cemented soils of bedrock encountered either
from bed level or at depth.
iii. Measurements of the drilling parameters including penetration rate,
torque, feed force, fluid pressure etc per drill run and a statement of
the drill specification and technique shall be made and recorded on
the driller’s logs.
iv. Backfilling of rotary boreholes may be required as described above
d) Types of Bits and Equipment
i. Core drilling shall normally be carried out with diamond or tungsten

carbide tipped bits which shall be suitable for the percentage core
recovery and diameter required. Drilling shall be required within the
weathered zones of strata and the strata may be friable, soft,
contain softer lenses within solid rock, or be other than solid
continuous strata. The contractor shall bring to Site suitable well-
maintained equipment for drilling to produce cores in such strata to
meet the recovery requirement. The equipment shall include triple
tube retractable core barrels and double tube swivel core barrels.
An approved semi-rigid clear plastic inner liner shall be utilised with
the double tube core barrel at no additional cost.
ii. The core barrels shall be fitted with new bearings and shall be
assembled such that the optimum clearance between the core lifter
adaptor and the core bit is maintained to minimise core erosion.
The ports and venting arrangements at the top of the barrel are to
be maintained clear at all times.
iii. The contractor shall have available on Site, surface set and
impregnated diamond core bits and tungsten carbide tipped bits of
various profiles and flush porting arrangements to fit the triple tube
and double barrel tube core barrels.
e) Core Recovery
Rotary core drilling shall produce circular cores of a minimum 76mm
diameter throughout the core length. The type and state of the drill bit, feed
rates and management of the drill shall be such that at least 95% core
recovery in any single run can be obtained. Where the material condition
permits, core recovery less than 90% in any drill run will not normally be
acceptable for payment unless DM is satisfied that more than 90% recovery
is impracticable under the prevailing conditions.
Where fractured rock or weak strata are encountered, the contractor shall
adopt such measures as necessary to obtain cores, including the use of
mud or polymer flush as required and/or resort to larger diameter core
drilling. In very dense or weakly cemented sands DM may instruct coring
and in such cases >90% core recovery is expected.
f) Drill Runs

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i. Drill runs shall not normally exceed 1.5m in length unless 100%
recovery is being obtained and the core barrel shall be removed
from the drill holes as often as may be required in order to get the
best possible core recovery. When any recovery is less than 90%
for a full length drill run, DM may require that the next drill run is
reduced by 50% or a minimum of 0.5m.
ii. The contractor shall carefully measure and record the depth to the
base of the hole prior to inserting the core barrel for each drill run
so that the presence and length of any core stub left in the hole
from the previous drill run can be identified.
g) Drilling Fluid
The drilling fluid shall be selected by the contractor with the agreement of
DM to ensure that the objectives of the Investigation are met whilst also
ensuring that contamination of samples, groundwater and seawater does
not occur. Where polymer mud is used as a drilling fluid, a closed circulation
system shall be used to prevent the loss of flush fluid and cuttings to the
surrounding area. The cuttings shall be removed off Site for disposal. The
drilling fluid shall be capable of supporting the boreholes throughout and
shall be suitable in all respects for use with specified down-hole testing.
Small disturbed samples of the drilling cuttings may be required by DM.
h) Removal of Cores
Core barrels shall be held horizontally and the semi-rigid plastic inner liner
containing the core shall be removed carefully from the barrel, sealed with
airtight purpose-made end caps and placed in a core box such that the liner
and core are retained in position. The plastic liner shall be fully supported
during transfer from the barrel to the core box to avoid flexing the core. Core
obtained from the drill bit and not within the liner shall be wrapped with a
minimum of two layers of plastic cling film. The core depths shall be marked
on the core liner with indelible marker and on the core box at the same time.
i) Examination of Cores
i. The cores shall be examined and logged on Site by a

Geologist/Engineering Geologist provided by the contractor, who
shall be approved by DM, in accordance with BS 5930: 1999
Code of Practice for "Site Investigations", and “A proposed scheme
for the classification & nomenclature for use in the engineering
description of Middle Eastern sedimentary rocks’ by Clarke and
Walker"
ii. On receipt of DM’s approval the core liner or wrapping shall be cut
using such methods as to ensure that no damage is caused to the
core by the cutting operation. The core shall then be
photographed, examined and logged on Site by a
Geologist/Engineering Geologist within 24 hours of recovery of the
core.
iii. Following examination, photography and sampling of the cores the
plastic liner shall be re-assembled, taped and wrapped in two layers

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of cling film and then aluminium foil with suitable spacers and
markers being inserted where core samples have been taken for
laboratory testing.
j) Preservation of Cores Boxes

After examination of each length of core the specimens selected for
laboratory testing by DM shall be wrapped individually with a fresh sheet
of aluminium foil that shall be sealed and secured by adhesive tape.
k) Packing Arrangements, Storing
Core boxes shall be soundly constructed in timber or other approved

material, fitted with stout carrying handles, fastenings and hinged lids
and shall be to the approval of DM. The total weight of cores and box
shall together not exceed 60kg. Cores shall be placed in the box with
the shallowest cores to the top left hand corner, the top being
labelled such that the origin of the core can be readily identified. Core
boxes shall be stored secured from interference and protected from the
weather.
During the period where core has been removed from its core box for
testing, a suitable wooden or PVC marker should be temporarily placed
in the core’s place. Information pertaining to the missing core should be
written on the marker. The marker should remain in place until the core
is returned from testing.
l) Photographs
i. Colour photographs shall be taken of all cores in a fresh condition

prior to logging. The photographs shall be taken with the core in
the core boxes and with identification labels, graduated scale and
colour reference chart clearly visible.
ii. Immediately prior to taking the photographs the cores shall be
surface dampened and cleaned of any drilling mud adhering to the
surface so that the core photographs clearly reveals and
distinguishes texture and microstructure and the actual colour of the
rock.
iii. Core boxes should be evenly and consistently lit, the focal plane of
the camera and the plane of the core box are parallel and the
camera is placed in the same position with respect to the core box
in every photograph.
iv. The prints and a colour copy of the colour reference chart shall be
bound in suitable transparent folders with the final report.
v. The photographs shall be collected using a digital camera with a
resolution of not less than 5 mega-pixels.

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21.4.4 SAMPLING
21.4.4.1 General
a) The selection of sampling technique, preparation for, method of taking
samples together with the quality and quantity required shall be in
accordance with BS 5930, 1999.
b) Accordingly four main techniques for obtaining samples are:
i. Taking disturbed samples from the drill tools or from excavating

equipment in the course of boring or excavation.
ii. Drive sampling, in which a tube or split tube sampler having a sharp
cutting edge at its lower end is forced into the ground, either by a
static thrust or by dynamic impact.
iii. Rotary sampling, in which a tube with a cutter at its lower end is
rotated into the ground, thereby producing a core sample (refer
2.4.3.7).
iv. Taking block samples specially cut by hand from a trial pit.
c) The quality of such samples can vary considerably, depending on the

technique and the ground conditions, and most exhibit some degree of
disturbance.
21.4.4.2 Preparations for Sampling
a) In the boreholes before taking a sample especially the “undisturbed
samples”, the bottom of the boring shall be carefully cleared of loose
materials and where a casing is being used, the sample shall be taken below
the bottom of the casing.
b) All samplers are to be frequently checked for inner-surface conditions,
defects, standard dimensions. The operational adequacy of check valves,
retainers and other components must also be monitored.
21.4.4.3 "Undisturbed" Samples

a) "Undisturbed" samples in cohesive soils shall be taken using open drive
sampling equipment as described in BS 5930, 1999 or push in “Shelby
tubes” except where an alternative method of pushing or driving the sampling
tubes is approved by the DM. The alternative method shall be such that the
sampling tube is driven smoothly into the ground without deviating from a
straight line. The open drive sampling tubes shall have a minimum internal
diameter of 100mm and a length of 450mm. The cutting shoes shall be
clean, sharp and without burred edges. The number of blows, weight of drop
hammer, height of drop and length driven shall be recorded when percussion
boring is used. Shelby tubes shall be clean, straight and with sharp cutting
edges.
b) Following a break in the work, such as overnight stoppage, borings shall be
advanced before tube sampling, for a depth to be agreed with DM at the start
of the Site Operations. The samples shall be sealed immediately to preserve
their natural moisture content and in such a manner to prevent the sealant
from absorbing external moisture. All samples shall be protected at all times
from temperatures below 5º and above 25º Celsius.

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21.4.4.4 Abortive Sampling

Where an attempt to take an "undisturbed" sample is aborted, the boring
shall be cleaned out for the full depth to which the sampling tube has been
driven and the recovered soil saved as a disturbed sample. A fresh attempt
shall then be made from the level of the base of the aborted attempt.
Should this second attempt prove abortive, the contractor shall adopt means
of sampling previously agreed with DM.
21.4.4.5 Bulk Disturbed Samples

Bulk disturbed samples shall be taken in both cohesive and non-cohesive
soils and shall be of sufficient size for laboratory testing and shall be placed
without delay in airtight containers. The samples shall be representative of
the zone from which they have been taken. Large bulk disturbed samples
shall weigh not less than 25kg.
21.4.4.6 Small Disturbed Samples

a) Small disturbed samples shall be not less than 0.7kg and certainly of
sufficient volume, as defined in the standards to allow for the expected
laboratory testing. They shall be placed immediately in airtight containers
which they should sensibly fill.
b) Small disturbed samples are obtained from the bailer during light cable
percussion, cuttings from the shoe of an undisturbed sample, a, spilt spoon
sampler and from trial pits.
21.4.4.7 Block Samples
Block samples may be collected from Trial Pits. The procedure for collection,
labelling, storage and preservation shall be in accordance with BS 5930,
1999.
21.4.4.8 Rock Core Samples

Refer to 21.4.3.6.
21.4.4.9 Groundwater Samples

a) The contractor shall ensure that sufficient measures and care are taken to
ensure that water samples are representative of the water bearing stratum
and have not been contaminated or diluted by water entering the borehole or
by contact with drilling fluid. Before sampling the water within the borehole
shall be removed by bailing or pumping and the sample collected from the
water that forms by seepage.
b) Sample containers shall be made of glass, polyethylene or polypropylene, be
clean, and completely filled with the water sample so as to minimize contact
with oxygen. The sample volume shall not be less than 0.25 litres and as
much as is required by the relevant standards for the expected testing. The
samples are to be stored in the dark, at low temperatures as soon as
possible after sampling.
c) More stringent requirements may apply in certain circumstances, particularly
when accurate or extensive chemical testing is to be undertaken in order to
investigate possible chemical contamination. Additional requirements may

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include special sampling techniques, multiple samples in different sample

containers with different fixing agents, duplicate sampling, and special
sample handling procedures.
d) Where more than one groundwater level is found, each one should be
sampled separately. Number of groundwater samples to be taken from each
exploratory hole shall be approved by DM prior to collection.
21.4.4.10 Special Sampling
DM may instruct special sampling, shall be carried out in accordance with
BS 5930, 1999 or as described in the Specification for testing under the
supervision of an experienced Geotechnical Supervisor or a specialized
testing laboratory approved by DM.
21.4.4.11 Contaminated Sampling
a) DM may order sampling at any depth in the exploratory holes for the purpose
of testing for a variety of contaminates.
b) When taking samples for chemical testing and in particular, on potentially
contaminated sites, additional care is needed to avoid cross- contamination
and chemical or biological reactions, which may affect the result.
c) Samples of suspected contaminated ground, groundwater and leachate for
chemical analysis shall be collected in accordance with the relevant
international standards under the supervision of a suitably qualified
environmental and/or geotechnical personnel approved by DM for
contamination testing.
d) The size and type of sample and container, method of sampling and time
limitations for carrying out specific analyses shall be commensurate with the
range of analyses to be carried.
21.4.4.12 Gas Sampling

a) Samples of gas for chromatographic analysis shall be obtained from
exploratory holes or standpipes in accordance with BS 10175, 2001 and the
companion publication (SISG, 1993).
b) The sampling method shall relate to the volume of gas available and the type
of laboratory analysis.
c) The sampler receptacle shall be airtight and may include lockable syringes,
Teflon-lined bags and gas bombs.
21.4.4.13 Sampling Frequency

a) The frequency of sampling and in situ testing is dependent on the ground
conditions DM may order sampling to be carried out at any depth in the
exploratory hole but in the absence of any special instructions the contractor
shall take samples as follows

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b) In boreholes
i. At each change in soil type or change in consistency, a small
disturbed sample shall be taken.
ii. Immediately following this an "undisturbed" sample shall be taken in
cohesive soils, a "bulk disturbed" sample in granular soils or a field
test carried out as appropriate.
iii. A "small disturbed" sample shall be taken from the cutting shoe of
each "undisturbed" sample.
iv. Further "small disturbed" samples shall be taken at intervals in the
same stratum midway between successive "undisturbed" or "bulk
disturbed" samples.
v. The maximum distances between "undisturbed" or "bulk disturbed"
samples measured centre to centre shall be 1m for the first 5m
below ground or sea bed level and 1.5m thereafter or as instructed
by DM.
vi. Continuous "undisturbed" sampling shall only be required in
percussion borings where instructed by DM.
c) In pits and trenches

i. Small disturbed samples shall be taken of the topsoil, at each
change in soil type or consistency and between successive bulk
disturbed samples.
ii. Bulk disturbed samples shall be taken at 1 m intervals with at least
one large bulk disturbed sample of each soil type.
iii. DM may instruct collection of a block sample. The depth
orientation and dimensions of the sample shall be clearly marked
and recorded.
21.4.4.14 Recording Depths of Samples

The depths below ground level at which samples were taken shall be
recorded and the limits of the sampled zone recorded.
21.4.4.15 Labelling, Protection And Transportation Samples

a) Samples obtained should be treated with great care. The usefulness of the
results of the laboratory tests depends on the quality of the samples
recovered, so it is important to establish a satisfactory procedure for the
handling and labelling of the samples, as well as their storage and transport
to prevent their deterioration, and to ensure that they can be readily identified
and drawn from the store when required.
b) Samples both disturbed and undisturbed obtained from boreholes and trial
pits shall be preserved in accordance with BS5930, 1999.
All samples shall be labelled with a unique reference number and recorded
on the daily drillers log or daily field report. Labels should be marked with
indelible ink and be sufficiently robust to withstand the effect of its
environment and the transport of the sample.
c) Samples collected shall be labelled in accordance with BS 5930, 1999.
Samples of fill, groundwater leachate or contaminated ground suspected to
be toxic or hazardous shall be tagged with a red label and should carry a
warning to that effect.

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d) The contractor shall be responsible for the packing of all samples and their
transport to his laboratory and for samples to be sent to DM’s office as
directed.
21.4.4.16 Sample Store
The contractor shall provide a store suitable for storage of samples and
cores that shall be sufficient in size for examination and storage of cores
during the Investigation. The store shall be secure and shall provide
protection from extremes of weather, with temperature maintained between
5and 25Celsius. The contractor shall maintain the store for the duration
of the Contract. Where the location and nature of the investigation requires,
the contractor shall establish a temporary store on site in accordance with
this stipulations.
21.4.4.17 Retention And Disposal Of Samples

All samples shall be kept for a period of not less than three months after
submission of the approved report and shall be discarded after that time only
on the instructions of DM. DM may request that certain of the samples
be retained either by the contractor or sent elsewhere.
21.4.5 DESCRIPTION AND LOGGING OF SOILS AND ROCKS

a) Detailed and accurate description of soil and rock is an important aspect of
ground investigation and shall be in accordance to BS 5930, 1999 and the
requirements of this guide.
b) Borehole and Trial pit Logs shall be of a standard format and in accordance
to BS 5930 1999 however a specimen borehole and trial pit log is attached in
the Appendices.
21.4.6 GROUNDWATER LEVEL
a) Groundwater - Groundwater pressure is of the utmost importance, because

of its profound influence on the behaviour of the ground during and after the
construction of engineering works. Various strata, particularly those
separated by relatively impermeable layers, can have different groundwater
pressures, some of which may be artesian; the location of highly permeable
water-bearing strata and the measurement of water pressure in each is
particularly important where deep excavation or tunnelling is required,
since special measures may be necessary to deal with the groundwater.
b) Groundwater pressure may vary with time owing to seasonal, tidal, or other
causes, and it may be necessary to take measurements over a period of time
so that such variations may be identified.
c) When designing drainage works, it is often helpful to determine the contours
of the water table or piezometric surface to ascertain the direction of the
natural drainage, the seasonal variation and the hydrological controls.
d) The time required for a measuring system to indicate the true groundwater
pressure is known as the response time and depends both on the quantity of
water required to enter the system (including all pipes and tubes) to operate
the pressure measuring device, and on the permeability of the ground.
Depending on the response time, a suitable method for measuring the

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groundwater pressure should be employed,e.g. digital data loggers with

remote recording device.
21.4.6.1 Groundwater Level Measurement Records

a) Groundwater encountered shall be measured in accordance with BS 5930,
1999.
b) Water levels shall be recorded as required by the Contract and at the
beginning and end of each shift or other rest periods during the work.
c) On each occasion when groundwater is recorded, the depth of the
exploratory hole, the depth of the casing and the time on a 24 hour clock
shall also be recorded.
d) Where artesian conditions are encountered, the contractor shall immediately
inform DM and agree a method for dealing with such conditions.
21.4.6.2 Installation of Standpipes And Piezometers

a) Standpipe Piezometers.
b) Standpipe piezometers for monitoring groundwater levels and changes in
groundwater levels at a particular depth in exploratory holes shall be installed
as instructed by DM in accordance with BS 5930, 1999 and all dimensions
and depths shall be recorded.
c) Piezometers.
i. When required in the Contract the contractor shall install
piezometers of the hydraulic, electrical or pneumatic type described
in BS 5930, 1999.
ii. The top of each standpipe, or piezometer tube shall be protected by
a cover fit for purpose and to be agreed with DM.
iii. Readings: Water readings - Daily readings of depths to water in
standpipes and piezometers shall be made by the contractor with
an approved instrument during the fieldwork period or as directed
by DM.
iv. Removal of piezometers and standpipes: Unless otherwise
described in the Contract, piezometers, standpipes and protection
shall not be removed from the site.
v. Other instrumentation and monitoring shall be carried out as
instructed by DM.
21.5 FIELD TESTING

a) Field tests are often desirable where it is considered that the mass
characteristics of the ground would differ appreciably from the material
characteristics determined by laboratory testing. Secondly samples
recovered from an investigation are not likely to reveal all the in-situ
characteristics either due to sample disturbance, contamination or sample
being unrepresentative.
b) Many field tests are expensive and should not be undertaken before
obtaining a comprehensive understanding of the geology and nature of the
investigated ground.

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21.5.1 GENERAL
a) Prior to conducting any field tests the contractor shall produce a method
statement, proposed test equipment, calculation and reporting formats for
approval of DM.
b) All field tests shall be carried out by a competent laboratory approved by DM
in accordance to the relevant international standards.
c) Safety procedures shall be strictly followed, risks if any shall be identified
prior to any field testing.
d) All testing equipment shall be calibrated in accordance with the relevant
testing standard and with the manufacturer’s instructions. Evidence of
calibrations and copies of the same shall be supplied to DM as and when
requested. Calibration stickers shall be clearly displayed on all equipment.
21.5.2 SIMPLE LOGGING TESTS

a) There are a number of relatively simple and quick tests that can be
performed on site or in the laboratory to assist the contractor with
identification and qualitative description of soils and rock. These are
considered to form an integral part of the logging process and the contractor
should carry out as many test with a frequency required confidently
identifying and describing the nature of soils and rocks.
b) The tests should be noted in the text of the factual report. Examples of such
tests are given below in Table 21.5.2.
Table 21.5.2 – Simple Logging Tests
Test Description / Property

Pocket Penetrometer Pressure required pushing a plunger
into the soil (cohesive). Indicative
apparent strength.
Hand Vane Force required to rotate a vane through
the soil. Indicative apparent strength.
Toughness Relative strength of air dried fragments
or lumps of soil crushed between
fingers.
Slake and Dispersion Relative ease as which samples
crumble and disperse in a jar of clean
fresh water.
Sedimentation Relative amount of sand, silt or clay
settling out of suspension in small bottle
or jar of clean fresh water.
Plasticity Relative ease in which soils can be
rolled into threads and spheres without
cracking or crumbling.
Slurry / Slump A slurry of soil is poured onto a flat
clean surface and the cone, lumps or
collapse described.

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Scrape Relative ease in which the soil can be

scrapped off with a pocket knife.
Absorption Rate of water absorption when
sprinkled onto a clean surface of the
soil.
Wash Off Relative ease in which a soil smear can
be washed off.
Collapse Description of how the sides of a slot
cut into a soil sample collapse when
agitated and wetted.
21.5.3 TESTS IN BOREHOLES

a) In-situ tests in boreholes should be carried out concurrent with soil/rock
sampling.
b) When tests are conducted in boreholes, the base of the borehole shall be
cleaned of any loose cutting.
c) The base of any casing used to support the boreholes shall always be above
the test level.
d) Water level in the borehole shall always be maintained at or above the
ground water level when tests are conducted below the ground water
21.5.3.1 Standard Penetration Test (SPT)

a) The purpose of the test is to obtain an indication of the relative density
measured by determining the number of blows required to drive a standard
split-barrel sampler of 300mm using a hammer of 63.5kg dropped from a
height of 760mm.
i. The penetration resistance "N" shall be determined in all

boreholes, both rotary and cable percussive, where instructed by
DM.
ii. The test equipment and procedure shall be as described in
BS 1377 Part 9, 1990 Cl 3.3 and the drive hammer shall be of the
type incorporating an automatic trip mechanism to ensure free fall.
iii. The information recorded shall be as required in BS 1377 Part
9, 1990 Cl 3.3.5 and shall indicate the number of blows for the
first 150mm (seating drive) and the number of blows for each
successive 75mm penetration or penetration produced by 50 blows.
iv. The maximum distance between tests measured centre to
centre shall be 1.0 meter for the first 10m below ground level
and 1.5m thereafter or as agreed with DM.
v. When tests are performed in soils containing gravel of weak
cemented soils, the driving shoe of the split barrel sampler may be
replaced by a solid 60o cone or the split barrel sampler with solid
cone may be replaced by an identically dimensioned solid test
rod and the test extended to record up to N = 100 if
penetration of 300mm below the seating drive is not obtained.
vi. If required by DM these tests shall be extended to record "N"

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values greater than 50.

vii. Where a solid cone is used or where no soil is recovered in the
split sampler, a small disturbed sample shall be obtained from the
position of the test.
viii. The water level in the casing shall be recorded at the start of
each SPT test as required by BS 1377 Part 9, 1990 Cl 3.3.5.
ix. All samples recovered from the split barrel shall be retained
as small disturbed samples in airtight plastic containers, in
accordance with the specification.
x. When SPT ‘N’ value is less than 15 DM may instruct extending
the test by recording blows for further penetration of 150 or
300mm to provide additional penetration values.
21.5.3.2 Shear Vane Test (In-Situ)

a) The test covers the determination of in-situ shear strength of weak intact
cohesive soils and shall be conducted in accordance to BS 1377 Part 9,
1990 Clause 4.4.
b) The test consists of a cross-shaped vane at the end of a solid rod forced into
the soil below the bottom of the borehole and then rotated. The torque
required to rotate the vane is used to calculate the shear strength of the soil.
c) After the peak vane shear strength has been determined, the vane shall be
rotated through at least five revolutions. The test shall then be repeated to
measure the remoulded strength of the soil.
d) A small disturbed sample representative of the ground from where the test
was performed shall be obtained.
e) The information to be submitted shall be as described in BS 1377 Part 9,
1990 Clause 4.4.6 together with the following:
i. Peak and remoulded vane shear strength in kN/m² expressed

to two significant figures.
ii. Dimensions of the vane and relevant constants.
iii. Maximum reading of torque scale in degrees.
iv. Time taken to reach maximum torque.
v. The sensitivity of the soil.
21.5.3.3 Permeability Test

a) Permeability is the hydraulic conductivity, a measure of the rate of water flow
through soil or rock due to the difference in a hydraulic pressure in the
borehole from that in the surrounding strata.
b) Permeability tests in the boreholes shall be conducted in accordance with BS
5930, 1999 Clause 25.4
c) Permeability tests can be conducted using a variable head or constant head
method of test.
d) Variable head method, in which the water pressure in the borehole may be
increased by introducing water into the borehole, a “falling head” test, or
decreased by pumping water out of the borehole, a “rising head” test. For a
falling head test it may be necessary to raise the casing above ground level
to provide an adequate head of water.

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e) Constant head method: The water pressure is maintained constant during a

test. The apparatus for the constant head test shall consist of an
arrangement that is approved by DM.
f) All measuring devices shall be adequately protected against changes in
temperature.
g) The head of water shall be applied in the minimum time possible. The flow
and or variation in water level shall be recorded at sufficient time intervals to
obtain a representative plot of flow against time.
h) The information to be submitted shall include:
i. Hole location and ground level.
ii. Strata description.
iii. Borehole diameter and casing details.
iv. Test section geometry.
v. Quality of water used (Fresh or sea water etc).
vi. For Constant Head tests, the excess head applied, methods
used to determine flow, plot of flow with time and permeability
together with calculations.
vii. For Variable Head tests, the level of water at start of test, end
of test, plot of variation of head of water against time and
permeability together with calculations.
21.5.3.4 Packer Test

a) The Packer test gives a measure of the acceptance of water under pressure
by in-situ rock.
b) In essence, it comprises the measurement of the volume of water that can
escape from an uncased section of borehole in a given time under a given
pressure. Flow is confined between known depths by means of packers.
c) The test equipment, procedure and results shall be in accordance to BS
5930, 1999 Clause 25.5.
d) The flow is confined between two packers in the double packer test, or
between one packer and the bottom of the borehole in the single packer test.
e) The test is used to assess the amount of grout that rock accepts, to check
the effectiveness of grouting, to obtain a measure of the amount of fracturing
of rock, or to give an approximate value of the permeability of the rock mass
local to the borehole.
f) The results of the test are usually expressed in terms of Lugeon units or in
terms of the permeability value.
g) The contractor shall demonstrate to the satisfaction of DM that an effective
seal has been obtained with each packer and that a steady flow rate has
been attained at every stage in any test.
h) The test shall be conducted in five stages at different pressure. The selection
of equipment, type of packer, selection of test sections, and selection of test
pressures shall be confirmed with DM prior to start of the test.
i) The contractor shall allow for the provision of a suitable pump and
monitoring system for the expected water flows.
j) The information to be submitted shall include:

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i. Location of test.
ii. Depth and spacing of packers, together with packer
inflation pressures.
iii. Readings of steady flow rates recorded at 5 minute intervals
per test pressure.
iv. Check readings on the apparatus, made to prove the seal of
the packers during the test.
v. Calibration data for test equipment.
vi. Level of water at start and end of test.
vii. Plot of head of water divided by the initial head of water (log
scale) against time.
viii. Value of permeability coefficient together with calculations.
21.5.3.5 Pressure Meter Test

a) The pressure meter test is an in-situ stress-strain test performed on the wall
of a borehole using a cylindrical probe that expands laterally. The test
consists of placing the inflatable probe in the predrilled hole and expanding it
while measuring the change in volume and pressure in the probe. Full details
of the types of test are described in BS 5930, 1999, Clause 25.7 and ASTM
D 4719-07.
b) Pressure meter tests can be conducted using a variety of equipment. The
measuring probe and the equipment should be sensitive enough to record
sufficient values of stress and strain to define both the elastic and plastic
deformation of the material being tested.
c) The selection of equipment and testing depths shall be confirmed with DM
prior to start of the test.
d) The following information shall be submitted:
i. Details of the equipment used.

ii. A plot of total pressure against displacement in mm for
each displacement transducer.
iii. A plot of total pressure against % cavity strain for each strain arm
at a suitable scale to define “lift-off”.
iv. Either a plot of total pressure against natural logarithmic value of
volumetric strain (clays, rocks) or a plot of natural logarithmic value
of effective pressure against natural logarithmic value of
current cavity strain (sands) for each displacement transducer.
v. An assessment of the in situ total lateral stress, limit ressure,
modulus and strength parameters.
xi. Details of all calibrations, the methods and constants used in
the calculations; and orientation of probe during test.
21.5.4 PUMPING TESTS

a) The tests involve pumping at a steady known flow from a well and observing
the drawdown effect on groundwater levels in monitoring wells some
distance from the pump well. The tests shall be in accordance to BS 5930:
1999 Clause 27 and BS 6316, 1992.

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b) Before undertaking a pumping test, reliable data should be obtained on the

ground profile.
c) In response to pumping, phreatic and piezometric levels around the pumping
well fall, creating a “cone of depression”. The permeability of the ground is
obtained by a study of the shape of the cone of depression, which is
measured by the water levels in the surrounding observation wells.
d) The shape of the cone of depression depends on the pumping rate; the
duration of pumping; the nature of the ground; the existence, or otherwise, of
intermediate or other boundaries; the shape of the ground water table; and
nature of recharge.
e) From the data obtained from the test, the coefficients of permeability,
transmissivity and storage can be determined.
f) The results obtained are averages for the entire mass of ground which has
been influenced by the pumping test.
g) In permeable ground, pumping from the well may have a significant effect on
piezometric pressures to a distance of 100 m or more. Flows from a well
pumping test are accumulated from contributions coming from strata that
may have very different values of permeability individually and may not be of
consistent thickness within the radius of influence of the well. The overall
result could be dominated by the flow from one highly permeable layer or
discontinuity; hence a thorough understanding of the geological sequence of
the ground is vital in the interpretation of the pump test results.
21.5.4.1 Test Wells

a) Refer BS ISO14686:2003.
b) Test wells should be of sufficient diameter to permit the insertion of a rising
main and pump of a suitable type and capacity, together with a standpipe
and velocity meter, if required. They should be provided with an adequate
well screen and filter pack to prevent the withdrawal of fine
c) particles from the surrounding soil; 300mm is often the minimum
borehole diameter for this purpose.
21.5.4.2 Observation Wells
a) Observation wells should have an internal diameter sufficient to permit the
insertion of a suitable water level measuring device or transducer. They
should penetrate the same ground as the pumping well and should permit
entry of water from the full length of ground being tested.
b) The recommended general layout is with four observation wells arranged in
two rows at right angles to each other. The minimum distance between
observation wells and the pumping wells should be ten times the pumping
well radius, and at least one of the observation wells in each row should be
at a radial distance greater than twice the thickness of the ground being
tested.
21.5.5 CONE PENETRATION TEST / STATIC PROBING
a) Cone Penetration tests shall be conducted in accordance to BS1377 Part 9,
1990 Clause 26. The basic principle is that a cylindrical probe, with cone
fitted to the lower end of a string of hollow rods, is pushed into the ground at

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a slow uniform rate by a static thrust. By considering the cone resistance and
friction ratios, a wide range of soils can be provisionally identified.
b) The equipment used in the test shall be able to produce a minimum
downward force of 200kN. The system shall use an electrical-piezo cone that
measures the tip resistance, frictional resistance and the pore water pressure
continuously using electrical measuring sensors in the system. Mechanical
measuring system using pressure gauges shall not be used unless approved
by DM.
c) Where refusal is encountered at shallow depth because of obstructions, the
CPT location shall be shifted by 0.5m to 1.0m and the test conducted.
d) Termination depth shall be to refusal or as indicated in the contract. In case
refusal is not encountered than DM can instruct the test to be extended to
deeper depths.
21.5.5.1 Dissipation Tests
a) DM may request that a pore water pressure dissipation tests be performed

during CPT testing. The penetration of the cone shall be stopped with the
rods “locked” to minimise relaxation, and the pore pressure recorded against
time for 45 minutes, or until 60% of the excess pore water pressure has
dissipated; this criteria may be subject to change as instructed by DM.
b) A continuous computer record of dissipation test data shall be made
commencing immediately the moment the cone is stopped for the dissipation
test. Zero time on the dissipation plots shall refer to the time when the cone
penetration is stopped for the dissipation test.
c) Cone resistance shall be monitored and recorded continuously during the
dissipation test.
d) The information to be submitted shall be as described in BS 1377, Part 9,
1990 Clause 3.1.6 together with the following:-
i. A general description of the work carried out including both

fieldwork and analytical techniques and explanation of data
processing.
ii. A plot versus depth for each CPT of cone resistance, sleeve
friction, friction ratio and pore water pressure together with the
results of any dissipation tests. The report shall also include an
interpreted soil profile cross referred where appropriate to
adjacent borehole information.
e) Comment on the problems encountered and validity of the results, together

with estimates of the possible error in the positions of the geological features
identified.
21.5.6 DYNAMIC PROBING
a) Dynamic Cone Penetration test or Dynamic probing test shall be conducted

in accordance to BS 1377 Part 9, 1990 Clause 3.2. A steel rod with a cone

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fitted at the base is driven into the ground by a constant mass falling from a
constant height. Blow counts to drive the rod successive 100mm depths are
recorded which can be plotted graphically and used for interpolation.
b) Table 4 in BS 5930, 1999 section 4 indicates the various types of hammer
weights that could be used to conduct the test.
c) Torque shall be measured using a suitable torque measuring device in the
course of the test.
d) The information to be submitted shall be as described in BS1377 Part 9,
1990 Clause 3.2.5.
21.5.7 FIELD DENSITY

a) The method of determination of field density is based on the in-situ
determining of the mass volume relationship of the soil.
b) The tests used to determine the field density shall be conducted in
accordance with BS 1377, 1990 Part 9 Clauses 2.1 to 2.5.
c) The various methods for determination of field density are:
i. Sand replacement method.

ii. Core cutter methods.
iii. Water replacement method.
iv. Rubber balloon method.
v. Nuclear method.
d) The selection of the test method depends primarily on the nature of the
material to be tested; however the contractor must obtain the approval of DM
for the method used prior to testing.
e) The information to be submitted shall be as described in BS 1377, 1990 Part
9 Clauses 2.1 to 2.5.
21.5.8 P AND S SUSPENSION LOGGING

a) Suspension P-S velocity logging, or suspension logging for short, is a
method for determining shear (VS) compressional (VP) wave velocity
profiles. It consists of a probe lowered in the borehole and attached to
measuring instrument; measurements are made in a single, uncased, fluid-
filled borehole.
b) It consists of a long probe containing a source and two receivers spaced 1m
apart, suspended by a cable. The probe is lowered into a borehole to a
specified depth where the source generates a pressure wave in the borehole
fluid. The pressure waves are converted to seismic waves (P and S) at the
borehole wall. Along the wall at each receiver location, the P & S waves are
converted back to pressure waves in the fluid and received by the
geophones, which send the data to the recorder on the surface.
21.5.8.1 Equipment
a) A typical suspension P-S Logging system, should be similar to the one

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manufactured by OYO Corporation, and consists of a borehole probe, cable,

winch, and control/recording instrument. The probe length is approximately 7
meters.
b) The probe consists of a source and two biaxial geophones, separated by
flexible isolation sections. It is centered in the borehole via the attached
nylon whiskers. The solenoid source is reversible and produces energy
between 500 and 5000 Hz.
c) The separation between geophones is one meter. The vertical axis of the
geophone corresponds to P-wave energy and the horizontal to S- wave
energy. The probe is connected to the recorder on the surface by an
armored 7-conducter cable. The cable serves both to support the probe, to
transmit activation signals to the source, and to transmit the geophone
signals back to the recorder. The depth is measured by the rotary encoder
on the winch.
d) The electronics system activates the source, and records the geophone
signals on different channels. Modern loggers have up to 8 channels. Filters
may be used in acquisition, but data are usually recorded unfiltered and
digitally filtered later during processing.
21.5.8.2 Tests
a) Tests shall be conducted in borehole identified for the purpose. The borehole
shall be drilled to its final depth, cleaned and filled with clean water.
b) The probe shall be lowered to the bottom of the borehole to verify total depth
and then raised slightly to the first measurement point. The source is
activated in one direction and the output from the two horizontal geophones
(SH-wave) is recorded.
c) The source is then activated in the reverse direction producing a reverse
polarity SH-wave. Finally the source is activated in the first direction again
and the geophone signal recorded which represents the P-wave.
d) After the data is stored, the probe is raised to the next level and the
measurement sequence repeated. Normally readings shall be undertaken at
every 1 meter interval unless otherwise specified. Gains, record length,
filters, stacking can be adjusted during acquisition.
21.5.8.3 Data Processing

a) The software provided with the suspension logging system, is used to pick
the wave arrivals and compute the velocities.
b) Commonly, the first break or first peak is picked on each waveform. If the
data are noisy, they can be filtered digitally first. The time differences
between horizontal and vertical receivers are used to calculate the interval S-
and P-wave velocities, respectively, over the 1- m interval. These values are
compared with source to receiver travel times and velocities.
c) Ideally, the shear wave signal on the horizontal geophones should be a
mirror image for normal and reverse source activation. This aids in identifying
the first arrival of the shear wave. The velocities calculated from normal and
reverse polarity are averaged.

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21.5.8.4 Data interpretation

a) The processed suspension logging results consist of the VS and VP profile,
sampled at the measurement interval. Constant velocity layers can be fit to
the discrete velocity points, by averaging travel time (or 1/V) over the layer
depths. Interfaces, such as the depth to water table in sediments, and the
soil/rock transition, should be identified.
b) P and S travel velocities combined with the in-situ density values should be
used to calculate the bulk density, bulk modulus, Young's modulus, shear
modulus, and Poisson's ratios which should be reported along with the
velocity data.
c) The result shall be produced as graphs of each value against depth which
should include the P and S wave velocity profile, the density profile, shear
modulus, Young’s modulus, and Poisson’s ratio.
21.5.8.5 Considerations for good quality analysis

a) The best borehole conditions are achieved by drilling with the mud-rotary
wash method which produces the smooth surfaces.
b) Tests shall be conducted as soon as possible after the borehole is drilled as
borehole quality deteriorates with time after drilling.
c) If another drilling method is used that results in a rough borehole surface, the
hole is usually grouted and cased. Care must be taken to use grout that is
comparable in stiffness with the native material so that good coupling
between the casing, grout, and native material is achieved.
d) PVC casing is acceptable but steel is not. Logging cased holes eliminates
standby time but may result in lower quality data.
e) Suspension logging does not always provide excellent results in the near
surface (< ~5 m depth). This is because it is difficult to generate waveforms
in the surrounding soil under low confining stress. Steel conductor casing
may also be present in the top of the borehole.
21.5.9 PLATE BEARING TEST
a) The test is used in the determination of the shear strength and the
deformation characteristics of soil and rock. The traditional plate bearing test
involves measurement of penetration of a rigid plate into soil or very weak
rock under specified applied load.
b) The test shall be conducted in accordance with BS 1377, 1990 Part 9 Clause
4.1
c) Care must be exercised during surface preparation and setting up to achieve
meaningful results during the observation of deformation particularly at low
stress levels.
d) The test plate shall be carefully bedded onto the soil to be tested using
sand/cement mortar or quick setting gypsum plaster.
e) The diameter of the plate, the maximum load to be applied and the method
of loading shall be as detained in the Specification. In the case of
incremental load tests the load shall be applied and maintained until
movement of the plate has ceased or has slowed to a rate not exceeding that

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specified.
f) The movement of the plate under load shall be measured by not less than
three dial gauges capable of reading to 0.02mm. The gauges shall be
attached to a rigid reference beam supported on a stable base which is not
influenced by the load test. The contractor shall submit his proposals for
protecting the test equipment from the weather and in particular from thermal
effects on the reference beam. The air temperature shall be recorded at
frequent intervals during the test.
g) For incremental plate load tests the plate dial readings shall be taken at 0.25,
0.5, 1, 2, 4, 8, 12, 16, 20, 30, 45, 60, minutes and 2, 4, 8, and 24 hours after
the application of the load unless stated otherwise in the Specification. For
constant rate of penetration tests the applied load shall be recorded at equal
time intervals detailed in the Specification.
h) The information to be submitted shall be described in BS 1377, 1990 Part 9
Clause 4.1.8 together with the following additional information:
i. Location of the test.
ii. Description of soil at the test depth.
iii. Plate displacement dial gauge readings (Incremental and
average) for each time interval.
iv. Applied load at specified time intervals for the constant rate of
penetration test.
v. Graphical presentation of average settlement against time, total
average settlement against pressure, and (for constant rate of
penetration tests) average penetration against pressure.
vi. The air temperature at the test site during the test.
i) The expected strength and deformation characteristics of the soil to be

tested must be estimated in order to decide on the applied loads and the size
of the apparatus, prior to undertaking the test.
j) The information to be submitted shall be as described in BS 1377, 1990 Part
9 Clause 4.1.8.
21.5.10 IN-SITU CALIFORNIA BEARING RATIO TEST (CBR)
a) The test is carried out by causing a cylindrical plunger to penetrate the soil at
a constant rate and comparing the relationship between force and
penetration into the soil to that for a standard material. The test shall be
conducted in accordance with BS 1377, 1990 Part 9.Clause 4.3.
b) Care should be exercised during surface preparation. The reaction load
against which the force is applied shall be of sufficient weight to prevent uplift
or eccentric loading.
c) The information to be submitted shall be as described in BS 1377, 1990 Part
9 Clause 4.3.6.
21.6 LABORATORY TESTS
21.6.1 INTRODUCTION
a) Soil, rock and water samples obtained from the field should be tested to
evaluate their engineering and chemical properties and to complement
field observations.
b) The purpose of laboratory testing on representative samples of soil,

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rock and water is to investigate the physical, mechanical and chemical

properties of these materials, in order to obtain parameters relevant to
the technical objectives of the investigation.
c) The samples shall be representative of the existing natural materials.
d) In addition to the samples and tests scheduled by DM, the
contractor will undertake at his own cost further testing as necessary to
prepare accurate and complete descriptions and logs for the project.
21.6.2 SAMPLES
a) All storage, handling, preparation and testing of samples shall be in

accordance with the relevant British Standards or equivalent International
Standards current on date.
21.6.3 QUALITY CONTROL

a) The tests shall be carried out in an approved laboratory with approved
technical capabilities inspected and approved by DM prior to testing. The
laboratory shall be UKAS, or similar accredited.
b) A short description of relevant laboratory equipment, test procedures, and
proposed report formats should be submitted along with the Geotechnical
investigation method statements. If the laboratory environment or test
procedures are to be modified from those described in the method statement
for some reasons, any changes proposed must be first discussed with DM
for approval.
c) The tests shall be carried out by suitably qualified technicians with
experience in the particular test, under the direction and supervision of a
Geotechnical Engineer.
d) The Geotechnical laboratory shall have adequate facilities for handling,
storing and testing samples. All samples delivered to the laboratory should
be registered and a receipt in a standard and well documented manner.
21.6.4 REPORTING OF RESULTS

a) Soil testing shall be undertaken and reported in accordance with BS 1377,
1990 unless otherwise specified/approved by DM.
b) Rock testing shall be undertaken and reported in accordance with the
relevant British, ASTM standard or ISRM commission on testing Methods.
21.6.5 SCHEDULE OF TESTS
a) DM will prepare a schedule of tests, or, if required by DM specified in Tender
Document the contractor shall prepare a schedule of tests for approval by
DM. It may also be necessary to specify additional testing after the results of
the original tests are available.
b) Unless otherwise agreed, testing schedules will be provided within 3 working
days of the receipt of the relevant preliminary records.
c) The contractor shall inform DM within 3 working days from the receipt of the

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testing schedule if a sample referred to in the schedule is not available for

testing.
d) Following DM’s instruction to the contractor to carry out laboratory tests, the
contractor shall submit to DM time schedule of testing to enable DM to attend
and supervise the test if necessary to confirm quality.
21.6.6 TESTING PROCEDURES

a) All preparation, testing and reporting shall be in accordance with the relevant
International Standards. Where tests are not covered by these Standards
they shall be performed in accordance with the procedures in the references
or as described in the schedules. In the absence of any of the above test
may be conducted using contractors proposed procedures approved by DM.
b) Calibration of measuring equipment shall be carried out in accordance with
the appropriate standards and the manufacturer’s recommendations.
Evidence of current Calibrations shall be supplied to DM whenever
requested.
c) Soil tests that may be required are tabulated in Table 21.6.1.
Table 21.6.1 – Soil Testing

Type of test Test Standard
Classification Moisture Content BS 1377 1990, Part 2.
Liquid and Plastic Limit BS 1377 1990, Part 2, Clause 4
Volumetric Shrinkage Limit BS 1377,1990, Part 2, Clause 6
Mass Density BS 1377,1990, Part 2, Clause 7
Particle Size Distribution BS 1377,1990, Part 2, Clause 9
Chemical and Organic content BS 1377, 1990, Part 3, Clause 3

Electro-Chemical
Tests Mass loss on ignition BS 1377, 1990, Part 3, Clause 4
Sulphate content BS 1377, 1990, Part 3, Clause 5
Carbonate content BS 1377, 1990, Part 3, Clause 6
pH value BS 1377, 1990, Part 3, Clause 9
Contamination tests * Relevant standards
Compaction tests Dry density or dry unit BS 1377, 1990, Part 4, Clause 3
weight/moisture content
relationship
Maximum, minimum dry BS 1377, 1990, Part 4, Clause 4
densities of granular soils
Moisture condition value BS 1377, 1990, Part 4, Clause 5

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California Bearing Ratio BS 1377, 1990, Part 4, Clause 7

(CBR)
Compressibility One-dimensional BS 1377, 1990, Part 5, Clause 3
and Permeability consolidation
Consolidation properties BS 1377, 1990, Part 6, Clause 3
using a hydraulic cell
Permeability constant-head BS 1377, 1990, Part 5, Clause 5
method
Permeability in a hydraulic BS 1377, 1990, Part 6, Clause 4
consolidation cell
Shear Strength Determination of shear BS 1377, 1990, Part 7, Clause 4
Tests (Total strength by direct shear
Stress) (small shear-box apparatus)
Determination of shear BS 1377, 1990, Part 7, Clause 5
strength by direct shear
(large shear-box apparatus)
Determination of residual BS 1377, 1990, Part 7, Clause
strength using the small ring

shear apparatus
Determination of the BS 1377, 1990, Part 7, Clause 7

unconfined compressive
strength
Triaxial compression test BS 1377, 1990, Part 7, Clause 8
without measurement of pore
pressure (definitive method)
Triaxial compression test BS 1377, 1990, Part 7, Clause 9

multi-stage loading method
without measurement of pore
pressure
Shear Strength Consolidated undrained BS 1377, 1990, Part 8, Clause 7
Tests (Effective triaxial compression test with
Stress) measurement of pore
pressure
Consolidated drained triaxial BS 1377, 1990, Part 8, Clause 8
compression test with
measurement of volume
change
* Contamination testing if required shall be specified along with the relevant Standard.

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d) Rock tests that may be required include the following as tabulated in Table
21.6.2
Table 21.6.2 – Rock Testing
Rock Unconfined ASTM D2938-86

Classification Compressive
Test Strength
Modulus of elasticity, BS 812-2, 1995
resistance to
weathering and ISRM Commission on Standardization of
degree of Laboratory and Field Tests.
weathering,
International Journal of Rock Mechanics and
Mining Sciences and Geomechanics, Abstract
1979
Moisture BS 812-2, 1995.

C ISRM Commission on Standardization of
ontent, Porosity, Laboratory and Field Tests.
Bulk Density, International Journal of Rock Mechanics and
Porosity, & Mining Sciences and Geomechanics, Abstract
Absorption 1979
Petrographic ISRM Commission on Standardization of
analysis Laboratory and Field Tests.
Suggested Methods for Petrographics Description
of Rocks. International Journal of Rock Mechanics
and Mining Sciences and Geomechanics,
Abstract 1978
Slake Durability ISRM Commission on Standardization of
Laboratory and Field Tests.
1979
Hardness ISRM Commission on Standardization of
and Abrasiveness Laboratory and Field Tests.
1978
Carbonate Test BS 1881-6, 1988

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Swelling Test BS 1377 1990, Part 5
ISRM Commission on Standardization

of Laboratory and Field Tests.

1979
ISRM Commission on Testing Methods

Dynamic Tests Seismic velocity ISRM Commission on Standardization

1978
Dynamic modulus ISRM Commission on Standardization of


1978.
ISRM Commission on Standardization of

Rock Strength Point load tests ASTM D573, 1995
Tests ISRM Commission on Standardization of
Suggested Methods for Determining Point Load
Strength, International Journal of Rock Mechanics
and Mining Sciences and Geomechanics,
Abstract 1985
Uniaxial ISRM Commission on Standardization of
compression Laboratory and Field Tests.
Suggested Methods for Determining the Uniaxial
Compressive Strength and Deformability of Rock
Mechanics, International Journal of Rock
Mechanics and Mining Sciences and
Geomechanics, Abstract 1979
Direct tension test ISRM Commission on Standardization of
Suggested Methods for Determining the Tensile
Strength Rock Material, International Journal of
Rock Mechanics and Mining Sciences and

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Indirect ISRM Commission on Standardization of

te Laboratory and Field Tests.
nsile strength test Suggested Methods for Determining the Tensile
Strength Rock Material, International Journal of
Rock Mechanics and Mining Sciences and
Triaxial compression ISRM Commission on Standardization

1989
Rock Strength Undrained Triaxial Hoek, E, and J.A. Franklin, A simple triaxial cell
Tests field or laboratory testing or rocks, Trans. Inst.
Min. Metall, Philadelphia, 1968
Undrained Triaxial Neff, T.L. Equipment for measuring pore pressure

with measurement of in rock specimens under triaxial load. ASTM
pore water pressure Special Technical Publication No. 402, 1966.
Donath, F.A. A triaxial pressure apparatus for

testing of consolidated or unconsolidated
materials subjected to pore pressure. ASTM
Special Technical Publication No. 402, 1966
Drained Triaxial ISRM Commission on Standardization of
1983.
Discontinuity Direct shear box of Krsmanovic D, Initial and residual shear strength
Strength Tests the discontinuity of hard rocks, Geotechnique, 1967, 17, 145-160.
material
Hoek, E. and P. Londe, The design of surface
working in rock, General Report, Int. Proc. 3rd
Congr. Int. Soc. Rock Mech. Denver, Colorado,
1974, 1(A) 613-654.

Rock Static ISRM Commission on Standardization of
Deformation elastic modulus Laboratory and Field Tests. Suggested Methods
Tests for Determining the Uniaxial Compressive
Strength and Deformability of Rock Mechanics,

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1979.

Laboratory and Field Tests. Suggested Methods
for Determining the Strength of Rock Materials in
Triaxial Compression, Revised Version,
1983.
Rock Creep tests Meigh, A.C., B.O. Skipp and N.B. Hobbs, Field
Deformation and laboratory creep tests on weak rocks, Int.
Tests Proc. 8th Int. Conf. Soil Mech. Found. Eng.
Moscow, 1973, 1.2, 265-271.
Gruden, D.M. The form of creep law for rock

under uniaxial compression, Int. J. Rock Mech.
And Min. Sci. 1971, 8, 105-126.
Rock Geological Society Engineering Group Working
Permeability Party Report, The logging of rock cores for
Tests engineering purposes, Quarterly journal of
Engineering Geology, 1970, 3(1), 1-25.
Daw, G.P. A modified Hoek-Franklin triaxial cell

for rock permeability measurements (Technical
Note) Geotechnique 1971, 21, 89-91.
Worthington, P.F. and R.D. Baker, A centrifugal

technique for rapidly estimating the permeability
of a consolidated sandstone (Technical Note),
Geotechnique, 1972, 22, 521-524.
Bernaix, J, Etude geotechnique de la roche de

Malpasset, Paris, Dunod, 1967.
21.7 REPORTING
21.7.1 GENERAL
a) Accurate and adequate reporting is a valuable reference for site investigation
practice which includes reports produced during and after the investigation.
This section of the document describes the methodology of reporting and the
content of each type of report.
b) Reports produced during the course of investigation include:
i. Daily reports and journals.

ii. Preliminary records of exploratory holes.
iii. Laboratory test.

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c) The final reports are classed as:
i. Factual and.
ii. Interpretative.
d) Final reports shall be preceded by a preliminary report summarizing the

ground investigation including the field and laboratory testing, and
interpretation and shall be submitted for review of the Engineer. The final
reports shall then be prepared incorporating all the comments of the
Engineer. In the case of more specialist investigation, such as geophysical
investigation, where a particular kind of reporting pattern is normally adopted,
the same shall be agreed with or approved by the Engineer.
e) The responsibility of the ground investigation contractor shall be clearly
specified in terms of reporting which may be limited by contractual
responsibilities. Factual reports should record all information obtained from
the field works and laboratory testing. Interpretative reports should contain all
information obtained from desk study and site reconnaissance, and
interpretation of the data contained in the factual report. Often it is
convenient to produce separate desk study reports and interpretative reports.
In such case, references to relevant desk study reports should be made in
the interpretative reports.
21.7.2 DAILY REPORT
a) The contractor shall prepare a daily journal of a type approved by the

Engineer for the Site Works. The Daily Report (Daily Journal) shall be
submitted in duplicate to the Engineer within 24 hours of the completion of
each day’s operations and shall as a minimum contain.
i. Information for all exploratory hole journals:
 Job name.
 Contractor's name and job reference number.
 Exploratory hole reference number and location.
 Date and depth at the end of working day or shift.
 Plant in use and operatives' names.
 Diameters and depths of all casings or supports used, data
on its stability if relevant.
 Ground level referenced to the local coordinate system (NAD
or equivalent) at each borehole location and depth of each
change of stratum.
 Brief description of each stratum with variations in consistency.
 Any addition of water to or pumping of water from
the exploratory hole.
 Details of time taken for each operation, e.g. setting up, boring.
 Details of any standing time or work for which hourly rates
are claimed, including the numbers and grades of men
involved.
 Details of services located.
 Weather and sea conditions.

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ii. Additional information required for percussive boring journals:
 Depths at or limits between which samples were taken.

 Depths of all in situ tests.
 Depths at which chiseling was employed.
iii. Additional information required for rotary drilling journals:
 Orientation of the drill hole given as an angle to the

horizontal and the azimuth.
 Method of penetration and flushing system.
 Type of core barrel and bit used.
 Depth and time of start and finish of each core run.
 Core diameters and depths of change in core diameter.
 Type of cuttings, estimated percentage fluid returns with depth
of any loss.
 Total core recovery with information as to possible location
of core losses..
iv. Additional information required for trial pit journals:
 Orientation of the trial pit.

 Dimensions of trial pit.
 Remarks on ease of excavation.
 Details of any obstructions encountered.
 Sketches of strata encountered.
21.7.3 PRELIMINARY RECORDS OF EXPLORATORY HOLES

a) The contractor shall prepare a Preliminary Record of each exploratory hole in
a form to be approved by the Engineer and which shall be
b) submitted to the Engineer in duplicate within seven days of the
completion of the borehole.
c) The format, information, description of strata, presentation of field and
laboratory tests on the logs shall be in accordance with BS 5930, 1999
Clause. 47.2.6 and EN ISO 14688 Parts 1 and 2, 2004. Carbonate rocks
shall be classified in accordance with ‘A proposed scheme for the
classification & nomenclature for use in the engineering description of Middle
Eastern sedimentary rocks’ by Clarke and Walker.
21.7.4 LABORATORY TEST RESULTS
Laboratory test results shall be submitted in duplicate to the Engineer no
later than 24 hours after completion of the test. The certificates shall be in a
format consistent with that required under BS 1377, 1990 and BS 5390,
1999 or equivalent standard, and shall clearly indicate, if appropriate,
whether the result represents conformance, or otherwise with the
material requirements under the Contract, if appropriate.

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21.7.5 PRELIMINARY GROUND INVESTIGATION FACTUAL REPORT

a) The contractor shall prepare a draft Ground Investigation Factual Report.
The Factual Report shall be in a form approved by the Engineer and in
accordance with the Specification include the entire factual field data
obtained during the investigation and the results of the laboratory
classification tests.
b) Laboratory and field test results shall be produced in graphical form where
appropriate and also in tabular form suitable for aggregation for statistical
purposes.
c) Two copies of this report shall be submitted to the Engineer in draft form as
specified in the Contract for review and comment which a copy shall be
returned to the contractor for corrections and resubmission as a Final report.
d) Once the corrections and amendments are made the contractor shall submit
one copy of the final report. If the Engineer is satisfied that all corrections
and amendments have been incorporated, he shall instruct the contractor to
submit the remaining copies.
21.7.6 FINAL GROUND INVESTIGATION FACTUAL REPORT
a) A report covering in detail every item of work carried out under the Contract
shall be produced by the contractor and submitted, in the first instance, in
draft form to the Engineer.
b) The report of boring, drilling and testing shall be prepared on A4 size paper.
All graphs, schedules and bound-in copies of drawings shall be
21.7.7 INTERPRETATIVE REPORT
a) The Interpretative Report shall include all contents required for the Factual
Report in addition to interpretation, conclusion and recommendations.
b) Prior to the submission of the Interpretative Report, two draft copies identical
to the proposed final submission are to be submitted to the Engineer for
comments out of which one copy shall be returned to the contractor for
corrections and resubmission for approval.
c) The Interpretative report should contain, but not limited to, the following
items:
i. Introduction, stating the background of the project, anticipated
engineering problems and the purpose and scope of the
investigation.
ii. Desk study: Desk study information should be included in the
interpretative report, unless a separate report has been compiled, in
which case a reference to the desk study report should be made.
iii. Ground type and stratigraphy: describing, in details, the
encountered geology of the site. A description of each ground type
should be given and any anomalies that have been observed
should be noted and commented on. Discussions on ground
type and stratigraphy should be supplemented by geotechnical
cross- sections illustrating the ground profile.
iv. Accurate and integrated interpretation of geological maps,
boreholes and other data. Relevant soil parameters shall be
indicated on sections; e.g., results of standard penetration
tests, RQD values, triaxial tests or earthworks relationship tests.

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v. Geotechnical properties: stating the engineering properties of each

layer or type of soil and rock encountered. It should consider each
type of soil and rock separately and summary of the in-situ
and laboratory test results carried out on samples obtained from
various depths and locations. Suggestion on design parameter
should be included for each type of material which shall include
where ever possible, comparison of the representative values
with experience and published data for similar geological
formations and explanation of the apparently anomalous or
extreme results.
vi. Ground water: The report should describe regional
groundwater conditions and the presence or otherwise of
perched, artesian or draining conditions. Comment should be
made on any anomalies and the possibility of the rise or fall of
groundwater with seasons, tide or other long term variation.
vii. Chemical Conditions: Comment should be made on chemical
conditions in the ground and groundwater, not only with regard
to attack on buried parts of the structure, but also with regard
to possible effects on construction and service life, whether these
be due to natural causes or to man's activities. Any conditions
that could affect health and safety during construction or in
subsequent use should be mentioned.
viii. Engineering considerations should relate to the nature of the
scheme. The following list, which is by no means exhaustive,
indicates the topics on which advice and recommendations are
often required, and also what should be included. Given the
availability of a wide and ever-changing range of
proprietary systems, all of which interact with the ground in
subtly different ways, it is important that the report does not
overstate the technical analysis of the engineering works in
relation to the ground interactions. However, it is essential to
provide adequate information needed to assess the suitability of
various design and construction options.
 Foundation and geotechnical design:
Suitable foundation types: safe or allowable bearing

capacity; estimated total and differential settlements; possible
alternative types of foundation; possible ground treatment is to
be given
Piles: types suited to the ground profile and environment;

estimated safe working loads, or data from which they can be
assessed; estimated settlements of structures.
Retaining walls: lateral pressures; wall friction; bearing capacity;

groundwater conditions, or data from which they can be
derived, shall be included.
Basements/shafts: comment on the possibility of flotation,

an estimate of the rise of the basement floor/shaft base
during construction, where appropriate, shall be dealt with.

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Ground anchorages: bearing stratum and estimated safe

loads, or data from which they may be calculated.
Chemical attack: most commonly takes the form of

recommendations for protecting buried concrete against
attack from sulfate-bearing soils and groundwater. Also to be
considered is the possibility of corrosion of steel in saline
waters or in the presence of sulfate-reducing bacteria. The
effect of acidic or highly alkaline soils may also need to be
considered. Contaminated soils, especially those containing
high concentrations of organic chemicals, should be
considered for their effects on all building materials.
 Pavement design:
Assessment of appropriate design parameters or California

Bearing Ratios; type and thickness of pavement; possibility
of soil stabilization for forming pavement bases or sub-bases;
recommendations, where appropriate, for sub-grade
drainage; consideration of effect of heat and climatic
conditions on pavement such as expansion and cracking.
 Slope stability:
Recommendations on temporary and permanent slopes for

excavations, including where appropriate, drainage measures.
Comment should be made, where relevant, on the possibility
of weathering of rock faces and the methods for dealing with
this hazard. Recommendations for the monitoring of unstable
slopes may also be required.
 Mining subsidence:
This is not a common issue in the UAE. However, if any voids

are identified, recommendations for methods of filling
known cavities near the surface; the design of structures to
withstand movements without damage or measures to limit
the damage and simplify repairs.
 Tunnels and underground works:
A description of the ground through which the tunnel is to

be driven, by chainage; possible covering of the following
points: methods and sequence of excavation; whether
excavation is likely to be stable without support; methods of
lining in unstable excavations; potential use of rock bolting;
likelihood of encountering groundwater and recommendations
for dealing with it; special features for pressure tunnels; risk
of encountering ground or water contamination; possibility of
natural or industrial gases.

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 Safety of neighbouring structures:
An assessment of the likely amount of movement caused

by adjacent excavations and groundwater lowering,
compressed air, grouting and ground freezing or other
geotechnical processes. The possibility of movement due to
increased loading on adjacent ground may also need to be
considered.
 Monitoring of movements:
Comment on the rate of movement taking place in structure

and slopes, together with recommendations for stabilisation
and prevention of ground failure.
ix. Recommendations on:
 Open excavations: method and sequence of excavation; what

support is needed; how to avoid boiling and bottom heave;
estimated upward movement of floor of excavation. Comment
on relative merits of sheet piling and diaphragm or bored
pile walls where appropriate.
 Underground excavations: method and sequence of excavation
and the need for temporary roof and side support; dealing
with gases.
 Groundwater: likely flow, head and quantity and how to
deal with it.
 Driven piles, bored piles and ground anchors: methods of
driving or construction suited to the ground profile,
environment and neighbouring buildings.
 Grouting: types of grouts likely to be successful in the
ground and recommended method of injection.
 Mechanical improvement of soil below ground level.
Comment on the suitability of techniques for the
consolidation of loose soils.
 Contamination: known or suspected contaminants and gases
in soil, groundwater and any cavities. Comment on health
and safety aspects both during and after construction.
 Sources of materials:
For fill, possibility of using excavated material for this

purpose as an assessment of the proportions of usable
material; methods and standards of compaction; possible off-
site sources of fill; bulking factor.
For aggregates: in areas where no commercial sources are

available, the possibilities of winning and processing materials
available locally.
x. Conclusions and recommendations: decision on the suitability of

the site for the proposed project. The section should propose for
solving anticipated geotechnical problem and advice on the

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excavation method and safety.
21.7.8 DIGITAL DATA
a) All reports and drawings shall also be submitted in digital form (CD or
similar).
i. The contractor shall provide on recordable CD media an

identical reproducible copy of the reports. This shall be in a PDF
format to be directly readable as a single file. The CD shall be
submitted within a duration not exceeding 7 working days from
the date of approval of the hard copy report in order for the work
to be considered complete.
ii. The contractor shall provide in digital format all relevant information
in AGS Version 3 or an editable Excel spreadsheet form able to
be directly convertible in “KEYAGS3”. The format spreadsheets will
be made available from the Engineer.
 The contractor should make himself aware of the following
software to ensure the relevant information and content is
provided.
 gINT (version 6 and above.
iii. The contractor shall provide in editable format the following in

CD media:
 All report test in *.doc (winword).

 All borehole records in *.jpeg, or .xls, or other approved format.
 All laboratory test data sheets and results in *.jpeg, or .xls,
or other approved format.
 All core photography in *.jpeg.
 Miscellaneous report drawings in *.dwg (AutoCAD Version 14
or above).
21.7.9 COPYRIGHT
Photographs taken by the contractor under the provision of this Clause shall
not be used for commercial advertisement either of his organisation or
of any materials or equipment used on the works, without the written
approval of DM Similarly no part of the report document may be
reproduced or transmitted, in any form or by any means electronic,
mechanical, photographic, recording or otherwise, without the written
permission of DM.
21.8 GEOPHYSICS
21.8.1 GEOPHYSICAL SURVEYING
a) The objective of the Geophysical Surveys is defined by the geotechnical
requirements. Geophysical methods are primarily employed to determine
significant cavities or broken, collapsed subsurface strata.
b) The primary objective of geophysical application in geotechnical engineering
is:

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i. Geological investigation and mapping geological boundaries

between layers; determining the thickness of superficial
deposits and depth to rock-head; identify structural features,
such as the location of buried channels, faults, dykes, etc.
ii. Hazard assessment and detection of voids and buried artefacts;
location of buried mineshafts and addits, natural cavities, old
foundations, pipelines etc.; detection of leaks in barriers; pollution
plumes on landfill sites.
iii. Determination of engineering properties of the ground, such as
dynamic elastic moduli of rock and rock quality; soil corrosivity for
pipeline protection etc.
c) Different geophysical techniques, such as seismic velocity, electrical

resistivity, microgravity, electromagnetic conductivity and Geo-Radar are
commonly utilised in ground investigation to obtain information relating to the
properties of subsurface materials. For any given geophysical technique the
variations in the information obtained can give an indication of the geological
structure. Invariably interpretation of geophysical survey data involves
adequate understanding of the underlying geological structure that may be
obtained from preliminary reconnaissance and from borehole records. In
comparison with borehole investigations, geophysical surveys can maximize
both time and money while providing comprehensive coverage of
investigation.
d) On sites where contamination is suspected, a geophysical survey may form
part of a preliminary risk assessment prior to drilling or sampling.
Geophysical surveys may be carried out within and between the boreholes to
determine the geological, hydro-geological and geotechnical properties of the
ground mass.
e) Geophysical methods used in site investigation are influenced by five

fundamental controlling factors:
i. Survey point configuration and related depth of penetration.

ii. Vertical and lateral resolution.
iii. Signal-to-noise ratio.
iv. Contrast in physical properties.
v. Groundwater level and moisture content.
f) Prior to the employment of geophysical methods, it is necessary to

determine the quality of information required, taking the above mentioned
factors into consideration, in order to achieve the objectives of the
investigation.

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21.8.2 QUALIFICATIONS
The geophysical investigation and all associated works shall only be carried
out by specialist companies with adequate application experience in the field
of ‘Geophysical methods in Geotechnical Engineering’, pre-qualified and
approved by the Engineer or Client’s Representative. The geophysical
company shall be licensed in Dubai as a Geophysical specialization
company with qualified geo-physists and company owned geophysical
equipment. Geophysical works can not be carried out by individuals hired
by the contractor.
21.8.3 INCEPTION REPORT
a) Within 7 days of receipt of the Letter of Intent for a Work Order, the
contractor shall submit an Inception Report to include the following:
i. Work Method Statement.

ii. List and details of staff to carry out the works including their general
responsibilities.
iii. Anticipated working hours and complete work programme.
iv. Anticipated calibration work that is required to fully assess
and interpret the geophysical results.
b) The contractor is to confirm his acceptance that the general objectives stated
within the Work Order are achievable with the specified work programme and
shall include statements relating to the achievable resolution of the chosen
methods (vertical and horizontal resolution should be included).
21.8.4 SEISMIC METHOD
a) The velocity of seismic waves varies with the material through which they
pass, and depends on the density, porosity, structure and elastic modulus of
the material.
b) In this type of test, a shock wave is produced either by mechanical or
explosive means, and primary waves (as opposed to surface and shear
waves) are monitored at detecting stations, which are equally spaced in a
line across the area being investigated.
c) The seismic method of investigation may be considered if the soils and the
boundaries between them fulfil the following requirements:
i. Depth of investigation is limited to the top 30m.
ii. The interfaces between the strata are approximate horizontal

or horizontal to inclined.
iii. Each stratum is of sufficient thickness to reflect a change in
velocity on time-dependent plot.
iv. The velocity of wave propagation increases with the depth of each
succeeding formation.

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21.8.5 RESISTIVITY SURVEY

a) In this method an electrical current is induced into the ground through two
earth connections (electrodes) and the voltage (potential difference) is
measured across a second pair of electrodes.
b) The resistivity surveys shall be generally conducted as follows:
i. Establish temporary benchmarks for topographic survey and mark

grids and resistivity routes. Try to establish resistivity survey grids
along likely interference zones.
ii. Record resistivity readings at predetermined electrode spacing
along pre-marked resistivity routes.
iii. Issues which may affect data quality and subsequent interpretation
shall be intimated to the Engineer and if necessary shall be
resurveyed.
iv. Exploratory boreholes shall be drilled to assist interpretation of the
resistivity survey results.
v. The reports shall include and not be limited to the following.
 Interpretation of resistivity anomalies supplemented with

interpretation from physical evidences (exploratory boreholes
or trial pitting).
 Surface survey report, resistivity survey report with the
sections along routes, sections shall be coloured with
reference colour scale and legend.
 Resistivity plots at a scale of 1:1000 horizontal and 1:500
vertical.
vi. Additional surveys may be required for locating the exact location of
adverse ground conditions. The survey required shall be location
specific. The contractor is required to submit his proposals for
the effective review and only undertake the additional work as
vii. The location of anomalies (cavities) shall be marked and flagged by
the contractor at the exact location indicated by UTM
coordinates Easting and Northing.
21.8.6 TOPOGRAPHICAL SURVEY FOR RESISTIVITY SURVEY

a) The Engineer will provide coordinated control points for setting out and
defining the boundaries of the area of investigation. The contractor shall set
out all the resistivity lines on site according to the co-ordinates of start and
finish points and spacing of intermediate points provided by the Engineer.
b) The following should be included:
i. The start and finish points of each line should be fixed and
clearly marked with a marker of indelible ink and sufficient size
for easy identification.
ii. Each survey line should be marked at every 50m intervals clearly
identifying the line information and chainage from the start of
the line.
iii. The contractor is to make records of the surface condition

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during the topographic survey, i.e., significant features such as

trenches, existing services, differing surface conditions, asphalt
road and other features.
iv. The contractor is to report to the Engineer immediately during
topographic survey of any issues which may affect the quality
of subsequent geophysical data so that alternatives can be
considered.
v. Topographical surveys accuracy shall be 3 cm in Easting and
Northing co-ordinates. The accuracy of elevations shall be 1 cm.
21.8.7 BORINGS FOR GEOPHYSICAL SURVEYS
a) Exploratory Borings for the calibration of the geophysical survey results are
included in the scope of work. One borehole for each five hundred survey
stations is to be incorporated unless otherwise instructed by the Engineer.
b) Information from the borehole shall be used by the contractor as necessary
for calibration/interpretation of the geophysical survey results. The contractor
is to advise if he considers alternative work more appropriate or the number
of boreholes allocated is inadequate or under specified for accurate
interpretation.
c) In general, boreholes drilling and related field testing, sampling, backfilling of
boreholes and reinstatement of borehole location shall be in accordance with
BS 5930, 1999 and BS 1377, 1999.
d) Refer to details on borehole exploration in Section 21.4.
21.8.8 PROGRESS REPORT
a) The contractor shall maintain a detailed work schedule of at least one week
ahead (1-week rolling schedule) for all work anticipated. The schedule shall
be maintained by the contractor and be provided weekly to the Engineer.
b) Reporting shall include daily records to be provided to the Engineer in a
compiled form which shall be updated and supplemented daily. At least
c) once a week, the contractor and Engineer shall hold co-ordination meetings
to ensure that all outstanding issues are resolved or acted upon and that
information and interpretations are up-to-date.
d) The daily and weekly reports shall be compiled along with all interpretations
and methodologies conducted throughout the Project and shall be formally
developed as the Work Order Report for submission, review, and approval
by the Engineer within one week of completion of the survey and the Work
Order.
21.8.9 DELIVERABLES
a) Format of all drawings, maps, sections and text shall be the standard format
approved by the Engineer. The contractor shall liaise and make himself
aware of the requirement in case the Engineer is not satisfied with the

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submittals and the contractor shall carry out the amendments accordingly
and resubmit the same within 7 working days from the date of instruction by
the Engineer.
b) The primary deliverables shall contain details of the survey work and shall
include:
i. Basic daily data records in digital and hard copy format.

ii. Progress reports.
iii. Preliminary interpretation in case of Resistivity survey.
iv. The final report shall include, but not limited to, interpretations of
Geophysical results, locating cavities with depth and
dimensions, classification of subsurface materials (type of rocks)
based on geophysical values and borehole logs, and core
photographs. The final report shall also include detailed risk maps
(plus sections and legend) for each sector or block or work order
in a format approved by the Engineer. The calibration boreholes
shall be shown on the sections.
v. Geological Cross Sections are to be produced to a scale of
1:1000 horizontal and 1:100 vertical and will include a clear
comprehensive legend.
21.8.10 GEOPHYSICAL INVESTIGATION REPORT
a) The contractor shall seek the Engineer’s approval for format of reporting. For
each works, the contractor shall submit the following as reports :
i. Preliminary Report:
Two sets of hard copy and one set of soft copy that includes
raw data of resistivity or seismic survey, survey sections and
proposed locations for calibration boreholes.
ii. Draft Report:

Three sets of hard copy and one set of soft copy that should
include: full text description and interpretation of the
subsurface
geology and associated features, resistivity or seismic sections or

other geophysical graphics, risk map with survey lines and location
of calibration borehole, borehole logs and core photographs.
iii. Draft Final Report:

One set of hard copy and one set of soft copy that should include:
detailed description of the work, geology of the area,
interpretation of the geophysical survey results, site location
plans, and survey location plan, risk maps showing locations of
all boreholes carried out in the area, resistivity and/or seismic
sections, borehole logs and core photographs, geophysical
sections, tables and figures as instructed by the Engineer.

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The Final report must be conclusive and incorporates results of

all previous works carried out in the area, (previous geophysical
survey lines and boreholes carried out shall be utilised in the
interpretation and reproduced in the report as directed by the
Engineer). Clear conclusions and recommendations must be
included in the report.
iv. Final Report:

Once the Draft Report has been accepted by the Engineer
the Contactor shall submit one copy of the Final Report. If the
Engineer is satisfied that all corrections and amendments have
been incorporated in the report, he shall instruct the Contactor
to submit the remaining copies of the report.
The final report shall be submitted in 6 hard copies and 2

electronic copies.
v. Digital data :
Refer to clause 21.7.8

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APPENDIX 2.1 - BORE HOLE LOGS
Borehole Logs, to be prepared in accordance to BS:5930, 1999 clause 47.2.6. For

typical formats refer to Figure 21 and 22 in the Report section of BS:5930, 1999.

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APPENDIX 2.2 - WATER MONITORING DETAIL

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APPENDIX 2.3 - TRIAL PIT LOG

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APPENDIX 2.4 - REFERENCES
The latest edition of the following references shall, to the extent specified herein, be
used.
1. AASHTO D 422 - 1963 - Particle Size Analysis of Soils.
2. AASHTO D 4318 - 2000 - Determining the Liquid Limit of soils.
3. AASHTO D 4318 - 2000 - Determining the Plastic Limit and Plasticity Index
of Soils.
4. AASHTO T 180 - 1990 - Moisture - Density Relations of Soils using a

10lb (4.5kg) Rammer and an 18inch (457mm) Drop).
5. AASHTO D 1452 - 1980 - Soil Investigation and Sampling by Auger Boring.
6. AASHTO D 1586 - 1999 - Penetration Test and Split- Barrel Sampling

of Soils.
7. AASHTO D 1587 - 2000 - Thin-Walled Tube sampling Of Soils.
8. AASHTO D 2166 - 2000 Unconfined Compressive Strength of Cohesive Soils.
9. AASHTO D 4186- 1989- One-Dimensional Consolidation Properties of Soils.
10. AASHTO T 223 - 76 - Field Vane Shear Test in Cohesive Soil.
11. AASHTO T 225 - 75 - Diamond Core Drilling for Site Investigation.
12. AASHTO D 2664 - 1995 - Triaxial Compressive Strength of Undrained Rock

Core Specimen.
13. AASHTO D 1194 - 1994 - Bearing Capacity of Soil for Static Load on
Spread Footings.
14. AASHTO D 1452 - 2000 - Soil Investigation and Sampling by Hollow-

Stem Auger Borings.
15. AASHTO D 2216 - 1998 - Laboratory Determination of Moisture Content

of Soils.
16. ASTM D 420 - 1993 - Guide for Investigating and Sampling Soil and Rock.
17. ASTM D 422 – 2002 - Method of Particle-Size Analysis of Soils.
18. ASTM D 653 - 2002 - Terminology Relating to Soil, Rock and

Contained Fluids.
19. ASTM D 698 - 2000 - Test Method for Laboratory Compaction

Characteristics of Soil using standard effort (12,400ft-lbf/ft3 (600 KN. m/m3)).

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20. ASTM D 1194 - 1972 - Test Method for Bearing Capacity of Soil for
Static Load on Spread Footings.
21. ASTM D 1452 - 80 - Practice for Soil Investigation and Sampling by

Auger Boring.
22. ASTM D 1557 - 2002 - Test Method for Laboratory

Compaction Characteristics of Soil using modified effort (56,000ft-lbf/ft3
(2,700 KN.m/m3)).
23. ASTM D 1586 - 1999 Method for Penetration Test and Split-Barrel
Sampling of Soils.
24. ASTM D 1587 – 2000 - Practice for Thin - Walled Tube Sampling of Soils.
25. ASTM D 1883 - 1994 - Test Method for CBR ( California Bearing
Ratio). Laboratory-Compacted Soils.
26. ASTM D 2113 - 1999 - Practice for Rock Core Drilling for Site Investigation.
27. ASTM D 2116 - 2000 - Test Method for Unconfined Compression Strength
of Cohesive Soils.
28. ASTM 2216 - 1998 - Test Method for Laboratory Determination of

Water (Moisture) Content of Soil and Rock.
29. ASTM 2487 - 2000 - Test Method for Classification of Soils for Engineering
Purposes.
30. ASTM D 2488 - 2000 - Practice for description and Identification of

Soils (Visual - Manual Procedures).
31. ASTM D 2573 - 72 Test Method for Field Vane Shear Test in Cohesive Soils.
32. ASTM D 3441 - 1998 - Test Method for Cone and Cone Penetration Tests
of Soil.
33. ASTM D 4220 - 1995 - Practice for Preserving and Transporting

Soil Samples.
34. ASTM 4318 - 2000 - Test Methods for Liquid Limit, Plastic Limit and
Plasticity Index of Soil.
35. ASTM D - 4429 - 93 - Test Method for Bearing Ratio of Soils In Place.
36. ASTM D 4554 - 2002 - In-Situ Determination of Direct shear Strength of Rock.
1. ASTM D 4633 - 86 - Test Method for Stress Wave energy Measurement

for Dynamic Penetrometer Testing Systems.
2. ASTM D 4719 - 2000 - Test Method for Pressuremeter Test of Soil.

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3. ASTM D 4750 - 87 - Test Method for Determining Subsurface Liquid Levels

in a Borehole or Monitoring Well ( Observation well).
4. ASTM D 4914 - 1999 - Test Method for Density of Soil and rock in Place.
5. ASTM D 5079 - 2002 - Practice for Preserving and Transporting Rock

Core Samples.
6. ASTM D 5093 - 2002 - Test Method for Field Measurement of Infiltration

Rate Using a Double-Ring Infiltrometer with a Sealed-Inner Ring.
7. ASTM D 5434 - 1997 - Guide for Field Logging of Subsurface Exploration

of Soil and Rock.
8. BS 1377 - 1990 - Methods of Tests for Soils for Civil Engineering Purposes.
9. BS 5930 - 1999 - Code of Practice for Site Investigation for Civil

Engineering Purposes.
10. ISRM (International Society for Rock Mechanics) - Document No. 1

- Suggested Methods for Determining In-Situ Shear Strength.
11. Site investigation manual, CIRIA special publication 25, 1983.
12. Site investigation in construction, Without site investigation ground is a

hazard, Site Investigation Steering Group, Thomas Telford, London, 1995.
13. ASTM D 2938 – 1995 – Unconfined compressive strength of intact rock

core specimen.
14. AASHTO T 191 – 2002 Standard Method of Test for Density of Soil In-
Place by the Sand Cone Method HM-22 Part IIA.
15. ASTM D1883 – 1999 Standard Method for CBR (California Bearing Ratio) of
Laboratory-Compacted Soils.
16. AASHTO M82 – 1975 Standard Specifications for Cut-Back Asphalt

(Medium- Curing Type) HM-22, Part IA R(2000)
17. AASHTO M29 – 1996 Standard Specifications for Fine Aggregate

for Bituminous Paving Mixtures HM- 22, Part IA (D1073 – 1994).
18. AASHTO M17 – 1995 Standard Specifications for Filter

Bituminous Pavements Mixture, 20th Edition (D242 – 1995).
19. AASHTO M81 – 1992 Standard Specifications for Cut-Back Asphalt
(Rapid- Curing Type) HM-22.
20. ASTM C150– 2003 Standard Specifications for Portland Cement.
21. ASTM C88 – 1999 Standard Test Method for Soundness of Aggregate by Use
of Sodium Sulfate or Magnesium Sulfate.

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22. AASHTO T96 – 2002 Standard Method of Testing for Resistance to

Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the
Los Angeles Machine HM-22, Part IIA (C131).
23. ASTM C418 – 1998 Standard Method of Testing for Abrasion Resistance
of Concrete by Sand-Blasting.
24. AASHTO M33 – 1999 Standard Specifications for performed Expansion Joint
Filler for Concrete (Bituminous Type) (ASTM D994-1998).
25. AASHTO M85 – 2002 Standard Specifications for Portland Cement HM-
22, Part IA (ASTM C150, 2002).
26. AASHTO T49 – 1997 Standard Method of Test for Penetration of Bituminous
Materials HM-22, Part IIA. (D5)
27. ASTM D445 – 2003 Standard Testing Method for Kinematic

Viscosity Transparent and Opaque Liquids (BS2000 - 1999, P71)
28. ASTM D92, Rev. B 2002 Standard Testing Method for Flash and Fine
Points by Cleveland Open-Cut Tester (T48).
29. ASTM D113 – 1999 Standard Testing Method for Ductility of

Bituminous Materials.
30. ASTM D4 – 1986 Standard Testing Method For Bituminous Content R 1998.
31. BS 882 1992 Specifications for Aggregate from Natural Sources for Concrete.
32. BS 812 1989, Part 103, Testing Aggregate, Method for Determination
of Particle Size Distribution, Sedimentation Test.
33. BS 812 1985, Part 106, Testing Aggregate, Method for Determination of
Shell Content in Coarse Aggregate.
34. BS 812 1989, Part 105, Testing Aggregate, Method for Determination
of Particle Shape, Flakiness Index.
35. BS 10175 2001, Investigation of Potentially Contaminated Sites, Code

of Practice.
END OF SECTION

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APPENDIX 1
STANDARD DETAILS FOR ROAD CONSTRUCTION

ROAD DIVERSIONS & ROAD SIGNS
BACKFILLING TO GRP PIPES
APPENDIX 2
TESTING AND WORKMANSHIP

OF
IN-SITU LINING MATERIAL
APPENDIX 2
TESTING AND WORKMANSHIP OF IN-SITU LINING MATERIALS
CONTENTS PAGES
1. Performance Requirements A2/1
2. Type Tests A2/1
3. Quality Control Tests A2/2
4. Control of Test Conditions A2/4
5. Workmanship Inspection and Certification A2/4
6. References A2/5
APPENDIX NO.2 - TESTING AND WORKMANSHIP OF IN-SITU LINING MATERIALS
1. PERFORMANCE REQUIREMENTS
The lining shall meet the minimum requirements given in Table 1 when tested in
accordance with those clauses indicated.
Property Requirements Clause
Short term 2200 MPa 2.2

bending modulus
---------------------------------------------------------------------------------------------------------------------
--
50 year flexural As agreed with 2.3
creep modules purchase but not
less than 500 Mpa.
2. TYPE TESTS
2.1 General
The test given in 2.2 to 2.5 shall have been satisfactorily completed before lining can
claim to have met this specification. All combinations of wall thickness, constituent
materials, material proportions and curing methods shall be tested. Should there be
any modifications to these, the tests must be repeated.
The Quality Assurance Schedule of the quantity system (see 3.1) may require type
tests to be repeated at specified intervals.
All tests are the responsibility of the contractor. Details and results for type tests
relevant to each material composition and manufacturing process shall be made
available to the Engineer or his representative on request.
Samples used for testing should be flat and formed in moulds but otherwise must be
manufactured and cured in an identical manner to the lining with which they are to be
identified or taken from site on the intermediate manholes.
2.2 Short term flexural (bending) properties
The initial tangent flexural modules of elasticity, flexural stress and strain at failure
shall be determined in accordance with the procedure described in BS 2782: Method
335A using a cross head displacement rate of 10 mm/min.
Each test piece shall be tested with the impermeable membrane in contact with the
load bearing supports.
The flexural properties of each test piece shall not be less than the following
requirements:
a) Initial tangent flexural modulus 2600 MPa

b) Flexural stress at first break * 50 MPa
c) Flexural strain at first break * 1.0% to 2.5%
A2/1
(* as indicated by the first discontinuity of the force/extension curve).
2.3 Flexural Creep Modulus
The lining material shall meet the requirement of Table 1 when tested under aqueous
conditions in accordance with the method described in Clause 7 of IGN-4-34-04.
2.4 Tensile Properties
The tensile strength, initial tangent modules of elasticity and elongation at first break
shall be determined in accordance with BS 2782: Method 1003 using Type II or Type
III test pieces, a grip separation rate of 2 mm/min. and either an optical or strain gauge
extensometer.
The tensile properties of each test piece shall not be less than the following
requirements:
a) Initial tangent tensile modulus 1700 MPa

b) Tensile stress at failure 25 MPa
c) Elongation at first break * 1.0 %
(* as indicated by the first discontinuity to the force/extension curve).
Results from samples breaking within 10 mm of the grips shall be discarded and the
test repeated with the occurrence being recorded.
2.5 Compressive Properties
The compressive strength shall be determined in accordance with BS 2782 : Method

345A using Type IV tests pieces and a cross head displacement of 0.5h mm/min
where h is the height of the test sample in mm. The compressive strength shall not be
less than 60 MPa.
3. Quality Control Tests
3.1 General
The test requirements of 3.2 to 3.6 are necessary in order to demonstrate a continuing
satisfactory level of production and installation quality in day to day production. The
Contractor shall establish a quality system to meet the requirements of BS 5750: Part
2.
Quality control tests shall be carried out by the manufacturer on each lining length
after it has been installed and cured. If any of the tests are failed the Engineer shall be
informed immediately.
3.2 Samples for Quality Control Tests
3.2.1 For each lining length one sample shall be fabricated and cured in a clamped mould
using the methods detailed in Clause 8 of IGN 4.34.04.
When curing of the lining has been completed the mould samples shall be
removed and subjected to quality control testing. With the exception of the wall
thickness requirement (3.4), if all tests are passed then no further quality control
testing is required.
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3.2.2 Unless otherwise approved by the Engineer, provision shall be made to suitably
support the lining bag either at the ends or at intermediate manholes. In cases
where disagreement or dispute exists over the results obtained from the clamped
sample, these samples or samples cut from the installed lining (removed at the
Contractor's cost) shall be used for repeat testing as required in 3.6.2. For test
purposes attention is drawn to the curvature limitations and orientation
requirements of samples taken from linings.
All cut away material shall be marked to indicate its place of origin and shall be
stored until the linign length has been tested and accepted as meeting the quality
control test requirements.
3.2.3 Should there be any disagreement following testing performed on samples

described in 3.2.2 then at the Contractor's discretion and cost either:
a) the creep modulus shall be validated against the Contractor's creep data
obtained for 2.3 using an abridged creep test on material removed from
the lining, or
b) the lining shall be replaced.
3.3 Visual Examination
After installation each lining shall be visually examined by CCTV. The installation lining
shall have a smooth internal surface which shall be generally free from wrinkles.
3.4 Wall Thickness
The minimum wall thickness shall be determined at a minimum of five locations on a

cut section of the lining using a method of measurement accurate to the nearest 0.1
mm. The minimum value shall meet the requirements of Specification.
3.5 Tensile Properties
The tensile strength, initial tangent modulus of elasticity and elongation at first break of
at least five samples shall be determined in accordance with BS 2782: method 1003
using Type II or Type III test pieces, a grip separation rate of 2mm/min. and either an
optical or strain gauge extensometer. The tensile properties shall not be less than the
minimum requirements set down in 2.4.
3.6 Short Term Flexural (bending) Properties
3.6.1 For normal quality control testing using clamped mould samples:-
A minimum of five samples shall be tested by the method prescribed in 2.2 with
the impermeable membrane of the sample in contact with the load bearing
supports.
The samples shall comply with the requirements of 2.2.
3.6.2 For repeat testing referred to in 3.2.2.:-
Where practicable, unless otherwise approved by the Engineer,a minimum of

five test pieces shall be prepared.
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Wherever possible, samples for test purposes shall have a radius of curvature
not less than 250mm and be taken from the hoop direction. However, for linings
where hoop samples cannot meet the curvature requirements, samples may be
taken from the longitudinal direction.
When tested by the method prescribed in 2.2 with the impermeable membrane in
contact with the load bearing supports, the samples shall comply with the
requirements of Table 1.
4. CONTROL OF TEST CONDITIONS
4.1 Test Conditions
Unless otherwise required by this specification the test measurements shall be

conducted at a temperature of 23 ± 2° C.
4.2 Specimen Conditioning
4.2.1 For type in air (or in any case of disagreement) specimens shall be kept in air at
23 ± 2° C for not less than 88 hours prior to testing.
4.2.2 For quality control testing, specimens shall be kept in air at 23 ± 2° C for not
less than 12 hours after they are considered to be cured.
4.3 Test Specimen Preparation
For mechanical tests, specimens shall be machined following the recommendations of

BS 2782: Method 930A.
5. WORKMANSHIP, INSPECTION AND CERTIFICATION
5.1 Workmanship
All raw materials shall be tested at a frequency sufficient to ensure consistency and
compliance with this specification.
The Contractor shall adequately supervise all stages of production and keep records
of the raw material batches used and products made each work shift or day.
Manufacture shall be under environmental conditions compatible with producing

satisfactory lining and raw materials shall be stored and used in accordance with the
recommendations of their manufactures.
The lining manufacturer shall be familiar with the changes in viscosity, gel time, etc.,
which may occur during storage of the resin and make appropriate allowance in the
lining manufacturing process. Resin stored in original unopened containers shall not
be used after the resin manufacturer's stated keeping period required by clause 4 of
BS 3522: 1962. The guidance of the resin manufacturer shall be sought and followed
for the useful life of resin delivered by tanker. Tanks used for bulk storage of polyester
resin must be inspected regularly and checked for contaminants.
Note:(For guidance only) A well cured polyester in-situ lining would be expected to
have a Barcol hardness of not less than 35 when tested in accordance with BS 2782:
Method 1001. Lining samples should be abraded to remove the soft impermeable
membrane and to produce a flat surface before testing.
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5.2 Inspection
In addition to the Contractors own inspection and supervision, the Engineer shall have
access at all reasonable times to those parts of the manufacturer's works engaged on
production and testing of linings and to all relevant test records.
5.3 Certification
The Contractor shall, on request, furnish the Engineer with copies of signed certificate
for each size and classification of lining, stating that the construction and testing of the
lining supplied comply with the requirements of this Specification and giving details of
minimum performance parameters. If required by the Engineer, the quality control test
results or a suitable summary shall be provided with the certificate.
6. REFERENCES
This specification makes reference to the latest editions of the following publications
(except where otherwise indicated) including all addenda and revisions:
BS 2782 Methods of testing plastics
Method 121A Determination of temperature ofdeflection under a

bending stress of 1.8 MPa, of plastics and ebonite.
Method 335A Determination of flexural properties of rigid plastics.
Method 345E Determination of compressive properties by deformation at

constant rate.
Method 432B Determination of the acid value of unsaturated resins.
Method 432C Determination of the hydroxyl value of unsaturated

polyester resins.
Method 620A Determination of density of solid plastics excluding cellular

plastic (immersion method).
Method 930A Preparation of test specimens by machining.
Method 1003 Determination of tensil properties
BS 3532 Unsaturated polyester resin systems for low pressure fibre reinforced
plastics.
BS 4618 Recommendations for the presentation of plastics design data.
Sub-section 1.1.2:1976. Creep in flexure at low strains.
BS 5750 Quality Systems
Part 2 : Specification for manufacture and installation.
IGN 4.34.04 - Specification for Polyester Insituform Sewer Linings
A2/5
APPENDIX 3
MANHOLE ENTRY
(INCLUDING ELEVATED MANHOLES AND ACCESS TO ELEVATED SEWERS)
APPENDIX 3
MANHOLE ENTRY (INCLUDING ELEVATED MANHOLES

AND ACCESS TO ELEVATED SEWERS)
CONTENTS PAGE
3.1 Lifting Manhole Covers A3/1

3.2 Entering Manholes - Rat Poison A3/1
3.3 Entering Manholes A3/2
3.4 Entering Low Risk Manholes A3/2
3.5 Entering High Risk Manholes A3/4
3.6 Access to Elevated Manholes & Sewers A3/4

3.7 Manhole Entry - Emergency Procedure A3/5
3.7a Pumping Station Chambers and Sump Entry A3/7

3.8 ESSENTIAL MINIMUM SAFETY EQUIPMENT A3/7
3.8.1 For Lifting Manhole Covers A3/7

3.8.2 For Entering Low Risk Manholes or Watercourse Culverts
with Open Ends A3/7
3.8.3 For Entering High Risk Manholes and Confined Spaces
Associated with Pump Stations A3/8
3.8.4 For Entering Sewers A3/8
3.9 HIGH PRESSURE WATER JETTING A3/9
3.9.1 Equipment A3/9
3.9.2 Protective Clothing A3/9
APPENDIX 3
MANHOLE ENTRY (INCLUDING ELEVATED MANHOLES AND ACCESS TO ELEVATED

SEWERS)
In deciding manning levels account must be taken of the location of manholes and sewerage
facilities in relation to availability of means of summoning assistance in emergencies.
3.1 Lifting Manhole Covers
Place traffic signs in accordance with regulations if the cover is in the Highway.
Unattended open manholes must be safely protected by suitable barriers. Remember that
some people are visually handicapped.
Whenever possible covers shall be lifted using lifting keys and proper lifting and handling
techniques or by the use of a hydraulic or other approved manhole lifting device.
Many accidents have been caused due to the misuse of tools while attempting to free tight
covers. A large proportion of these accidents have been associated with the misuse of
chisels and hammers. Sledge hammers should only be used to 'shock' a cover into vertical
movement by blows to the cover, they should never be used to hit chisels, etc. Chisels,
should not be allowed to become burred over.
The following is the approved method for lifting tight covers:-
a) Clean out any gap between cover and frame and clean keyholes using suitable
handtools without the application of force in the form of hammering unless a seaming
chisel is used with a small hammer in order to clear the gap.
b) Strick the cover using a sledge hammer in order to move the cover and assist
penetration of the water and/or using a properly tempered (not brittle) chisel, hammer
the chisel into the gap between cover and frame using a lump hammer of no more
than 4 lb. weight. The striker of the chisel must hold the chisel with one hand. Do not
strike a chisel held by someone else and do not strike a chisel when it is wedged to the
point where it is under great stress signified by rapid increased in the pitch of the
sound when it is struck. When using a chisel always wear safety goggles, and ensure
that other persons are not exposed to danger or loss.
c) Apply the hydraulic lifter or other approved lifting equipment and attempt to lift the cover.
If the cover does not lift repeat the above procedure. Extra lift can also be achieved by
the use of a long bar (about 1.2m long) passing through the eye of the ring type
manhole keys and levering onto a block of wood resting on the ground adjacent to the
cover.
Patient application of the above will safely remove most covers. If a cover does not lift after
applying the above procedure several times the cover needs to be dug out.
When lifting covers wear protective clothing as specified.
3.2 Entering Manholes - Rat Poison
Protective clothing should be worn when entering manholes and a watch should be kept
for any poisons. On no account should rat bait be touched. If protective clothing is
accidentally contaminated wash the clothing down thoroughly before removal and do not
touch the contaminated parts with exposed skin. If rat bait is seen and work cannot be
A3/1
completed without risk of contacting the bait the manhole should be first jetted clean before
entering. If rat bait is removed, the contract manager shall be informed. Wear appropriate
clothing. Do not touch dead rats, remove with a shovel and bucket.
3.3 Entering Manholes
The entry requirements for manholes and chambers have been selected on a basic risk
element and are divided into two types entitled 'Low Risk' and 'High Risk'.
Low Risk
Access applies to shallow manholes with small diameter pipes where there is little risk of
falling or being swept away.
High Risk
Access applies to deep manholes with any pipe size or shallow manholes with a large
diameter pipe where there is a greater risk of falling or being swept away.
The factors differentiating between 'Low' and 'High' risk entry is as below and all the listed
conditions must apply.
Low Risk Conditions
i. Chambers with good access
ii. Depth not exceeding 3.0m (10')
iii. Sewers not exceeding about 375mm (15") diameter or up to 1.5m (5')diameter if the
flow is very low in both depth and velocity.
High Risk Conditions
i. Chambers with poor access
ii. Depth greater than about 3.0m (10') but less than about 7.0m (22'6")
iii. Sewers exceeding about 375mm (15") diameter
Note:All Trunk Sewers 1.5m (5') diameter or over and manholes deeper that 7.0m
(22.'6")require a Permit to Work.
3.4 Entering Low Risk Manholes
i. With approved winching system
Where entry into low risk manholes require the operative to work at the point of entry the
operative must be attached to an approved winching system at all times.
Minimum number of men 2.
ii. Without approved winching system
Lifting Manhole Covers, Entering Manholes and Chambers with good access not exceeding
3.0m (10') deep on sewers not more than 375mm (15") in diameter.
A3/2
a) Locate nearest usable telephone or if available usable radio telephone set,

before entering the manhole.
b) Lifting Cover - comply with Sections 3.1 and 3.2.
c) Before entering the manhole ensure that the cover has been removed to
give natural ventilation for a minimum of 5 minutes.
d) Test for Toxic and Flammable Gases, and Oxygen deficiency, using
approved detector. If Toxic and Flammable Gases or Oxygen deficiency is
detected do not enter manhole and inform your Supervisor.
e) When in the manhole keep the gas detector, with you (switched on).
Leave the manhole immediately if the alarm sounds and inform your
Supervisor.
f) Wear protective clothing as appropriate.
g) Use safety equipment as specified.
h) Do not enter the manhole if access is bad. Take the following factors into
account when considering access:-
i) Size of access hole and shaft.
ii) Presence of standing water in manhole.
iii) Structural condition of manhole.
iv) Visibility in manhole.
v) Position and condition of step irons/ladders.
If access is bad or there are other reasons for not entering the
manhole report to your Supervisor who if necessary will assign
another man or appropriate equipment to your gang so that
manhole entry can be attempted using the working methods
specified in Section 3.5. A permit to work may be required.
i) It is essential that rapid egress from the manhole can be achieved without
panic if the gas alarm sounds. If the manhole is on a storm overflow
chamber or other lateral chamber the chamber itself should only be
entered providing there is no appreciable fall risk and providing a source of
fresh air can be contacted within a few seconds of the gas alarm being
sounded.
j) Particular care should be taken in entering manholes. The next foothold

should be tested with a large proportion of bodyweight before relinquishing
a firm support from other points.
k) If the manhole is less than approximately 3m (10')deep and has good

access but a pipeline of 375mm (15") or more in diameter, the manhole
itself can be entered providing the above is complied with and providing
the sewer is not steep and is dry or almost dry.
A3/3
3.5 Entering High Risk Manholes
Entering Manholes and Chambers more than 3m (10') deep or with poor access or on
sewers of 450mm (18") or more in diameter.
a) Comply with 3.4 a),b),c),d),e) f), g), h) and i).
b) When entering the manhole wear full safety harness and line supported by
two topmen or by one topman and approved winching system.
c) Only relinquish the security of your lifting line where:-
i) No fall risk is present.
ii) There is no danger of being swept downstream.
iii) Safety chains (where available) have been fixed or alternatively

mechanical struts have been placed across sewer entrances.
d) Do not at any time leave the manhole bottom without being attached to your
lifting line unless you have a source of fresh air available within a few seconds.
This means that if you leave the security of your lifting line wear approved BA
escape equipment.
e) Do not enter any sewers.
f) The topman/men must remain at the top of the manhole at all times when a
person is in the manhole.
g) Do not enter any manhole over approximately 7m (22'6") deep
- Permit to Work required.
h) Do not enter a manhole where visibility is bad due to steam, spray, etc.
Report this to your Supervisor.
i) Do not enter any manhole without step irons or fixed ladder unless a ladder
can be placed. If there are no or few step irons and a ladder cannot be placed,
a Permit to Work is required.
3.6 Access to Elevated Manholes and Sewers
a) Elevated Manholes
When elevated manholes require to be entered suitable and safe access to

the cover must, so far as is reasonably practicable, be provided. Generally,
this will apply to manholes protuding above ground level by more than one
metre and will take the form of scaffolding erected in accordance with
regulations.
b) Elevated Sewers
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When a sewer is at such a level above ground as to make it unreasonable to
work on the sewer while standing at ground level then a ladder must be used.
If the height is such (1.98m [6'6"]) that a ladder cannot be used than
scaffolding must be used.
If this is not practicable then slung or suspended scaffolds, boatswains chairs

or similar must be used.
In all the above cases the Construction Regulations 1961 and 1966 must be
observed. Supervisors must have a copy of the Construction Regulations
Handbook.
3.7 Manhole Entry - Emergency Procedure
NOTE:This emergency procedures assumes that approved working methods have

been used and that personnel are wearing specified safety equipment, and
using and/or deploying safety equipment as required by the appropriate safe
methods of working.
The following emergency situations:-
a) The presence of flammable and toxic gases or Oxygen Deficiency Alarm.
b) Collapse of person at bottom of manhole.
are considered below where the approved response is described in different

working circumstances.
a) Work Circumstance - Low Risk Manhole Entry
1. Emergency - Flammable and toxic gases or Oxygen

Deficiency Alarm.
Response - i) Bottom man must don Escape Set immediately and leave
manhole.
ii) Report alarm to supervisor or to base and warm anyone else

known to be working in the vicinity.
2. Emergency - Collapse of Operative
Response - If an operative collapses a rapid assessment by the

topman needs to be carried out. This assessment will be
based upon two prime factors
a) If the casualty is conscious
b) If the casualty is unconscious
a) If the casualty is conscious
i) Topman to inform emergency services immediately.
ii) Topman to monitor and reassure the casualty.
A3/5
iii) When emergency services arrive, topman to give details of situation.
b) If the casualty is unconscious
i) If the gang consists of two men then an approved winching system

must be used. The topman must immediately winch the casualty
clear of the confined space and place him in a safe area.
ii) If the gang consists of three men without an approved winching

system the two operatives must remove the casualty to a safe area.
iii) Once the casualty is clear of the confined space a rapid assessment
must be made of his condition i.e. ascertain as to whether he is
breathing, or his heart has stopped.
NOTE: Operators should be trained in basic first aid and resuscitation.
iv) An operative must then radio or telephone for ambulance assistance

and return to casualty.
b) Work Circumstances- High Risk Manhole Entry -

Three Man Gang Plus Approved
Winching System
1) Emergency - Gas or Oxygen Deficiency Alarm
Response -
i) Bottom man must don mask of Escape Set and must leave manhole
immediately.
ii) Report alarm to supervisor or to base and warn everyone else

known to be working in the vicinity.
2) Emergency - Collapsed Person at bottom of Manhole
Response -
i) The topman must immediately winch the bottom man out of the
manhole and pull him onto the ground adjacent to the manhole.
ii) If the man recovered from the manhole is not breathing, artificial
respiration must be applied.
iii) Ensure that the casualty is laid on his side in a safe comfortable
position, with the head in such a position that breathing is easy, is
not slumped forward or back.
iv) Where the casualty cannot be winched out of th manhole, and has
stopped breathing, resuscitation should be applied. An operative
should stay with the casualty with gas detector continuously
monitoring and breathing apparatus to hand until the emergency
services arrive.
A3/6
v) The topman must radio or telephone for Ambulance assistance. See
below "Communicating with Base or Ambulance in an Emergency".
Communicating with Base or Ambulance in an Emergency
The most direct method of communicating with the Ambulance is by telephone, this is
therefore the preferred method where a telephone is available. If a telephone is not
available near at hand a vehicle equipped with radio must be used or the workgroup
must be supplemented by extra personnel and/or transport in order to give quick
access to an available telephone.
3.7a PUMPING STATION CHAMBERS AND SUMP ENTRY
a) Any manhole, tank, dry or wet well or enclosed space at a Pumping Station
which normally has sufficient ventilation and in which gas has not previously
been detected should be treated as a 'High Risk' manhole entry (see Section
3.5).
b) Any manhole, tank, dry or wet well or enclosed space at a Pumping Station
which does not normally have adequate ventilation, or if hazardous or toxic
gas has previously been detected, the person entering the confined space
must wear and use a BA set providing the person entering is suitably trained.
c) Except in an emergency, no confined space shall be entered where gas has

been detected, and then only if suitable approved BA is worn. This does not
include an Escape Set.
EQUIPMENT
3.8 ESSENTIAL MINIMUM SAFETY EQUIPMENT
3.8.1 For Lifting Manhole Covers
a) Appropriate safety footwear
b) Suitable and sufficient signs to enable compliance with signing requirements.
c) First Aid Kit.
d) Retro reflective clothing.
e) Gloves/goggles.
3.8.2 For Entering Low Risk Manholes or Watercourse Culverts with Open Ends.
a) Appropriate safety footwear.
b) Hard hat, gloves.
c) Gas detection equipment and line.
d) Barrier cream.
A3/7
e) First Aid Kit.
f) Washing Facilities
g) Intrinsically safe lamp
h) Air line* or approved BA escape set.
i) Full safety harness.
j) (16mm)Polypropylene rope of adequate length with nonferrous spring shackle

at one end and non-ferrous eye at the other.
k) Approved winching system (dependant on number of operatives).
l) Oxygen resuscitator
* Not for watercourses.
3.8.3 For Entering High Risk Manholes and Confined Spaces Associated with Pumping
Stations
a) As for 3.8.2 plus :-
b) Rescue set
c) Approved winching system.
3.8.4 For Entering Sewers
a) For manhole entry part of job as 3.8.3.
b) For entry to sewer :-
i) Appropriate safety footwear.
ii) Hard hat, gloves.
iii) Intrinsically safe lamp.
iv) Full safety harness.
v) Gas detection equipment
vi) Escape BA set (one per person to enter).
vii) To be deployed on surface :-
a) Full breathing apparatus (minimum of two).
b) Spare lifting line.
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3.9 HIGH PRESSURE WATER JETTING
Only personnel who have been adequately instructed or are under instruction and are
familiar with this Code of Safe Practice shall operate High Pressure Water Jetting
Equipment. All operations shall be controlled and supervised by a competent person.
The term High Pressure Jetting covers all operating pressures above 50 bars (700
psi).
WARNING - THE WATER PRESSURE DELIVERED AT THE NOZZLE CAN CAUSE

VERY SERIOUS INJURY AND POSSIBLE DEATH, UNDER NO CIRCUMSTANCES
MUST THE NOZZLE BE ALLOWED TO POINT AT ANYONE.
3.9.1 Equipment
Equipment comprises of the following:-
a) Pressuring Pump - This delivers the water at various pressures. The lowest
pressure should always be used compatible with the work to be done.
b) Fail Safe Valve - This, when released, immediately diverts the water from the
hose or lance and releases the pressure from the pump completely.
c) Long Lances - These vary in length and are used for internal pipe or tube
cleaning and surface cleaning when fitted with an 'in line' valve, they shall be
manufactured from solid drawn tube and be of one complete length, i.e. Not
coupled lengths.
d) Short Lances - These are used mainly for surface cleaning and can be fitted
with a pistol grip valve in lieu of remote 'in line' valve.
e) Flexible Hoses - Used for internal cleaning in pipework where it is necessary

for the nozzle to navigate bends and contours.
f) Nozzles - There are different types and sizes of nozzles and those used
should be suited to the machine and application required.
g) High Pressure Hoses - Used for connecting the High Pressure Pump to the
jetting nozzle or working lance. Such hoses shall be restricted to the
manufactures maximum recommended working pressure.
h) Any fault or problems with the equipment must be reported at once to the
appropriate supervisor.
3.9.2 Protective Clothing
Wear protective clothing as appropriate.
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APPENDIX 4
ADDITIONAL SPECIFICATIONS FOR ROADWORKS
1
SECTION 1 - GENERAL
1. The work shall be carried out to correct alignment within the respective designated corridors
for Drainage, Sewers and Irrigation.
2. Contractor to obtain No Objection Certificate and alignment approvals from Roads &
Transport Authority on case by case basis. Applications to be submitted a minimum of 2
weeks in advance of proposed construction works (except in the case of house connection
works) and will be required for each and every corridor. This should be done well in advance
in accordance with Clause 14- Programme of Works in accordance with Contract
Specification. N.O.C submission shall be forwarded through the Consultant Resident
Engineer and DM Liaison Engineer. This application shall be submitted in 3 sets with case
history sheet and should include:
a) 4 Nos. typed standard NOC application forms.
b) 3 Nos. plans giving road references (city map at suitable scale) and highlighted to
show works in progress, NOC obtained work not started and proposed.
c) 3 Nos. of Plan showing existing and proposed net work indicating 3 road numbers
and/or land marks. The standard NOC conditions shall be indicated in the right margin
or unused area of the plan. The scale of the drawing shall be 1:1000 and in
exceptional situation 1:2000. The size of the submittals shall be A4, A3, A2, A1, and
A0. The plan should include a legend showing the quantity of entire scope of works
d) 3 nos; Cross-sections showing the full width of R.O.W indicating the proposed works
from ROW/Building line to ROW/Building line showing all existing services off sets,
excavation profile ,safety barricades, final levels, MH/Chamber width etc;
e) 3 Nos. road diversion drawings in different colour scheme showing the staging, width
of diversion, construction make up with days for each stage and duration.
Photographs shall be attached for new road cutting and/or dual carriageways.
f) Floppy Diskette/CD to be submitted for the proposed work plans & cross section
either during NOC submission or one week after the approval of NOC.
g) Programme of works, date of commencement and date of completion to be shown

(allow minimum of 14 days from submission date except in the case of house
connection works)
h) Details of civil works materials to be provided once or as applicable.
i) Organization chart indicating the details of staff responsible for the supervision of
works from both Consultant and Contractor connected with materials, safety, NOC’s
etc;
j) Services Organization NOC’s and where applicable NOC’s from DM horticulture

Dept; DUGAS, Shell for jet fuel line etc, and D.M Planning Dept; NOC for
applications where work has been proposed in unplanned area, public facilities and
sikkas.
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The entire Submissions must be checked and endorsed by Consultant and DM Drainage
Liaison Engineer. N.O.C’s for the unplanned and/or areas not levelled shall be issued on
temperorary basis.
NOC’s will be valid for a maximum initial period of 6 months and that revalidation is not to be
taken for granted. If the Contractor can not meet intended dates then RTA/DM must be
informed early so that reasons for delays can be checked at the time the problem occurs. It
is suggested that half way through the NOC validity period, the Contractor should assess the
completion of the work. If completion by expiry date of NOC is not possible then contractor
should send a letter with an explanation of reasons for requesting a revalidation of the
N.O.C. An extension request should be submitted not less than two weeks before expiry of
the N.O.C with photographs showing progress of work in the approved format.
Backfilling and reinstatement of trial pit excavation is to be completed within 48 hours (24
hours on main access or dual carriageways). Compaction and testing in layers is not required
if the area is to be excavated later. However, asphalt surfaces are to be compacted
sufficiently & reinstated with asphalt, which can be placed cold, on a temporary basis.
Block paving will not be permitted for the temporary reinstatement of asphalt roads.
3. Non-Disruptive Works
Standard procedures for N.O.C to be followed, including submission of sub-contractor details

and method statement to RTA and the taking of initial levels prior to commencement of the
works and final levels after 6 months or towards the end of the contract. A suitable format
showing the status of levels and level difference is to be submitted to Roads & Transport
Authority through the Consultant. Full details regarding location of NDRC to be put on the
Levels Format. N.O.C’s for dual carriage ways will be issued initially for the purpose of
establishing Thrust/Reception pits, appointment of sub-contractor, soil test etc., final NOC to
carry out the work will be issued upon the receipt of particular method statement for the
location, recommended by the Consultant.
Thrust boring activities or any other non disruptive/trench less works (ND/TL) as referred in
Article 8 of Administrative Order No.16 shall be carried out under the following standard
conditions of NOC's for thrust bore or ND/TL across any road. Additional specific condition
may be laid down for a particular road when the NOC is granted, depending on usage.
a) Excavation for access/reception pit shall be carried within caisson/sheet piles driven to
a toe depth of 0.25 H or lesser depth as supported by calculations. Caissons/sheet pile
shall be placed at a minimum offset of 5m from the edge of any asphalt pavement or
as specified in the NOC.
b) The excavations must be well guarded by crash barriers, barricades, cones, and tapes,
flashing lights as directed by Roads & Transport Authority and Dubai Traffic Police from
time to time.
c) Break tank must be provided in discharge line to monitor silt migration during any
dewatering. If silt is observed, the dewatering operation must be stopped immediately.
d) The road levels must be recorded at thrust bore or ND/TL across the asphalt surface
shall be taken at 2m intervals upto 20 m on either side along each lane divider line.
ND/TL works along the asphalt surface shall be taken along the centre line as well as
along 2 m grid on either side up to 4 m width in longitudinal direction at 2m spot
intervals to the full length in transverse direction. The record of initial levels to be
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submitted to Roads & Transport Authority as initial reference in an approved format and
prior to any dewatering work. All levels to be recorded druing 2300 hours 0600 hours
and no lane closure will be permitted during the day time. Roads & Transport Authority
Traffic Unit and Police must approve the traffic diversion for levels before any work is
carried out. The points where initial and subsequent levels are to be taken should be
fixed with Hilti type nails for repeatability. Surface paint, chalk or other marks are not
acceptable.
Any subsidence of soil or road structure shall be immediately brought to the notice of
Roads & Transport Authority and all operations must be immediately stopped until such
time as full extent of damage is determined.
The levels on predetermined points must be jointly observed every alternative day to
determine subsidence (if any) up to the end of dewatering. The final levels shall be
taken jointly with Consultant and Roads & Transport Authority representatives at three
months from the date of removal of dewatering lines or as directed by Roads &
Transport Authority. A report on final levels shall be submitted through Consultant to
Roads & Transport Authority not later than 2 weeks from the date of final level.
e) The pipe jacking method shall be such that the steel sleeve must at all the times have a
1 m plug of soil in the pipe and no occasion unsupported advance bore excavation to
be carried out.
f) The access and reception pit areas must be fully lit during nighttime, and noise and dust
pollution is kept to minimum to avoid disturbance to local residents.
g) In the event of damage to roads, service or adjacent structures that may occur due to
the thrust bore or ND/TL operations, the entire repairs and compensation will be to
Contractor's account. The reinstatement shall be carried out as per method statement to
be agreed with and executed to the approval of Roads & Transport Authority.
h) NOC approval is subject to approval by Traffic Engineering Department of Dubai Police

as well as Dubai Municipality Roads Department.
4. An initial list of existing signs in the project area should be prepared and verified with the
inventory drawings (available with Dubai Municipality Roads Department, Traffic and
Transportation Unit) by the Contractor together with Consultant and the list shall be
forwarded to Dubai Municipality Roads Department with photographs, location plan, etc.,
within two weeks from the date of commencement of work. All signs removed by the
Contractor are to be transported to site stores and protected carefully for reuse.
If deteriorated or damaged conditions are not reported, it will be assumed that an item was in
good condition prior to commencement of the works.
The contractor should advise of any damage by others during the course of the contract so
that DM can inspect and verify at the time.
Existing signs shall be individually referenced and must be returned to their original location.
Referencing shall be in the form of 3 sets of numbers as follows:
Community No.
Road No.
Sign No.
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5. The Contractor shall make sufficient provision for pedestrians across or around the site
during the progress of work to the approval of Roads & Transport Authority.
6. Asphalt cutting programme showing locations where diversion in progress of the project area
shall be submitted to Roads & Transport Authority at monthly intervals upon the request by
Roads & Transport Authority. Asphalt reinstatement information shall be submitted in an
approved format three days prior to the asphalt work to Roads & Transport Authority.
NOC schedule indicating the NOC reference, date of issue, proposed

commencement/completion, actual commencement/ completion and location map showing
the status of work on project area (including the cases for NOC obtained works not started)
shall be submitted after one month from the date of commencement of work and thereafter
an update at fortnight interval should be submitted to Roads & Transport Authority.
7. Among other items, the Contractor shall use the following checklist in order to satisfy the
Consultant/Roads & Transport Authority during the reinstatement work inspection.
a) Whether new asphalt has been laid to correct gradient, line and length.
b) The cutting and sealing of joints between old and new surface layer.
c) Workmanship in general in the work area.
d) If any M.H. exist in the work area, the cover levels in relation to road levels and distress
around the M.H.
e) Quality and quantity of road signs, location as per traffic inventory. Traffic sign post to
be painted to full length irrespective of the extent of damage. Replacement of traffic
signs if damaged or beyond repairable limit.
f) Kerbs, footpath edgings, footpaths and paved areas whether those units are of same
texture, colour and type confirming (as nearly as possible) to those being replaced.
g) General site cleaning, removal of broken pipes and other construction materials from
the road corridor.
h) Set of alignment and material approval taken from DM and Consultant for the use in the
road works.
i) Test results of in-situ tests and asphalt tests carried out by Dubai Central Laboratory
(DCL) and Consultants at selected locations.
8. Following Standard Procedures shall be followed for obtaining Roads & Transport Authority.
Services Co-ordination Offices (SCO) N.O.C. for project completion:
a) Service authorities DEWA-ED & WD, Etisalat & Roadt Lighthing Section etc. NOC's
shall be produced before the issue of SCO, N.O.C.
b) On completion of reinstatement works of roads and road furniture (traffic signs etc;) by
the Contractor, the Consultant shall inspect it and issue a list of snags, if any, to be
attended by the Contractor within 4 weeks time.
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c) The Consultant shall also inspect and check the complete reinstatement of all road
furniture and traffic sign inventory as to whether these are of same quality and correct
quantity existed before the commencement of project.
d) Once the snags such as road settlement, defects etc., are rectified by the Contractor,
the Consultant shall re inspect and issue a letter to Roads & Transport Authority.,
through DM Drainage and Irrigation Dept. for inspection.
e) If any further snags are found during Roads & Transport Authority Inspection,
Contractor should complete the snags within 4 weeks from the date of substantial
completion. In the event the Contractor fails to complete the snags within the
aforementioned period then the maintenance period for such works will be accounted
from the date of actual completion of work and not from the date of substantial
completion.
The Roads & Transport Authority NOC for substantial completion will be issued only
after the completion of reinstatement and snags, in all respects.
f) During defects liability period, the defects shall be followed up by usual procedures.
Final inspection for the issue of end of Maintenance Certificate on works connected with
Roads & Transport Authority will be made on receipt of the notification from the
Consultant.
g) The defect liability period for road related works would be one year from the date of
issuing Roads & Transport Authority NOC for completion. Contractor shall submit their
application for end of maintenance NOC from Roads & Transport Authority 6 weeks
before the expiry of defects liability period defined above.
h) In the event the Contractor does not complete the work within the NOC validity period
he may apply for approval of NOC revalidation. Such applications shall be submitted in
the prescribed form and the format as approved by the SCO.
9. Road cutting in main roads and busy areas will be permitted only when it is reasonably
proved that non-disruptive crossing of the road is not possible. In main roads and busy areas
the Contractor should be prepared to work either during night or off-peak day depending on
the traffic volume of the road. In local roads the Contractor shall only occupy half the width of
the road and a full closure of the road should be avoided. In case of a full closure the
Contractor must make alternate access arrangements.
The Roads & Transport Authority and Dubai Traffic Police before the actual commencement
of the work must approve all necessary diversions and access arrangements. The Contractor
should submit the actual sequence of the work. All traffic signs that will be used for
temporary diversions shall be of approved quality. Contractor shall maintain the diversion to
the satisfaction of Roads & Transport Authority. An NOC must be obtained from Roads
Lighting Section prior to implementation of any traffic diversion adjacent to traffic signals.
The Contractor should follow the following guidelines to submit the diversion proposal for
approval: -
a) Diversion drawings should be according to the Dubai Municipality standard diversion

drawings, showing, road markings, cones, flashing lights, crash barriers, and distance
radii of curves and information signs if any.
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b) Alternative vehicular and pedestrian accesses and circulation should be highlighted on
the drawing.
c) Drawings should be submitted in triplicate showing the existing road and diversion in
different colours.
d) A location map to be attached.
e) A cross section with dimension of the diversion and construction make up of diversion
road shall be shown on the diversion drawing itself.
f) Date, time and stages of diversion to be written on each drawing.
g) Revolving and floodlights to be provided at sharp curves and areas where there are no
streetlights exist.
h) A summary of total number of cones and details of flashing lights, signs, information
signs, distance of the diversion, access to plots/residence, other equipment used for
diversion to be mentioned.
i) All the above details (item a to g) to be furnished with a covering letter from the
Contractor and drawings duly signed by the Consultant and the Dubai Municipality
Liaison Engineer, if applicable. Minimum of 4 working days time required processing the
application for diversion proposal.
j) Any missing details mentioned above will cause delay in approval.
k) Any revised drawing should be submitted for re-approval with drawing showing revision.
l) All temporary signs must –

be of correct size
be fixed at correct height, 1400mm to the bottom of the sign.
be reflective
be fixed vertically
be fixed firmly in an acceptable manner
have wording in both Arabic and English
state where the diversion is to
be constantly monitored and maintained
10. In the event of Contractor fails to provide or maintain the diversions for roads and services
according to the requirements of Traffic Police and Roads & Transport Authority, Traffic and
Transportation Unit after written notification by the Engineer or Engineer's representative
then the Employer shall be entitled to employ other persons to carry out the required works
and all expenses consequent thereon or incidental thereto shall be recoverable directly from
the Contractor or may be deducted by the employer from any monies due or which may
become due to the Contractor.
Furthermore, the Contractor shall pay as per Local Order No.84/93 for the delay in opening
the diversion and/or Dhs.10.000 per each day delayed for dual carraige ways Dhs.5000 per
each day delayed for local roads.
11. All road and road related works including reinstatement of kerbs, road markings etc, shall be
carried out by a Road Contractor having prior approval from Roads & Transport Authority.
12. Diesel spills areas and damages caused by shovel teeth in carriageways shall be cut out and
reinstated by the Contractor free of cost to Dubai Municipality. Where asphalt patch
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reinstatements are required, the Consultant and Dubai Municipality Roads Department shall
approve the area of cutting.
13. Contractor shall take pre construction photographs together with Consultant to show the
existing condition of roads, footpath, kerbs, road signs and other road furniture. One set of
such photographs shall be made available at the Consultant's site office for the use of
Consultant and Roads & Transport Authority's representatives. Surfaces, which are settled,
damaged, deteriorated, etc., if any shall be brought to the attention of Roads & Transport
Authority on case by case basis.
14. In each case where sewer or storm water drainage lines are laid on one side of a dual
carriageway then the "total width of carriageway" shall be considered as width of one side
measured from the median to the edge of asphalt.
a) In each case where an existing asphalt carriageway is cut and removed on either side
for laying sewer and storm water drainage lines and by which if the remaining width of
the asphalt is less than 60% of the full width of the carriageway, then the remaining
portion of asphalt to be removed and new construction shall be carried out to the full
width of carriageway together with footpath (if existed), kerb stone and hard shoulder.
Refer Sketch I.
b) In each case where an existing asphalt carriageway is cut on either side in two stages
for laying sewer and storm water damage lines and by which if the width of the
undisturbed asphalt is less than 60% of the full width of the carriageway then during
second stage reinstatement of asphalt the undisturbed asphalt should also be removed
and reinstatement extended up to the line of first stage reinstatement so as to form a
single longitudinal joint. Refer Sketch II.
c) In each case where the sewer or storm water drainage lines are laid only on one side
of an existing asphalt carriageway and by which if the disturbed width of the asphalt is
equal or more than 60% of the carriageway then new construction of full width of the
carriageway is required. Refer Sketch III.
15. AMENDMENTS FOR ADMINISTRATIVE ORDER NO.16 & 22 APPLICABLE FOR

DRAINAGE PROJECTS
i. ARTICLE 5 OF ADMINISTRATIVE ORDER NO.16 AND AS AMENDED IN ARTICLE 1 OF
ADMINISTRATIVE ORDER NO.22.
Reinstatement works referred in Article 5 of Administrative Order No. 16 and as amended in

Article 1 of Administrative Order No. 22 shall be carried out as clarified below: -
The reinstatement works should be carried out by the Contractor "one time" and " as
permanent" basis as per the details given in Appendix 1 under the final reinstatement of the
Administrative Order No.16 and Appendix 1 Amendment of Administrative Order No.22.
In the event of any depression or other distress in and around the reinstated locations at the
end of the defects, liability period, it will be considered as defective workmanship and the
Contractor will redo the reinstatements at his own cost.
ii. ARTICLE NO. 6.5 OF ADMINISTRATIVE ORDER NO.16 WHICH IS REPLACED BY
ARTICLE NO. 3 OF ADMINISTRATIVE ORDER NO.22 IS AMENDED AS FOLLOWS:
Roads which are reinstated "one time" and "as permanent" basis in accordance with
description in item 13(a), should be inspected by the Consultant during substantial
completion stage and at the end of defects liability period.
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The Consultant shall issue a list of snags, if any, to be attended by the Contractor within a
specified period. Also Consultant will certify as to the satisfactory completion of the
reinstatement works for the final approval of Roads & Transport Authority.
iii. ARTICLE 6.3 OF ADMINISTRATIVE ORDER NO. 16
2nd line deletes "temporary".
iv. ARTICLE 17.0 OF ADMINISTRATIVE ORDER NO. 16
a. Article 17.1.1 first line delete "Temporary" add "of” after "Reinstatement".
b. Article 17.2.1 fifth line delete "with temporary reinstatement" after "for" 6th line, 7th
line and 8th line - delete completely. Add after "requirements for " the following "final
reinstatement shall be carried out "one time" reinstatement as permanent basis.
c. Article 17.2.2 second line delete "temporary" add "One time".
d. Article 17.3 Permanent Reinstatement - deleted.
e. Article 17.5.1 - Fourth and Fifth Line
Delete: "as nearly as possible to those adjacent".
Add in Fourth Line after "Conforming"-"to details shown in the attached typical
construction sheets no. SCU-1&2-93 and to the approval of Roads & Transport
Authority.
f. Article 17.5.2 - Deleted.
g. Appendix 1 of Administrative Order No.16, Sheet 1 and 2.
Delete "Temporary Reinstatement" column and details given below:-
Under column "Final Reinstatement" delete word "Final". Add "One time". Second line
"To be carried out by Dubai Municipality" delete "Dubai Municipality" Add
"Contractor".
h. Appendix 2 of Administrative Order No.16 - Clause 6.1.3b - 12th line delete 20%, add
25%.
i. Article 6 of Administrative Order No.22 - 6th line add " and Engineers" after "Roads
Inspectors".
j. Article 7 of Administrative Order No.22 - 4th line delete "temporary".
k. Article 11.2.3 of Administrative Order No.22. Add Roads & Transport Authority’s prior
express approval should be obtained in the case of stepped excavation in the
carriageway.
16. Administrative Order No.372 of 1993 issued on 9th August, 1993 the Local Order 84/93 on
the adjustment of some of the provisions of Local Order No.21/81 some of the provisions of
Local Order No. 21/81 regarding the laying services lines through road corridors in the
Emirates of Dubai is applicable to this contract in addition to other existing Local Others,
Administrative Orders, Dubai Municipality standard requirements and regulation.
17. a. In the event of an existing Subkha road being excavated for laying
Sewerage/Drainage pipe lines, the Contractor shall provide alternate access route to
the approval of Roads & Transport Authority and subkha road shall be reinstated on
the basis of “as found” condition.
b. Existing Subkha access roads shall be frequently maintained by the Contractor, to
the approval of Roads & Transport Authority, at locations where damages may be
caused by the movement of Contractor's Vehicles, Machinery, Equipment, etc.
18. Forms ERC 1 and ERC 2, as per the format and guidance notes included at the end of this
Section shall be used during the execution of the project.
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19. The contractor should provide temporary signals to approvals in the traffic diverted corridor
where requested by Roads & Transport Authority.
20. Where there is a need arises for reinstatement of existing cast in-situ flush kerbs/ upstand
kerbs, it shall be done with pre cast concrete kerb as per details shown in the drawing.
21. Generally throughout the site excavations in the road corridors the trench shall have sand
bag protection (or as approved by Roads & Transport Authority.) at least to the height of the
cones. Along main access and other dual carriageways the sandbags shall be two rows to
cone height in addition to "jersey barriers" as required.
The work area in the residential side shall be completely cordoned off with approved type
barricades.
Refer sketches IV, V, VI for more details for minimum safety protection required at site.
22. 22. Grouting across dual carriageways shall be carried out subject to following:
(a) Method statement to approval of Roads & Transport Authority.
(b) Grouting to be controlled by a pressure device and monitored by the consultant
throughout the grouting operation.
(c) Grouting to be continuously done without any lapse of time.
23. 23. Alternative material for backfilling in road corridor shall be used only after
obtaining prior approval from Roads & Transport Authority.- SCO.
24. 24. Damage caused to an existing structure and/or under ground services resulted from
the contractors work either directly or indirectly shall be rectified to the approval of SCO. The
contractor and/or consultant shall prepare and submit a “Service Damage Report” to SCO
within one week from the occurrence of the damage. The damage report shall consist the
details of the following elements.
a. Report of failure analysis, conclusion and recommendation.

b. Detail report the damage
c. Contractor’s method statement of work where damage occurred.
d. Soil Test Reports
e. In-situ density test report
f. Technical data of the used material.
g. Contractor’s method statement for repair, if applicable
h. Plans, Cross Sections & Sketches.
i. Copies of NOC’s & Photographs
j. Minutes of Meeting, if any
k. Any other relevant information.
25. Outstanding reinstatement works in the road corridor shall not be construed as snags and
should be completed before the substantial completion certificate is issued. Failure to do so
will be treated, as violation to administrative orders No: 372/93 for each location and issue of
completion certificate will be delayed.
26. The contents of this section relationg to Road works will supersede any other specifications,
details, drawings, notes indicated elsewhere covering the road works, road furniture etc.
27. Contractor's attention is drawn to items 18.2 & 18.3 of Article 18 of Administrative Order 16
for 1987 for the reinstatement of footpaths and Paved areas.
28. Improved sub grade material ("subkha" - CBR > 30%) shall be compacted to Ninety-Eight
(98) percent of the maximum dry density.
29. Dewatering crossings shall be laid permanently with uPVC ducts, duct markers at location
when requested by Roads & Transport Authority.
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30. Prior to implementation of any traffic diversions adjacent to the traffic signals, Roads Lighting
Section NOC should be obtained.
31. The reinstatement work shall be carried out to suit the Roads Classification issued by the
Roads Department or as per existing condition found at the site, whichever is higher in
quality and in thickness to and the approval of Services Coordination Office.
32. Safety inspection covering the project area shall be carried out jointly by the Contractor and
Consultant at least once a week during day and night inspection shall be weekly/fortnightly.
At the end of the inspection Consultant shall issue Safety Report with copies to SCO in an
approved format for Contractor’s immediate compliance or within a week depending on the
situation. The consultant will again inpsect the site following week and issue comments for
the week and also check the previous week’s comments. If the contractor had not attended
to the previous comments even after one week, it will be recorded in the safety report for the
current week and consultant shall advice SCO accordingly. Action as per Local Order 84/93
will be taken for non compliance.
33. Copies of approved N.O.C’s and its attachments shall be kept at the place of work for house
connection and miscellaneous contract works.
34. Removal of debris, excavated materials and site cleaning shall be done once a week in the
project area as per Circular no.10/2000 issued on 26th January 2000.
35. All excavations within or adjacent to existing road less than 5 years old (calculated from the
end of the defects liability period of the road project under which the road was constructed)
shall be supported by close trench sheeting pre-driven into the ground instead of stepped
open trench excavation in order to avoid causing damages to the new asphalt surface. The
above condition shall also be applied to all excavations within or adjacent to road having
right of way width equal or more than 30.0 m, irrespective of the age of the road.
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SECTION 2 - SITE CLEARANCE AND EARTHWORKS
2/1 SITE CLEARANCE DESCRIPTION
2/1.1 This work shall consist of the removal, wholly or in part, and satisfactory disposal of all
buildings, fences, structures, abandoned pipelines, and any other obstruction which
are not designated or permitted to remain. It shall also include the salvaging of
designated materials and backfilling the resulting trenches, holes and pits.
2/2 SURVEY BEFORE COMMENCEMENT
2/2.1 Prior to starting the site clearance, the Contractor shall carry out a thorough survey of
buildings, structures, fences, trees, etc.. that are to be removed. The Engineer shall
be fully informed of the results of this survey and the amount and extent of the
demolition and site clearance shall then be agreed with the Engineer.
2/3 DEMOLITION REQUIREMENTS
2/3.1 The Contractor shall in a careful manner, raze, remove and dispose of all buildings
and foundation structures, fences and other obstructions or any portions of which are
within the right-of-way, except utilities and those for which other provisions have
been made for removal. All designated salvageable material shall be removed,
without unnecessary damage, in sections or pieces which may be readily transported,
and shall be stored by the Contractor at specified places within the project limits or at
designated storage areas as directed by the Engineer. All such salvageable material
shall be deemed the property of the Employer.
2/3.2 Foundations of building structures shall generally be removed to a depth of 1 m below

ground level or more if considered necessary by the Engineer.
2/3.3 Where shown on the drawings or where directed by the Engineer, underground
structures, culverts, chambers and foundations other than building foundations shall
be removed to such a level as may be indicated on the drawings or directed by the
Engineer.
2/3.4 Where directed by the Engineer, the Contractor shall excavate in trench and break
out redundant pipe ducts and surrounds. Where pipes are to be removed and either
salvaged or relaid they shall be carefully removed and every precaution taken to avoid
breaking or damaging the pipe. The pipes shall be stored when necessary so that
there will be no loss or damage before relaying. The Contractor will be required to
replace sections lost from storage or damage by negligence or by the use of improper
methods in their removal.
2/3.5 Trenches and pits resulting from demolition and site clearance below ground level
shall be properly cleaned out (including pumping) and filled with suitable material and
compacted in accordance with the relevant Specifications up to subgrade level or as
otherwise directed by the Engineer.
2/3.6 Where required, the Contractor shall be responsible, prior to demolition, for the
disconnection of all services and clearance from the Dubai Municipality and all
Service Authorities.
2/4 GENERAL SITE CLEARANCE
2/4.1 Before commencing any excavation or fill, the area shall be cleared of all trees,
stumps, roots, bushes, vegetation, debris, materials or other obstructions.
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2/4.2 Before removal of any trees or shrubs the Contractor shall obtain written consent from
Dubai Municipality Horticultural Section at least two weeks in advance of the planned
removal.
2/4.3 The Engineer's approval of any removal of trees and undergrowth must be obtained
before commencement of work. Where directed all bushes, undergrowth, etc. shall be
grubbed up and burnt or otherwise disposed of in tips off site (Sub section 2/8). Holes
left by stumps or roots shall, within one week, be filled with suitable material,
compacted to the Engineer's satisfaction in accordance with Specification Clause
2/17.
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS
2/5.1 Attention is directed to the Contractor's obligations under law and under this Contract
with regard to damage, particularly with regard to protection of property, plants and
landscape and to responsibility for damage claims.
2/5.2 Existing highways, improvements, facilities, adjacent property, services, and trees and
plants designated for preservation shall be protected from injury or damage which
could result from the Contractor's operations.
2/5.3 The form of protection for vegetation within the site shall be of a type and standard
approved by the Dubai Municipality Horticultural Section.
2/6 ROAD SIGNS
2/6.1 All existing road signs, street name plates and the like affected by the works are to be
carefully taken down and stored. Signs to be re-erected shall be cleaned, provided
with new fixings where necessary and the posts re-painted in accordance with the
Specifications. Redundant signs shall be transported to the stores or depots of
relevant Authorities. Any sign, street name plate or the like damaged by the
Contractor during his operation shall be repaired or replaced at the Contractor's cost.
2/7 DISPOSAL OF HISTORICAL ARTIFACTS
2/7.1 Where specified, certain materials arising from the site clearance and excavation are
to remain the property of the Employer. All fossils, antiquities and other objects of
interest or value which may be found or uncovered on the site shall remain or become
the property of the Employer and upon discovery of such an object the Contractor
shall forthwith:
a. Use his best endeavours not to disturb or damage the object;
b. Cease work which would endanger the object or prevent or impede its
removal;
c. Inform the Engineer of the discovery and precise location of the object;
2/7.2 The Engineer will issue instructions on the procedure to be adopted which may
include conditions to permit the examination, excavation or removal of the object by a
third party.
2/8 DISPOSAL OF SURPLUS MATERIAL
2/8.1 Subject to the provision of Clause 27.1 of the Conditions of Contract Part I and of the
Specification, all materials arising from site clearance which are surplus to or
unsuitable for use in the Works shall become the property of the Contractor and shall
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be disposed of by him either off the Site to an approved tip or if directed or otherwise
agreed by the Engineer on the Site in an approved manner.
2/8.2 Following consultation with Dubai Municipality Public Health Department and in
conformance to the Clause 2/13.3 of the Specification the Contractor shall propose
two sites for disposal of unsuitable or surplus material, one of which shall be specified
as having priority and which must be filled before the second is used, together with a
separate location where hard debris, such as concrete, building rubble, kerbing, road
pavement, etc.. shall be disposed of. The Contractor shall seek approval for all the
proposed sites from RTA/ Dubai Municipality before work commences and disposal at
such sites shall be at no extra cost to the Employer.
2/9 EXCAVATION FOR ROAD CONSTRUCTION
2/9.1 This work shall consist of excavating the roadway and borrow pits, removing and
satisfactorily disposing of all materials taken from within the limits of the Work. It shall
include all dewatering, excavation, shaping and sloping as necessary for the
construction, preparation and completion of all embankments, cuttings, subgrade,
shoulders, slopes, gutters, intersections, approaches and private entrances, as
directed, and in conformity to the alignment, grades, and cross- sections shown on
the plans or established by the Engineer.
2/10 CLASSIFICATION OF EXCAVATION
2/10.1 Excavated material shall be classified as:
- Roadway Excavation.
- Borrow Excavation.
2/10.2 Roadway excavation includes all material of whatsoever nature, suitable or

unsuitable, excavated within the limits of the Right of Way for the preparation of the
road bed. All such material after deduction for material declared unsuitable by the
Engineer, shall be considered to be available for use at locations requiring fill.
Roadway excavation shall be sub-classified as Common Excavation and Rock
Excavation.
2/10.3 Authority to identify and define the physical characteristics which determine the
classification as "Common Excavation" and "Rock Excavation" in accordance with the
intent of the following provisions shall be vested in the Engineer.
2/10.4 Common Excavation - shall consist of the excavation and satisfactory disposal
(subject to Clause 2/15.3) of all soils, certain strata and rock boulders less than one
(1) cubic metre in volume. Strata which are altered and weathered and are in place,
but which are not firm enough, or in the opinion of the Engineer are not rigid enough
to have all the characteristics of rock excavation shall be classified as common
excavation.
2/10.5 Rock Excavation - shall consist of the excavation and satisfactory disposal (subject
to Clause 2.15/3) of all unaltered and unweathered firm and rigid igneous,
metamorphic and sedimentary solid rock that in the opinion of the Engineer can only
be excavated by the use of pneumatic hammers (if excavated by hand) or by bull
dozers of over 250 Horse Power equipped with ripper (if excavated mechanically).
2/10.6 Borrow Excavation
If the demand for fill material exceeds the quantity of suitable material obtained from
the necessary roadway excavation then suitable material shall be imported to the
2/3
work site from an approved borrow pit. The excavation, haulage and discharge of
material in its final place from a borrow pit shall be classified as Borrow Excavation.
2/11 EXCAVATION REQUIREMENTS
2/11.1 All materials removed from an excavation shall be used in the formation of the
embankment, shoulders and at such other places as directed, unless it is declared
unsuitable and ordered to be sent to tip by the Engineer. No excavated material shall
be wasted without written permission from the Engineer, and when such material is to
be wasted, it shall hauled to the approved tip (Clause 2/8) or as otherwise directed by
the Engineer.
Material suitable for top soil, base material, mineral aggregate or other specified
purpose, encountered in excavation, shall be reserved, if so directed, until it can be
placed in its proper position in the roadway. When specified or designated, top soil
shall be used as cover on embankment slopes to aid the regrowth of vegetation or
other purposes.
2/11.2 Excavated materials wasted by the Contractor without written permission of the
Engineer shall be replaced by the Contractor at his own expense.
2/11.3 During the construction of the roadway, the prepared formation shall be maintained in
such condition that it will be well drained at all times.
2/11.4 Rock, shale and other unsuitable material encountered in cuts shall be excavated to
the lateral limits and depth indicated on the plans or as otherwise directed. Any
overbreakage below the depth shown on the plans or as otherwise directed will not be
paid for. Backfill of the overbreakage shall be approved suitable material and shall
have the same density requirements as specified by the Contract and shall be at the
expense of the Contractor. If the backfill of the overbreakage area designated by the
Engineer is to be a crushed aggregate concrete or other special aggregate the entire
cost of the backfill of the overbreakage shall be at the expense of the Contractor.
Undrained pockets shall not be left in the surface of the rock, but they shall be treated
as directed by the Engineer.
2/11.5 All slopes, except in solid rock or other material which, in the judgment of the
Engineer, require a modified slope, shall be trimmed accurately to the slopes shown
on the cross-section drawings, and care must be exercised that no material shall be
loosened beyond the required slopes. Side ditches if required shall be excavated in
conformity to line, grade, and cross-section as shown on the Drawings or as directed
by the Engineer.
2/11.6 In cut areas, excavation shall be for the full construction width down to 'earthworks
formation level'. For a further depth of 15 cm the existing material shall be scarified,
watered as necessary, mixed and compacted to not less than 95% maximum dry
density as determined by BS 1377 Part 4 (Method 3.5 or 3.6) latest edition. Field
density shall be determined by BS 1377 Part 9 (Method 2.1 or 2.2) latest edition.
2/11.7 The 'improved subgrade layer', using specified imported material, shall then be placed
and compacted to 95% maximum dry density as determined by BS 1377 Part 4
(Method 3.5 or 3.6) latest edition to bring the embankment level up to 'top of improved
subgrade level'. Field density shall be determined by BS 1377 Part 9 (Method 2.1 or
2.2) latest edition.
2/11.8 For cuttings 1.5 metres or more in depth the technical requirements, of the
Specification for "Excavation for Structures" (Sub-Section 2/23) shall be complied
with.
2/4
2/11.9 Where excavation to the finished graded section, that is 'earthworks formation
level',results in a formation or slopes of unsuitable soil, the Engineer may require the
Contractor to remove the unsuitable material to a depth directed and backfill to the
finished graded section with approved material compacted in accordance with
specified requirements for embankment construction. The Contractor shall conduct
his operations in such a way that the necessary cross-sectional measurements can be
taken and agreed with the Engineer before the backfill is placed.
2/11.10 When the Contractor is required or directed to excavate unsuitable material in fill
areas, following general clearance of the area (see Specification Sub-Section 2/16
"Embankment Foundation"), the depth to which these unsuitable materials are to be
removed will be determined by the Engineer. The Contractor shall so schedule the
work so that authorised cross-sections can be taken before and after the material has
been removed.
2/11.11 All slopes, lines and grades shall be true, correct, and accurate and according to
those on the drawings or otherwise directed and approved by the Engineer. The
'earthworks formation level' in cuts shall be accurate to the authorised profile grade to
plus or minus two (2) centimetres and, for 'top of improved subgrade' level, plus or
minus one (1) centimetre. Where discrepancies are found in the Work the Contractor
shall make necessary corrections.
2/11.12 The Engineer will check all or any part of the Work, as he deems necessary, to
determine conformance to the lines, grades, elevations and cross-sections.
2/12 BORROW PIT SITE
2/12.1 The Contractor shall obtain approval from the Employer for the location of the
borrow pit site. The Contractor shall be responsible to determine the quantities
and quality of the available material in the approved borrow site to meet the
requirements of the Contract. When required the borrow area shall be cleared
and grubbed in accordance with the requirements of Section 2/1.
2/12.2 The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such
notice from the Employer, the Contractor shall immediately cease removing
material from said borrow site. In the event the Employer revokes approval of
the borrow site, the Contractor shall locate a new borrow pit site as specified
above.
2/12.3 The Contractor shall not claim any additional payment for any costs by reason
of the necessity of changing borrow site locations due either to the shortage of
the supply of borrow material available from the borrow pit site approved by the
Employer, or due to the Employer's decision to revoke approval of the borrow
site where the Contractor is obtaining borrow material for the Works.
2/12.4 The Contractor shall leave borrow pits in a condition acceptable to the Employer
and to the Engineer.
2/12.5 The Contractor will be solely responsible for ascertaining the location of such
approved borrow areas during the tender preparation stage. Locations,
distances to the work site and haulage from such approved borrow areas shall
be taken into consideration when preparing the unit tender price for Borrow
Excavation.
2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS

MATERIALS
2/5
The following definitions of earthwork materials shall apply:-
2/13.1 Top Soil shall be fertile, friable soil obtained from well drained arable land and
shall be free draining, non toxic and capable of sustaining healthy plant growth.
2/13.2 Suitable Material shall comprise all material that is acceptable in accordance
with the Contract and in conformity with Clause 2/13.4 of this Specification for
use in the Works. Suitable material for earthworks shall be approved soil with a
plasticity index not exceeding 6 obtained from excavations within the Works or
from borrow pits approved by the Engineer. It shall not contain an excess of
fines (not more than 20% passing Sieve Number 200 as per BS 1377:Part
3:Test Method 3) or in excess of 2% organic material (BS 1377 Part 3). Suitable
material for earthworks shall have a soaked CBR value at 95% maximum dry
density of not less than 15% when tested according to BS 1377 Part 4 latest
edition (method 7). The maximum particle size shall not exceed 63 mm.
2/13.3 Unsuitable Material shall comprise:-
- Rock particles exceeding 60 mm in size.
- Organic material (BS1377 Part 3 (method 3)) latest edition containing greater
than 2% (stumps and other perishable material).
- Material susceptible to spontaneous combustion.
- Soils of liquid limit (BS 1377 Part 2 (method 4.5)) latest edition exceeding 40%
and/or plasticity index exceeding 6 (BS 1377 Part 2 (method 5)).
- Material containing more than 5% of water soluble salts by weight of dry soil
as per BS 1377 Part 3 (Method 8) latest edition methods 7 & 5 for water
soluble chloride and sulphate respectively.
- Any other material which the Engineer may deem to be unsuitable for
earthworks.
2/13.4 Material for Improved Subgrade layer shall meet the following requirements:-
- Moisture content determination in accordance with BS 1377:Part 2:Test 3.2

latest edition.
- Not more than 20% by weight passing 75 micron to BS 1377:Part 2 latest

edition Clause 9.2.
- CBR value at 95% maximum dry density (soaked) BS 1377 Part 4 latest
edition (Method 3.5&3.6) not less than 30% when tested according to BS
1377 (Part 4 method 7) latest edition
A chemical analysis of the proposed material shall be carried out to satisfy the
following requirements:-
- The material shall be shown to have an acid soluble sulphate content of 2% or

less and a chloride content in the form of acid soluble chloride of 2% or less by
dry weight. The applicable Test methods should be in accordance with
BS1377 Part 3 (method 5) latest edition and BS 1377 Part 3 (Method 7) latest
edition respectively.
2/6
When approved by the Engineer a sulphate content greater than that specified
may be acceptable when the carbonate content is in the region of 30 - 40%(BS
1377 Part 3 (method 6)) latest edition.
Higher chloride contents may be tolerated provided that the ratio of (carbonate
+ sulphate) to chloride contents is maintained at approximately 15:1.
The moisture content of the compacted material shall not vary by more than +
3% of the optimum moisture content.
The material shall possess satisfactory binding characteristics to enable it to be

compacted to give a smooth well knit surface as judged by the Engineer.
2/13.5 No excavated suitable material shall be removed from the Site without the
Engineer's written permission. Should the Contractor be permitted to remove
suitable material from the site to suit his operational requirements, then he shall
make good any consequent deficit filling arising therefrom at his own expense.
2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION
2/14.1 The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in-situ state or during handling and
placing or in its final compacted state. Unsuitable or faulty plant shall be
removed from the work site and borrow pits at the order of the Engineer.
2/14.2 The plant and equipment used for earthworks construction shall be maintained
in good working condition for the duration of the works. The Contractor shall
apply adequate quantities of plant and equipment necessary for the proper
execution of the works in an expeditious manner.
2/14.3 Main plant and equipment shall meet the requirements outlined in Clause 1/29
of these Specifications.
2/15 EMBANKMENT CONSTRUCTION
2/15.1 This work shall consist of constructing roadway embankment with suitable
material, including the preparation of the areas upon which they are to be
placed and the placing and compacting of approved material within roadway
areas where unsuitable material has been removed. All operations will be
performed in accordance with the Specifications and in conformity with the lines,
grades, thickness and typical cross-sections shown on the drawings or as
established by the Engineer.
2/15.2 Compaction equipment shall conform to the number and type outlined in the
Contractor's detailed programme of work as approved by the Engineer and
satisfactory performance shall be the basis for such approval.
2/15.3 All materials derived from excavation shall be used in the embankment unless
otherwise declared unsuitable by the Engineer.
2/15.4 Prior to the commencement of embankment the Contractor shall construct trial
compaction lengths as directed by the Engineer. The soils used in the trials shall
be those encountered along the line of the road as approved by the Engineer
and/or those originating from the approved borrow pit. The object of the trials is
to determine the Field Compactibility of the material with the plant and
compaction equipment available with the Contractor. The Engineer may order
additional compaction trials when he deems them necessary.
2/7
2/15.5 During the construction of embankments the Contractor shall control and direct
construction traffic uniformly over the full width of the embankment. Damage to
compacted layers by construction traffic shall be made good by the Contractor
at his own expense.
2/15.6 The Contractor shall be responsible for the stability of all embankments and
shall replace all sections which, in the opinion of the Engineer, have been
damaged or displaced due to carelessness or neglect on the part of the
Contractor, or due to natural causes, such as storms, and not attributable to the
unavoidable movement of the natural ground upon which the embankment is
made. During construction, the roadway shall be kept shaped and drained at all
times. When unsuitable material has been placed in the embankment, its
removal shall be at the expense of the Contractor.
2/16 EMBANKMENT FOUNDATION
2/16.1 All debris, unsuitable material and vegetable matter shall be removed from the
surface upon which the embankment is to be placed and the cleared surface
shall be completely broken up by ploughing, scarifying or stepping to a minimum
depth of twenty (20) centimetres.
2/16.2 The foundation material shall be adjusted to a moisture content within the
moisture range of + 2% of the optimum moisture content and compacted to not
less than ninety-five (95) percent of the Maximum Dry Density as determined by
BS 1377 Part 4 (method 3.5 or 3.6) latest edition where the embankment is less
than one and a half (1.5 m) metres below subgrade; and compacted to not less
than ninety (90) percent where the embankment is more than one and a half
(1.5 m) metres below the subgrade.
2/16.3 If the original surface upon which the embankment is to be placed is an old
roadbed, the surface shall be ploughed scarified or broken up, regardless of the
height of the embankment to be placed and compacted to a density as
2/16.4 Where an embankment is to be placed on appreciably sloping ground, this

surface shall be benched in steps or trenched in accordance with the Engineer's
instructions, including if necessary any under-draining of the affected part of the
site.
2/16.5 In circumstances where backfill has to be deposited below standing water. In

such cases the Contractor shall use only an approved granular material of
maximum size not greater than 37.5 mm and which on analysis by sieving
complies with the requirements of Table 1 below. Such material shall have a
"ten percent fines" value of not less than 5 tonnes when tested in accordance
with BS 812 Part 111 latest edition and may be deposited below water without
the associated use of compaction plant.
TABLE 1 - FREE DRAINING MATERIAL
B.S.SIEVE SIZE % BY WEIGHT PASSING
10 mm Up to 100
5 mm Not more than 85
2/17 PLACING AND COMPACTION REQUIREMENTS
2/8
2/17.1 Only approved materials shall be used in the construction of embankments.
2/17.2 In the formation of the embankment it is strictly forbidden to push the excavated
materials from the side of the road to the embankment by means of bull dozers.
2/17.3 The fill material shall be delivered and spread in layers not exceeding 25 cm
compacted thickness. The layers of fill shall be graded, levelled, pulverised and
mixed, with water added as necessary, to ensure homogeneous conditions
through the full depth of the uncompacted layer. For field density testing refer to
specification sub-section 2/19.
2/17.4 The compacted density of the fill shall be equal to or greater than 95 (ninety-
five) percent of the Maximum Dry Density as determined by BS 1377 Part 4
(method 3.5 or 3.6) latest edition.
2/17.5 The material to be imported for the "improved subgrade layer" to be constructed
above "earthworks formation level" up to "top of improved subgrade" level as
shown on the drawings shall conform to the Specification Sub-Section 2/13
Para 4.
2/17.6 All slopes, lines and grades shall be true, correct, and accurate and according
to those shown on the Drawings or otherwise directed and approved by the
Engineer. The "earthworks formation level" in embankments shall be accurate to
the authorised profile grade to plus one (1) cm or minus two (2) centimeters
and, the 'top of improved subgrade' level, plus or minus one (1) centimetre for 3
locations maximum each 100 m interval. Selected material shall be placed
wherever required. Where discrepancies are found in the work the Contractor
shall make necessary corrections in a manner approved by the Engineer.
2/18 MOISTURE CONTROL REQUIREMENTS
2/18.1 When the moisture content of the embankment soil does not fall within + 2% of
the optimum moisture content, water shall be added and thoroughly mixed into
the soil, by approved methods or the material shall be aerated, whichever is
needed to adjust the soil to the proper moisture content.
2/18.2 The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide a moisture content in the soil
within the required range plus a reasonable amount to compensate for
evaporation and other unavoidable losses. Water added in excess of this
amount shall be considered as excess water and must be removed by aeration
or other suitable means as directed by the Engineer. Satisfactory methods and
sufficient equipment shall be used for the furnishing and handling of the water
so that there will be no undue loss due to evaporation or waste. If water is
added to cut areas or borrow pits, the surface of the areas or pits shall be
maintained in such a manner that will prevent undue loss of moisture and
segregation.
2/18.3 Use of saline water for earthworks will only be permitted if the percentage of
water soluble salts in the compacted fill does not exceed 3% by weight of dry
soil.
2/18.4 For subgrade material moisture range refer to sub-clause 2/13.4.
2/19 TESTING METHODS
2/9
2/19.1 A moisture-density test in accordance with BS 1377 Part 4 (method 3.5 or 3.6)
latest edition will be made for each type of soil to be used in the construction of
the work to determine the Maximum Dry Density, the Optimum Moisture Content
and the Moisture Range required of the soil for satisfactory compaction. The
Field Density and actual Moisture Content of the compacted embankment shall
be determined by field tests according to BS 1377 Part 9 (method 2.1 or 2.2)
latest edition.
2/20 MINIMUM TEST REQUIREMENTS
2/20.1 For the Contractor's general guidance, the following tests will be required prior
to use, and during the construction of the embankment and of the subgrade.
EMBANKMENT
2/20.2 Soil samples for Soil classification according to BS 1377:Part 1 latest edition,
laboratory moisture / density relationship tests and California Bearing Ratio shall
be taken prior to use, from any proposed source of material. Each sample shall
represent not more than 3,000 Cu.m.
2/20.3 For every completed layer of fill three field density tests shall be performed
every 2250 Sq.m. of carriageway or as otherwise directed by the Engineer.
2/20.4 The Contractor shall carry out any additional compaction tests as ordered by the
Engineer at no additional cost.
IMPROVED SUBGRADE
2/20.5 Samples for Soil classification, laboratory moisture density relationship tests
and CBR tests shall be taken prior to use, from any proposed source of
material. Each sample shall represent not more than 1,500 Cu.m.
2/20.6 For every completed layer of subgrade, three field density tests shall be
performed on every 1500 sq.m. of carriageway.
2/20.7 The frequency of field compaction tests on the shoulders shall be three every
1500 Sq.m. constructed or as directed by the Engineer.
ROCKFILL
2/20.8 Where embankments to be compacted are formed of material consisting

predominantly of rock fragments of such size that the material cannot be placed
in layers of the thickness prescribed without crushing, pulverizing or further
breaking down the pieces resulting from normal excavation methods, the
material may be placed in the embankment in layers not exceeding a thickness
twice the average size of the larger rocks, except that no layer shall exceed 600
mm of loose measurement.
Materials shall be carefully placed so that all large stones will be well distributed
and the voids completely filled with smaller earth, sand or gravel to form a solid
embankment. Each layer shall be bladed or levelled with motor grader, bull
dozer or similar equipment capable of shifting and forming the layer into a neat
and orderly condition. No. rocks larger than eighty (80) mm in any dimension
shall be placed in the top one hundred and fifty (150) mm of the embankment
unless otherwise noted on the drawings. Conformance to these provisions and
compaction in a manner and to a point of consolidation approved by the
Engineer will be considered as fulfillment of the requirements for the type of
compaction shown on the drawings. Normally, compaction tests will not be
2/10
performed in these areas but the Engineer reserves the right to test compaction
in some other manner if he deems a test necessary to ensure consolidation.
Each layer must be approved by the Engineer before the next layer is placed.
Embankments, which are formed of materials that contain rock but also
sufficient compatible material other than rock or other hard material to make
rolling feasible, shall be placed and compacted in the manner and to the point of
consolidation approved by the Engineer. Moisture shall be added as directed by
the Engineer. Compaction tests will be made wherever the Engineer determines
they are feasible and necessary. Each layer must be approved by the Engineer
before the next layer is placed.
2/21 STABILISING CRUSHED MATERIAL
2/21.1 In the event the foundation on which the embankment or the subgrade materials
will be laid is saturated by water and unstable, the Engineer may decide to lay
crushed granular material to stabilise the foundation. Stabilising crushed
material shall not be laid directly on ground soil but it shall always be laid on
geotextile fabric covering the area to be stabilised as shown on the drawings or
2/21.2 Such stabilising crushed material when tested in accordance with BS812
Section 103.1 Clause 7.3 shall have the following gradation:-
ASTM SIEVE % PASSING

2" 100
1" 80 - 100
1/2" 60 - 85
No.4 40 - 70
No.10 20 - 50
No.20 15 - 25
No.40 0 - 10
No.80 0 - 2
2/21.3 The stabilising crushed material shall have the following characteristics:-
- Los Angeles Abrasion - Not more than 30% loss

(ASTM C131/C535) (after 500 revolutions)
- Bulk Specific Gravity - Not less than 2.65

(ASTM C127)
- Absorption - Not more than 2.0%

(ASTM C127)
2/21.4 The stabilising crushed material will be laid in layers of 15 cm and compacted
until the foundation is fully stabilised such that the total thickness of the
stabilising layer shall not be less than 30 cm. Only after inspection and approval
by the Engineer the Contractor may be allowed to continue the construction of
the embankment with other layers of embankment material and/or subgrade
material. The Engineer may decide, after having taken the levels of the existing
water table in the area, and keeping in consideration the finished road levels, to
excavate portions of the foundation saturated by water, disposing of the
excavated material, and replacing it with stabilising crushed material.
2/11
1/21.5 Before starting any stabilising of the foundation the Engineer will instruct the
Contractor specifying the areas to be stabilised and the final levels to be
reached with the stabilising crushed material.
2/22 GEOTEXTILE FABRIC
2/22.1 In areas where the Engineer deems the use of geotextile fabric necessary, the
Contractor shall furnish and place geotextile fabric as specified and as directed
by the Engineer.
2/22.2 The geotextile fabric furnished by the Contractor shall be of an approved

grade suitable for placement over fine sand. The geotextile fabric shall be a
woven or non-woven fabric consisting only of long chain polymeric filaments or
yarns formed into a stable network such that the filaments or yarns retain their
relative position to each other. The fabric shall be stabilised against ultra violet
light, inert to commonly uncounted chemicals and chemical properties of the in-
situ soil and water, and it shall conform to the following minimum requirements:
Property Test Unit Min.Average

Method (metric) Roll Values
(140N)
Grab Tensile ASTM D lbs (kN) 120
Strength 4632
Grab Tensile ASTM D % 50

Elongation 4632
Mullen Burst ASTM D psi (kPa) 240 (1654)

Strength 3786
Puncture ASTM D lbs (kN) 70 (0.31)

Resistance 4833
Trapezoid Tear ASTM D lbs (kN) 50 (0.22)

Strength 4533
Permittivity ASTM D sec 1.5

4491
2
ASTM D gal/min/ft 120 (4903)
Flow Rate 4491 (1/min/m2)
2/22.3 The surface to receive the geotextile fabric shall be prepared to a relatively
smooth condition free of obtrusions, depressions, and debris. The geotextile
fabric shall not be laid in a stretched condition, but shall be laid loosely with the
long dimension parallel to the centreline of the roadway. In the event that the
width of the proposed area for fabric requires more than one panel width of
fabric, the panels shall be overlapped a minimum 15 percent of the panel width.
Longitudinal joints in the fabric shall have an overlap of 50cm. To prevent
slippage of the overlapping fabric, the areas of overlap shall be stabilized as
approved by the Engineer with pins, anchor blocks, or aggregate piles. In the
2/12
event construction machinery is used to place the fabric, the working platform
for the machinery shall be the soil and not the previously laid fabric.
2/22.4 Prior to placement of the granular material (Stabilizing crushed material) the
Contractor shall spread a layer of sand over the geotextile fabric as directed
by the Engineer. The aggregate material shall not be dumped directly on
the fabric, nor shall haul trucks be run on the fabric. The aggregate shall be
spread by a wheeled front-end loader.
The blade or bucket shall be kept sufficiently high so that the aggregate is not
being pulled over the fabric, but being dropped at a minimum height to the
2/22.5 Fabric damaged or displaced before or during installation or during placement of

overlaying aggregate material shall be replaced or repaired to the satisfaction of
the Engineer at the Contractor's expense.
2/23 EXCAVATION FOR STRUCTURES
2/23.1 This work shall consist of all excavation for structures, culverts, headwalls, catch
basins, manholes, inlets, and retaining walls and shall include all necessary
clearing and grubbing, all necessary bailing, drainage, pumping, sheeting,
strutting and the construction of coffer dams or cribs, if found necessary, and
their subsequent removal; also the disposal of all material obtained from such
excavation and backfilling to the level of the original ground; it shall include the
removal of that portion of existing structures below the ground which is
necessitated by the construction of the new structure.
2/23.2 Prior to commencing any structural excavation work 1.5 metres or more in
depth, the Contractor shall design and submit to the Engineer for review and
approval, within a minimum period of 1 week before the intended
commencement date, detailed working drawings of the structural excavation
support member materials, sizes, spacing and engineering calculations to
validate their design, including the maximum theoretical deflections of the
support members. The system shall be designed in such a manner that no raker
struts or any other support members extend through surfaces exposed in the
finished construction, and no shoring or bracing is placed under permanent
structures.
2/23.3 The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation and
removal and concrete placement, the anticipated equipment loads, surcharge
loads of any description, the maximum design loads to be carried by various
members of the support system and strut preload forces.
2/23.4 If the structure support system proposed includes tieback anchors, the
Contractor's submittal drawings shall show the profile of the soil in which each
anchor is to be installed, the design load for the full depth of the excavation, the
maximum design and proof loads, surcharge loads of any description;
equipment loads, forces at various stages, support during installation and
removal, and the criteria proposed for deformations under proof loads. Where a
proposed system of tieback anchors projects beyond the vertical projection of
the Contract limit lines shown on the Drawings on to the adjoining property, the
permission of the owner shall be obtained in writing and such permission
submitted to the Engineer at the time the shop drawings of the support systems
are submitted.
2/13
2/23.5 At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the hydrostatic
pressure and lower the ground water levels below excavation levels, as required
for the safe and proper execution of the work and which will result in obtaining a
stable, dry subgrade for the execution of subsequent operations. The
Contractor shall design dewatering methods and settling basins so that no
critical amounts of soil, sand or silt are removed during either the initial
operations or the construction operations. Complete working drawings showing
the type of dewatering and ground water control system proposed shall be
submitted to the Engineer for his review.
2/23.6 The Contractor's submittal drawings shall show the arrangement, location and
depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedures to be followed shall
be shown, together with the standby equipment, standby power supply and the
proposed location or locations of points of discharge of water. Any required
dewatering system design shall also include the measures taken to prevent
damage due to settlement of pavement, utilities, sewers, buildings and other
structures outside the excavation but within the area affected by the
procedures.
2/23.7 The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Professional
Engineer approved by the Engineer specialising in this type of design work.
Approval of the designs and shop drawings shall not relieve the Contractor of
the adequacy and performance of these temporary works.
2/23.8 Pre-Construction Inspection-prior to the beginning of construction, the

Contractor and the Engineer shall make a detailed inspection of all adjacent
buildings, pavements, wells and other structures in order to determine its pre-
construction condition and the Contractor shall prepare, for the Engineer's
approval, a typed Inspection report of the findings.
2/23.9 The Report shall include photographs, drawings and sketches with levels and
dimensions illustrating the structures condition, noting in particular any existing
damage or structural inadequacy. Deficiencies and damage shall be suitably
marked on the structure such that it is not permanently defaced.
2/23.10 Three copies of the Report shall be submitted for the approval of the Engineer.
Once approved, five additional copies shall be supplied to the Engineer.
2/23.11 The Contractor shall notify the Engineer sufficiently in advance of the beginning
of any excavation so that cross-sectional elevations and measurements may be
taken of the undisturbed ground. The natural ground adjacent to the structure
shall not be disturbed without the permission of the Engineer.
2/23.12 Trenches or foundation pits for structures or structure footings shall be

excavated to the lines and grades or elevations shown on the drawings, or as
ordered by the Engineer. They shall be of sufficient size to permit the placing of
structures or structure footings of the full width and length shown. The
elevations of the bottoms of footings, as shown on the Drawing shall be
considered as approximate only and the Engineer may order, in writing, such
changes in dimensions of elevations of footings as may be deemed necessary,
to ensure a satisfactory foundation.
2/23.13 Unless otherwise provided for in the Drawings or Contract Documents or

directed by the Engineer Structural excavation shall be carried out for a width of
at least 500 mm beyond the horizontal outside limits of the foundation, footing,
2/14
box culvert or structural member to which the excavation relates. Concrete
blinding or sub- foundations are not to be considered as structure for the
purpose of defining such excavation.
2/23.14 If during the progress of the work, loose or improperly compacted soil is
encountered below the structural foundation levels, or adjacent thereof, which is
the result of prior removal of utilities or structures, such material shall be
completely removed within the limits as directed by the Engineer, backfilled with
suitable material and compacted to 95% of the maximum dry density as
determined by BS 1377 Part 4 (method 3.5 or 3.6) latest edition. Any previous
excavations encountered which would in the opinion of the Engineer be
detrimental to load distribution of new foundations to the underlaying soil, shall
be excavated and backfilled with Class 25 concrete (clause 4/15).
2/23.15 After each excavation is completed, the Contractor shall notify the Engineer, for
approval of the depth of excavation and the character of the material, prior to
further structural works. Any over excavation shall be backfilled with Class 25
concrete (clause 4/15) at the Contractors expense.
2/23.16 All rock or other hard foundation material shall be cleaned of all loose material
and cut to a firm surface, either level, stepped, or serrated as directed by the
Engineer. All seams or crevices shall be cleaned and grouted. All loose and
disintegrated rock and thin strata shall be removed.
When the footing is to rest on material other than rock, excavation to final grade
shall not be made until just before the footing is to be placed and special care
shall be taken not to disturb the excavation. When the foundation material is
soft or otherwise unsuitable as determined by the Engineer, the Contractor shall
remove the unsuitable material and backfill with approved granular material.
This foundation fill shall be placed and compacted in 150mm layers up to the
foundation elevation and compacted to 95% of the maximum dry density as
determined by BS 1377 Part 4 (method 3.5 or 3.6) latest edition.
The placing of concrete shall follow as closely as practicable the structural

excavation.
2/23.17 Control of Ground Water - Prior to the commencement of construction at any

particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area which in
the opinion of the Engineer is likely to be affected by the dewatering. The
number, location and depth of all standpipes shall be to the satisfaction of the
Engineer.
- The Contractor shall check ground water levels at weekly or where instructed
by the Engineer, more frequent intervals and submit within 24 hours written
reports to the Engineer in a form to be agreed.
- In the case of uncontrolled flow of water into any excavation, the Engineer
reserves the right to order an immediate cessation of work and to order the
Contractor to take immediate action to control the inflow of water. Such
actions and remedial works shall be to the Engineer's approval.
2/23.18 Notification of Damage- The Contractor shall notify the Engineer immediately
of any movement or any damage not noted in the pre-construction report, to any
structure. The Contractor shall immediately cease his construction operations in
the vicinity and shall take immediate action to prevent further movement or
damage. The Contractor shall keep the Engineer fully informed of all such
action.
2/15
2/23.19 Remedial and Preventive Works- Should remedial works be necessary due
to damage caused to the structure or should the Engineer direct the contractor
to carry out any works necessary to prevent damage to the structure due to the
Contractor's construction works, the Contractor will present, without delay,
detailed drawings and specifications, as necessary, showing his proposed
remedial or preventive works for the Engineer's approval.
In either case the Contractor will suspend all construction activities in the vicinity
of the structure until such time as the remedial or preventive works are carried
out to the Engineer's satisfaction at the Contractor's expense.
2/23.20 Post Construction Inspection- On completion of, but prior to final acceptance
of the works, the Contractor and the Engineer shall re-examine the structure to
determine any change from the original conditions. The Contractor shall supply
to the Engineer for approval five copies of a report describing measures he
proposes to take to correct any damage which resulted from the construction of
the works. The approved corrective measures shall be carried out by the
Contractor at his expense, to the Engineer's satisfaction before final acceptance
of the works.
2/23.21 Utilisation of Excavated Materials- All excavated material determined as

suitable by the Engineer, shall be utilised as backfill or roadway fill. The surplus
material, shall be disposed of as specified in sub-section 2/8 para 2. Excavated
material shall not be deposited, at any time, so as to endanger the partly
finished structure or cause an obstruction of any kind. All unsuitable material
shall be disposed of to approved tips.
2/23.22 Backfill- Excavated areas around structures shall be backfilled with excavated
materials or imported granular material approved by the Engineer. Backfill
materials shall be placed in horizontal layers not exceeding 150mm in depth
after compaction to 95% of the maximum dry density as determined by BS 1377
Part 4 latest edition(Method 3.5 & 3.6). The field density shall be determined by
BS 1377 Part 9 latest edition(Method 2.1 or 2.2). Each layer of material shall be
moistened or dried as required to enable thorough compaction as specified.
Backfill shall be placed to the original ground level or as indicated on the
drawings.
2/23.23 Backfill or embankment shall not be placed behind the walls of concrete
structures or rigid frame structures until the top slab is placed and cured. Backfill
and embankment behind abutments when held at the top of the superstructure
shall be carried up simultaneously behind opposite abutments. Backfill shall be
carried up equally on either sides of box culverts.
2/23.24 For frequency of testing of backfill material refer to sub-section 2/20.
2/16
SECTION 3 - PAVEMENT CONSTRUCTION
3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS
3/1.1 All aggregates for use in the construction of the Pavement Layers shall be obtained only
from sources approved by the Engineer.
3/1.2 The contractor shall have determined the location, suitability and quantity of material
available before tendering as well as the cost and the amount of work required to
extract, crush, screen and clean the material and the length of haul to the job site.
3/1.3 The Contractor shall provide the Engineer, within thirty (30) days prior to the scheduled
beginning of the crushing and screening operations, with a complete report on the origin
and composition of all stone and/or gravel aggregates to be used in the Work
(Aggregate Resources Report). All materials shall comply with the specified
requirements for the various aggregates.
3/1.4 The source and manufacture of the aggregates which will meet the requirements of the
Specification is the sole responsibility of the Contractor. It is also the contractor's sole
responsibility to manufacture such aggregates at the rates and in the quantities required
to complete the work within the specified Contract Period.
3/1.5 The approval of the Contractor's crushing and screening plant equipment by the
Engineer shall in no way relieve the Contractor of the responsibility of producing
aggregates which meet the Specifications and in the quantities required for the
completion of the work within the specified Contract Period.
3/1.6 No aggregate producing equipment shall be put into operation prior to the approval of
the equipment by the Engineer. If after the equipment is put into operation it fails to
perform as proposed, the Contractor shall provide additional equipment or replace the
original equipment with more suitable equipment, as may be directed by the Engineer.
3/1.7 The Contractor shall commence crushing and screening of aggregate immediately after
the Contractor receives approval of his aggregate sources.
3/2 TESTING OF AGGREGATES
3/2.1 Testing to ascertain the properties of all aggregate materials shall be carried out in
accordance with Appendix 'A' given at the end of this volume of specifications.
3/3 APPROVAL AND INSPECTION OF AGGREGATES
3/3.1 All sources of aggregates shall be approved by the Engineer prior to the processing of
material from such sources. An individual source of aggregate is deemed to be a
particular location within a quarry or borrow pit where material of a constant specific
gravity is obtained (with possible variation due to minor changes in characteristics of
rock). Test certificates obtained by the Contractor or tests performed by the Contractor
at his expense are intended to assist him in his estimate of the location, extent and
quantities which will comply with the Specifications, when properly processed, and will in
no way obviate the need for future testing by the Engineer.
3/3.2 Only materials from approved sources shall be processed for incorporation into the
work. Approval of specific sources of materials shall not be considered as final approval
and acceptance of materials from such sources. The presence of weathered materials
discovered in the quarry areas shall be a cause of rejection of the source of materials.
3/1
3/3.3 After having received approval of specific sources of material the Contractor cannot
change these without prior written approval of the Engineer.
3/3.4 All processed materials shall be tested and approved before being stored on the site or
incorporated in the works and may be inspected and tested at any time during the
progress of their preparation and use. Questionable materials, pending laboratory
testing and subsequent approval shall not be unloaded and incorporated with materials
previously approved and accepted.
3/3.5 If the grading and quality of the material delivered to the site does not conform to the
grading and quality as previously inspected and tested, or does not comply with the
Specifications, the Engineer reserves the right to reject such material at the site of the
work.
3/3.6 Samples must meet all test requirements as specified under the Specifications. The
Contractor shall permit the Engineer to inspect any and all material used or to be used,
at any time during or after its preparation, or while being used during the process of the
work or after the work has been completed. All such materials not complying with the
required specifications, whether in place or not, shall be rejected and shall be removed
promptly from the work. The Contractor shall supply, or arrange with any producers or
manufacturers to supply, all necessary material, labour, tools and equipment for such
inspection.
3/4 STORAGE OF AGGREGATES
3/4.1 The stockpile site shall be prepared by clearing and smoothing and must be approved
by the Engineer. Prior to any stockpiling of aggregates, cross- sections of the stockpile
site shall be taken and control points established for use in determining the quantity of
subsequently stockpiled material.
3/4.2 The equipment and methods used for stockpiling aggregates and for removing
aggregates from the stockpiles must be approved by the Engineer and shall be such
that no segregation of the aggregate will result and no foreign material will contaminate
the aggregate.
3/4.3 Material shall be stored in a manner that will ensure preservation of their specified
quality and fitness for the work. They shall be placed on hard, clean surfaces and, when
required by the Engineer they shall be placed under cover. Stored materials shall be
located in such a manner to facilitate prompt inspection and control. Private property
shall not be used for storage purposes without written consent of the owner or lessee
and payment to him, if necessary, at the Contractor's expense.
3/4.4 The centre of the storage area shall be elevated and sloped to the sides in order to
provide proper drainage of excess moisture. The material shall be stored in such a way
to prevent segregation and to allow proper control of moisture. Aggregate stockpiles
shall be built up in layers not exceeding one (1) metre. The height of each stockpile,
shall be limited to a maximum of five (5) meters.
3/4.5 Sufficient material must be stored in stockpiles to allow for testing and approval of such
materials prior to use in the works.
3/5 TIDYING-UP OF QUARRY AREA
3/5.1 The Contractor shall tidy-up the quarry areas on completion and ensure that side-slopes
are not steeper than 1 to 2 and in a condition acceptable to the Employer and to the
Engineer.
3/2
3/6 GRANULAR SUB-BASE
3/6.1 DESCRIPTION
Granular sub-base shall consist of furnishing, spreading, and compacting sub-base in

accordance with the details shown on drawings and these Specifications.
3/6.2 MATERIALS
Granular sub-base material for Road sub-base shall consist of hard, durable
natural/screened gravel or crushed stone, and shall be free from clay balls or other
deleterious substances. Granular sub-base shall be well graded and lie within the
grading envelope stated below when tested in accordance with BS 812 Part 103 latest
edition Clause 7.3. The material should have a minimum C.B.R. of 30 % at 95 % of
maximum dry density and should comply with Clause 3/6.4. Organic impurities (BS 812:
Part 103 Section 103.1) shall not exceed 0.2%.
SIEVE SIZE PERCENTAGE PASSING

75 mm 100
37.5 mm 85 - 100
9.5 mm 40 - 85
4.75 mm 25 - 45
0.6 mm 8 - 25
0.075 mm 0 - 10
3/6.3 CONSTRUCTION
Road sub-base material shall be delivered to the roadbed as uniform mixture and shall
be spread in layers or windrows. Segregation shall be avoided and the sub-base shall
be free from pockets of coarse or fine materials.
Each road sub-base layer shall be spread by finisher and or grader or other approved
mechanical methods, watered, shaped to a compacted thickness not exceeding 150 mm
and compacted to the required grade and cross-section.
The compaction procedure and plant shall be to the satisfaction of the Engineer. At the
time of compaction the moisture content of the laid material shall not vary by more that +
2 % from the optimum moisture content.
The granular sub-base shall be compacted to not less than 95 % of the maximum
density determined in accordance with BS 1377 Part 4 latest edition Method 3.6. Particle
size analysis of soils for sieve analysis of fine and coarse aggregate shall be carried out
in accordance with BS 812 Part 103 Section 103.1 latest edition Clause 7.3. The surface
on completion of compaction shall be well closed, free from movement under
compaction plant and free from ridges cracks or loose material. The finished surfaces of
the road sub-base shall not vary at any point more than 10 mm above or below the
grade established by the Engineer. The road sub- base shall be maintained in a
condition satisfactory to receive any subsequent base or surfacing material. Sub-base
which does not conform to the above requirements shall be reshaped or reworked,
watered and thoroughly recompacted to conform to the specified requirements.
3/3
3/6.4 RELEVANT TEST AND STANDARDS
The following tests should be carried out and the material shall conform with the
requirements stated:
TEST STANDARD LIMIT

(Latest Edition)
Sampling ASTM D75 --
Los Angeles Abrasion ASTM C131/ 30 % max.

ASTM C535
Soundness (5 cycles)
(Magnesium Sulphate ASTM C88 12 % max.
Solution)
Liquid Limit BS 1377:PART 2 35 % max.

Latest Edition
Plasticity Index BS 1377:Part 2 6 max.

Latest Edition
Compaction Test BS 1377:Part 4 --

(Modified Proctor) Method 3.6
Latest Edition
C.B.R. at 95 % of BS 1377:Part 4 30 % min.
modified Test 7 Latest

Proctor density Edition
(96 hour soaked)
Field Density BS 1377:Part 9 95 % min.MDD

Latest Edition
Linear Shrinkage BS 1377:Part 2 3 % max.

Method 6.5
Latest Edition
Sulphate Content BS 812:Part 118 0.5 % max.

(Acid soluble) Latest Edition
Chloride Content BS 812:Part 117 1 % max.
3/4
(Acid soluble) Latest Edition
3/6.5 MINIMUM TEST REQUIREMENTS
One sample every 1,000 cu.m. shall be tested for Grading, Plasticity Index, Maximum
Dry Density, CBR and Loss by Abrasion, three in-situ Density tests shall be made for
every 1500 sq.m. of granular sub-base laidas per ASTM D979.
3/7 AGGREGATE ROADBASE DESCRIPTION
3/7.1 This work shall consist of furnishing and placing one or more courses of aggregate,
including binder soil if required, on a prepared subgrade or sub-base in accordance with
sub-section 3/8 to 3/13 of the Specifications, in conformity with the lines, grades,
thickness and typical cross-sections shown on the drawings or established by the
Engineer.
3/8 AGGREGATE ROADBASE MATERIAL
3/8.1 All aggregate roadbase material shall be free from dirt, shale or other deleterious matter
and shall be of such quality that it will bind readily to form a stable aggregate roadbase.
3/8.2 The requirements for aggregate roadbase are:-
Liquid Limit (BS 1377:Part 2:Test 4.5 25% maximum

Latest Edition)
Plasticity Index (BS 1377:Part 2:Test 5 6 maximum

Latest Edition)
Sand Equivalent (ASTM D2419) 40 minimum
Loss by Abrasion (ASTM C131/C535) 30% maximum
Flakiness Index (BS 812 Part 105.1) 35 maximum

Latest Edition (Coarse Aggregate)
Elongation Index (BS 812 Part 105.2) 35 maximum

Latest Edition (Coarse Aggregate)
Soundness (ASTM C88) 12% maximum

(Magnesium Sulphate)- 5 cycles
Organic Impurities (BS 1377: 0.2% maximum

Part 3:Method 3 Latest Edition)
Acid Soluble Chlorides (BS 812: 1% maximum

Part 117 Latest Edition)
(Combined Aggregate)
Acid Soluble Sulphates (BS 812: 0.5%

Part 118 Latest Edition)
(Combined Aggregate)
3/5
Maximum Dry Density (BS 1377: 2.20 Mg/m3 min.
Part 4 : Test 3.6 Latest Edition)
CBR on Remoulded Samples after 80% minimum

4 days soaking at 100% of the
maximum dry density (BS 1377
Part 4:Test 7 Latest Edition)
Sampling method in accordance with ASTM D75 for all tests.
Atleast three field density tests shall be carried out per unit as indicated in ASTM D979.
3/8.3 The gradation limits when tested in accordance with BS 812 Part 103 Section 103.1
Clause 7.3 shall be as follows:-
SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 70 - 100
28 mm 55 - 85
20 mm 50 - 80
10 mm 40 - 70
5 mm 30 - 60
2.36 mm 20 - 50
0.425 mm 10 - 30
0.075 mm 5 - 15
Aggregate roadbase shall consist of uniform mixtures of gravel and/or crushed gravel
with sand, silt and clay, conforming to the specified gradation limits.
3/9 SPREADING AGGREGATE ROADBASE
3/9.1 Aggregate roadbase shall be spread on subgrade or sub-base which has been
approved by the Engineer. Aggregate roadbase which has been placed on a subgrade
or sub-base not approved by the Engineer shall be removed at the Contract's expense.
3/9.2 Aggregate roadbase shall be spread on the approved subgrade in layers not exceeding
fifteen (15) centimeters in compacted depth.
3/9.3 The material shall be handled in a manner which avoids segregation. Segregated
materials shall be remixed until uniform. Suitable precautions shall be taken to prevent
rutting of the subgrade or sub-base during the spreading of aggregate road base
materials. No hauling or placement of material will be permitted when, in the judgment
of the Engineer, the weather or road conditions are such that the hauling operations will
cause cutting or rutting of the subgrade or cause contamination of aggregate roadbase
material.
3/10 COMPACTION OF AGGREGATE ROADBASE
3/6
3/10.1 The moisture content of the aggregate roadbase material shall be adjusted prior to
compaction, by watering with approved sprinkler trucks or by drying out, as directed by
the Engineer, to that required to obtain the specified density for aggregate roadbase.
Aggregate roadbase shall be compacted to Ninety Eight (98) percent of the maximum
dry density, as determined according to BS 1377:Part 4:Test 3.6 latest edition at a
moisture content between ± 2 % of the O.M.C. The field density and actual moisture
content shall be determined according to BS 1377:Part 9:Test 2.2 latest edition.
3/10.2 The aggregate roadbase shall be compacted by means of approved compaction

equipment progressing gradually from the outside of the road towards the centre with
each succeeding pass uniformly overlapping the previous pass. Rolling shall continue
until the entire thickness of each layer is thoroughly and uniformly compacted to the
specified density. Rolling shall be accompanied by sufficient blading in a manner
approved by the Engineer, to ensure a smooth surface free from ruts or ridges and
having the proper section and crown.
3/10.3 The surface of the material shall on completion of compaction be well closed, free from
movement under the compaction plant and free from compaction planes, ridges, cracks,
or loose material.
3/10.4 Any areas inaccessible to normal compaction equipment shall be compacted by means
of mechanical tampers until satisfactory compaction is obtained.
3/10.5 The Contractor shall program his operations to avoid the drying out of the sub-base
during construction. If any layer of aggregate roadbase material, or part thereof, is
permitted to dry out after compaction, or does not conform to the required density or
finish, the Contractor shall, at his own expense, rework, water and recompact the
material, as directed by the Engineer, to the density specified, before the next layer of
aggregate roadbase or subsequent pavement layers is placed.
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE
3/11.1 If directed by the Engineer, prior to the commencement of the aggregate roadbase
operations, the Contractor shall construct trial lengths not to exceed 250 meters. The
materials used in the trials shall be those approved for use as aggregate roadbase, and
the equipment used shall be that according to the Contractor's approved detailed
program of work.
3/11.2 Trial lengths may not form part of the permanent works but may be permitted in the
construction of temporary detours of sufficient length.
3/11.3 The object of these trials is to determine the adequacy of the Contractor's equipment,
the loose depth measurements necessary to result in the specified compact layers
depths, the field moisture content, and the relationship between the number of
compaction passes and the resulting density of the material.
3/11.4 The Contractor may proceed with the aggregate roadbase work only after the methods
and procedures established in the compaction trials have been approved by the
Engineer.
3/12 FINISHING OF AGGREGATE ROADBASE
3/12.1 Immediately prior to the placing of the first layer of the next pavement course on to the
aggregate roadbase the final layer of aggregate roadbase shall be at the specified
density and to the required grade and section. In order to maintain these requirements
while placing the next course it may be necessary to water and reshape the surface of
the aggregate roadbase. This work shall be at the Contractor's expense.
3/7
3/12.2 The surface of the finished aggregate roadbase will be tested with a three (3) metre
straightedge by the Engineer at selected locations. The variations of the surface from
the testing edge of the straight edge between any two (2) contacts with the surface shall
at no point exceed twelve (12) millimeters when placed on or parallel to the centreline, or
twelve (12) millimeters when placed perpendicular to the centreline of the roadway. The
aggregate cross section as shown on the drawings and shall not vary by more than ten
(10) millimeters from the required elevation. All humps and depressions and thickness
deficiencies exceeding the specified tolerance shall be corrected by removing the
defective work or by adding new material as directed by the Engineer.
3/13 MINIMUM TEST REQUIREMENT FOR AGGREGATE ROADBASE
3/13.1 One sample every 1,000 cu. m. shall be tested for Grading Plasticity Index, Sand
Equivalent, Maximum Dry Density, C.B.R. and Loss by Abrasion. Three in-situ Density
tests shall be made every 900 sq. m. of aggregate roadbase laid.
3/14 WET-MIX MACADAM ROADBASE, DESCRIPTION
3/14.1 This work shall consist of furnishing and placing one or more courses of high quality
crushed aggregate, bound by means of carefully controlled moisture content, on the
prepared subgrade or sub-base in conformity to the line, level and thickness shown on
the drawings or as directed by the Engineer.
3/15 WET-MIX MACADAM ROADBASE MATERIAL
3/15.1 The coarse aggregate shall consist of crushed rock (each particle shall have a minimum
of one crushed face - DM DCL Test Method DM 301) and the fine aggregate shall be
crushed rock or naturally occurring material. The aggregate shall conform to the
following gradation :
SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 95 - 100
20 mm 60 - 80
10 mm 40 - 60
5 mm 25 - 40
2.36 mm 15 - 30
0.6 mm 8 - 22
0.063 mm 2- 8
The particle size shall be determined in accordance with the requirements of BS 1377
Part 2 (Method 9.2 and 9.3) latest edition.
3/15.2 The gradation shall be adjusted as required or as directed by the Engineer within the
above limits to ensure the mix has adequate binding properties.
3/15.3 Wet-mix road-base material shall have physical properties which do not exceed the
following values :
Liquid Limit (BS 1377:Part 2:Test 4.5 25 %

Latest Edition)
Linear Shrinkage (BS 1377 Part 2 Method 6.5 3%

Latest Edition)
3/8
Plasticity Index (BS 1377:Part 2:Test 5 6
Latest Edition)
Aggregate Crushing Value (BS 812 Part 110 25 %

Latest Edtion)
Water Absorption (ASTM C127/C128) 2%
Flakiness Index (BS 812 Part 105.1 30

Latest Edition)
Elongation Index (BS 812 Part 105.2 30

Latest Edition)
Los Angeles Abrasion Loss (ASTM C131/C535) 30 %
Soundness Loss (ASTM C88) (Magnesium sulphate) 12 %

(after 5 cycles)
Organic Impurities (BS 1377 Part 3 0.2 %

Method 3 latest edition)
Chloride Content (Acid Soluble) BS 812:
Part 117 latest edition) 1% max
Sulphate Content (Acid Soluble) BS 812

Part 118 latest edition) 0.5 % max
The sand equivalent shall not be less than 45 (ASTM D2419).Sampling shall be in
accordance with ASTM D75.
3/15.4 The moisture content of the wet-mix macadam at the time of laying shall be the optimum
+ 1 %. Water required to achieve this moisture content shall be added at the mixing
plant.
3/16 TRANSPORT AND SPREADING WET-MIX MACADAM ROADBASE
3/16.1 Transport vehicles carrying the plant mixed material shall have a capacity suited to the
output of the mixing plant and the site conditions and be capable of discharging cleanly.
Material when mixed shall be removed at once from the mixer transported directly to the
point where it is to be laid and protected from the weather both during transit from the
mixer to the laying site and whilst awaiting tipping.
3/16.2 The material shall be placed and spread evenly. The material shall be spread using a
paving machine or spreader box operated with a mechanism which levels off the
material at an even depth and without delay. Except where otherwise specified, the
material shall be laid and compacted in layers of maximum thickness of 150 mm.
3/17 COMPACTION TRIALS OF WET-MIX MACADAM ROADBASE
3/17.1 If directed by the Engineer, prior to the commencement of the Wet-mix Macadam
Roadbase operations, the contractor shall construct trial lengths, not to exceed 250
meters. The materials used in the trials shall be those approved for use as Wet-mix
Macadam Roadbase and the equipment used shall be that according to the Contractor's
approved detailed programme of work.
3/9
3/17.2 Trial lengths may not form part of the permanent works but may be permitted in the
construction of temporary detours of sufficient length.
3/17.3 The objective of these trials is to determine the adequacy of the Contractor's equipment,
the loose depth measurements necessary to result in the specified compacted layer
depths, the field moisture content, and the relationship between the number of
compaction passes and the resulting density of the material.
3/17.4 The Contractor may proceed with the Wet-mix Macadam Roadbase work only after the
methods and procedures established in the compaction trials have been approved by
the Engineer.
3/18 COMPACTION OF WET-MIX MACADAM ROADBASE
3/18.1 The material shall be compacted to a field density equal to or greater than 100% of the
maximum dry density value obtained when tested in accordance with BS 1377:Part
4:Test 3.7 latest edition and shall have a minimum CBR of 80% at 100% compaction
after 96 hours soaking (BS 1377: Part 4: Test 7:1990). Field Density tests shall be
carried out in accordance with Clause 3/20.2
3/18.2 Compaction shall be completed as soon as possible after the material has been spread.
3/18.3 Special care shall be taken to obtain full compaction in the vicinity of both longitudinal
and transverse joints.
3/18.4 The surface of any layer of material shall on completion of compaction be well closed
free from movement under compaction plant and free from compaction planes, ridges,
cracks or loose material. All loose, segregated or otherwise defective areas shall be
made good to the full thickness of layer and recompacted.
3/18.5 Where directed by the Engineer a Sieve analysis shall be carried out on the material
recovered from 5 consecutive field density tests. Where this sieve analysis shows
oversize material content of 10 % or greater the area of construction will be removed
and the source of the material rejected until further notice. Where considered necessary
other areas of work which were carried on using material from the same source shall be
tested in a similar manner.
3/19 FINISHING OF WET-MIX MACADAM ROADBASE
3/19.1 Immediately prior to the placing of the first layer of the next pavement course on to the
Wet-mix Macadam Roadbase the final layer of Wet-mix Macadam Roadbase shall be at
the specified density and to the required grade and section. In order to maintain these
requirements while placing the next course it may be necessary to water and reshape
the surface of the Wet-mix Macadam Roadbase. This work shall be at the Contractor's
expense.
3/19.2 The surface of the finished Wet-mix Macadam Roadbase will be tested with a three (3)
metre straight edge by the Engineer at selected locations. The variations of the surface
from the testing edge between any two (2) contacts with the surface shall at no point
exceed ten (10) millimeters when placed on or parallel to the centreline, or ten (10)
millimeters when placed perpendicular to the centreline of the roadway. The Wet-mix
Macadam Roadbase shall be compacted to the thickness and cross sections as shown
on the drawings and shall not vary by more than ten (10) millimeters from the required
elevation. All humps and depressions and thickness deficiencies exceeding the
3/10
specified tolerance shall be corrected by removing the defective work or by adding new
material as directed by the Engineer.
3/19.3 Before placing the next construction layer or applying prime coat, the wet-mix roadbase
shall be mechanically swept then cleaned with compressed air to remove loose material.
As soon as possible after cleaning of the surface, the wet-mix roadbase shall be sealed
by the application of a prime coat as specified. Should the surface of the material be
allowed to dry out before the seal is applied, it shall be lightly watered and re-compacted
immediately prior to spraying with prime-coat. In the event of a section of wet mix
roadbase failing to comply, either by level or degree of compaction, and where the full
depth of the layer has been allowed to dry out, it shall be removed and replaced at the
Contractor's expense, with fresh material. Watering and re-mixing in place will not be
permitted.
3/20 MINIMUM TEST REQUIREMENTS FOR WET-MIX MACADAM ROADBASE.
3/20.1 One sample every 1,000 cu. m. shall be tested for Grading Plasticity Index, Sand
Equivalent value, Maximum Dry Density, C.B.R. and Loss by Abrasion.
3/20.2 For compaction and moisture content; three tests per 750 sq.m. (max.) of each layer of
carriageway and three tests per 450 lin. m. of shoulder.
3/20.3 Special care shall be taken to obtain full compaction in the vicinity of both longitudinal
and transverse joints.
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION
3/21.1 This work shall consist of the construction of the following hot-mix bituminous courses
which shall be either Asphaltic Concrete or Dense Bitumen Macadam as shown on the
drawings.
- Bituminous Base Course

- Bituminous Binder Course
- Bituminous Wearing Course
Bituminous Paving Courses shall consist of coarse aggregates, fine aggregates, filler
material, and bitumen binder.
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE
3/22.1 Coarse aggregates, which is the material retained on a 4.75 mm sieve, shall consist of
crushed rock or crushed gravel. It shall be clean, hard, tough, durable and sound, and
shall be of uniform quality and free from decomposed stone, shale, clay, lumps and
other deleterious substances. Sampling of coarse aggregate shall be in accordance with
ASTM D75.
3/22.2 Crushed gravel for use as coarse aggregate shall consist of the product obtained by
crushing material that has first been screened in such a manner that not less than ninety
(90) percent of the material to be crushed is retained on an ASTM 3/8 inch sieve.
3/22.3 Each particle shall have a minimum of one crushed face. In addition, at least 85% by
weight of each separate stockpile of aggregate shall have all faces crushed. This 85%
value may be reduced to 50% for certain categories of road where indicated on the
drawings.
3/11
Crushed face determination shall be as per Dubai Municipality CQC & RS Test Method
DM 300 and 301.
3/22.4 Eachstockpile of Coarse aggregate shall have properties which comply with the
following values:-
Los Angeles Abrasion Loss (ASTM C131/C535)

Base Course and Binder Course 30% max.
Wearing Course 25% max.
Aggregate Crushing Value (BS 812 Part 110

Latest Edtion)
Base Course and Binder Course 25% max.
Wearing Course 20% max.
Soundness Loss (ASTM C88) 10% max.

Magnesium Sulphate 5 cycles
Flakiness Index (BS 812 Part 105.1

Latest Edition)
Base Course and Binder Course 30 max.
Wearing Course 25 max.
Elongation Index (BS 812 Part 105.2

Latest Edition)
Base Course and Binder Course 30 max.
Wearing Course 25 max.
Water Absorption (ASTM C127) 2% max.
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE
3/23.1 Fine aggregate shall consist of the material passing a 4.75 mm sieve.
3/23.2 Fine aggregate including filler shall be obtained from 100% crushed gravel or crushed
rock pre-screened to exclude natural uncrushed fine material or weathered unsound
fines. The use of dune sand shall not be permitted.
3/23.4 Fine aggregates shall have properties which comply with the following values:-
Soundness Loss (ASTM C88) 10% max.

Magnesium Sulphate 5 cycles
Plasticity Index (BS 1377:Part 2 Non-Plastic

Test 5 Latest Edition)
Acid Soluble Chlorides 0.1% max.

(BS 812 Part 117 latest edition)
Acid Soluble Sulphates 0.5% max.
(BS 812 Part 118 latest edition)
Water Absorption (ASTM C128) 2.3% max.
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE
3/12
3/24.1 When the combined grading of the coarse and fine aggregates is deficient in material
passing the ASTM No.200 sieve, mineral filler shall be added as approved by the
Engineer at the Contractor's expense.
3/24.2 Mineral filler shall consist of finely ground particles of limestone or cement in accordance
with ASTM D242. It shall be thoroughly dry and free from organic substances and clay
and meet the grading requirements following:-
MINERAL FILLER
B.S. SIEVE ASTM SIEVE SIZE PERCENTAGE BY

MASS PASSING
600 micron No. 30 100

300 micron No. 50 95 - 100
150 micron No. 100 90 - 100
75 micron No. 200 70 - 100
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES
3/25.1 The combined mineral aggregate shall meet the following physical requirements:-
Sand Equivalent (ASTM D2419)

determined after all processing
except for addition of asphalt
binder 65 minimum
Plasticity Index (BS 1377:Part 2 Non Plastic

Test 5 latest edition)
3/25.2 When tested according to ASTM C117 and ASTM C136, the combined mineral
aggregate shall conform to Table 1 for Asphaltic Concrete and Tables 2, 3 and 4 for
Dense Bitumen Macadam:-
TABLE 1 - AGGREGATE GRADING FOR ASPHALTIC CONCRETE
Sieve size TOTAL PASSING (BY WEIGHT)

(Square Openings)
ASTM
Base Course Binder Course Wearing
Course
37.5 mm 100 -
25 mm 80 - 100 100 100
19 mm 62 - 92 80 - 100 86 – 100
12.5 mm - 63 - 85 69 – 87
9.5 mm 45 – 75 57 – 77 58 – 78
4.75 mm 30 – 55 40 – 60 40 – 60
2.36 mm 20 – 40 25 – 45 25 – 45
0.85 mm 15 – 30 15 – 30 15 – 30
0.425 mm 10 – 22 10 – 22 10 – 22
0.18 mm 6 – 15 6 – 15 6 – 15
3/13
0.075 mm 2-8 2-8 2–8
TABLE 2 - AGGREGATE GRADATION FOR DENSE BITUMEN

MACADAM ROADBASE
B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR GRAVEL
mm Percentage by mass Passing
50 100
37.5 95 - 100
28 70 - 94
14 56 - 76
6.3 44 - 60
3.35 32 - 46
0.300 7 - 21
0.075 2 - 8
Note: The aggregate shall be in a surface dry condition prior to mixing.
3/14
MACADAM BASECOURSE
------------------------------------------------------
------------------------------------------------------
mm Percentage by mass Passing for
Finished Thickness of Basecourse
mm mm mm
65 - 80 50 - 60 35 - 45
50 100 - -
37.5 95 - 100 100 -
28 70 - 94 90 - 100 100
20 - 71 - 95 95 - 100
14 56 - 76 58 - 82 65 - 85
10 - - 52 - 72
6.3 44 - 60 44 - 60 39 - 55
3.35 32 - 46 32 - 46 32 - 46
0.300 7 - 21 7 - 21 7 - 21
0.075 2-8 2-8 2- 8
------------------------------------------------------

MACADAM WEARING COURSE
------------------------------------------------------
-----------------------------------------------------
mm Percentage by mass Passing for
Finished Thickness of Basecourse
mm mm mm
35 - 50 25 - 30 20
28 100 - -
20 95 - 100 100 -
14 70 - 90 95 - 100 100
10 55 - 75 70 - 90 95 - 100
6.3 40 - 60 45 - 65 55 - 75
3.35 25 - 40 30 - 45 30 - 45
1.18 15 - 30 15 - 30 15 - 30
0.075 2-6 2-6 2-6
------------------------------------------------------
3/25.3 The gradings given in Tables 1, 2, 3 and 4 represent the extreme limits which shall
determine suitability of aggregate for use from all sources of supply. The aggregate as
finally selected for use in the work shall have a grading within the limits designated in
Tables 1, 2, 3 and 4 as appropriate and for Table 1 may with the Engineer's agreement
vary from the low limit on one sieve to the high limit on the adjacent or vice-versa for
base course and binder course but for wearing course shall be uniformly graded from
coarse to fine. Combined gradings for Tables 2, 3 and 4 which approach maximum
limits on some sieves and minimum limits on other sieves shall not be permitted.
3/15
3/25.4 The coarse aggregate, shall show no detrimental amount of stripping when tested in
accordance with ASTM D1664. The minimum value of non stripped area shall be 95%.
If stripping occurs, the aggregate shall be rejected and an approved method of
treatment specified to change the material from a hydrophilic to a hydrophobic state as
directed by the Engineer, or an approved additive shall be used with the bituminous
binder.
3/25.5 When necessary to improve the coating of aggregate by bitumen, additives of

approved type will be added to the bituminous material in such percentage as required
to obtain satisfactory results in the affinity with bitumen test performed in accordance
with ASTM D1664. The approved additive will be used in accordance with Technical
Specifications issued by the manufacturer and approved by the Engineer after
appropriate testing.
3/25.6 No extra payment will be made for required anti- stripping additives.
3/26 BITUMEN BINDER
3/26.1 Bitumen Binder for the "Bituminous Paving Courses" shall be Bitumen Binder
penetration grade 60 - 70 unless otherwise specified as 40 - 50. Sampling shall be in
accordance with ASTM D140.
3/26.2 The bitumen shall be prepared by refining crude petroleum by suitable methods and
shall be homogeneous, free from water and shall not foam when heated to 175° C (347
F).
3/26.3 Bitumen penetration grade 60 - 70 and 40 - 50 shall conform to the requirements of

Table 5.
TABLE 5
60 - 70 PEN 40 - 50 PEN
TEST METHOD MIN. MAX. MIN. MAX.

ASTM
Penetration D5 60 70 40 50
at 25 deg.C
100g, 5 sec.
Flash Point, D92 232 - 232 -

Cleveland
Open Cup,
deg.C.
Ductility at D113 100 - 100 -

25 deg.C, cm
Solubility D2042 99 - 99 -
trichloro
ethylene, %
Thin film D1754 - 0.80 - 0.80

oven test
3.2mm, 163
deg.C, 5 hr
3/16
loss on
heating, %
Penetration D5 52 - 55 -
of residue
% of original
Ductility of D113 50 - - -
residue at
25 deg.C,
5 cm/min. cm
Kinematic D2170 240 - 280 -

Viscosity
(Centistokes)
at 135 deg.C
Softening
Point
Ring & Ball D36 48 52 51 55
apparatus
3/26.4 A sample of the bitumen that the Contractor proposes to use in the work, together with
a statement as to its source and properties shall be submitted to and approved by the
Engineer at least 45 days before the asphalt work begins.
3/26.5 No bitumen other than that representated by the approved sample shall be used by the
Contractor except with the written consent of the Engineer. Blending of bitumen from
different refineries will not be permitted.
3/26.6 For Asphaltic Concrete the percentage range of bitumen by weight of total mix to be
added to the aggregate shall be as prescribed in Table 6: For Dense Bitumen
Macadam the range shall be as prescribed in Table 9.
TABLE 6 : BITUMEN CONTENT FOR ASPHALTIC CONCRETE
-------------------------------------------------------------------------------------------
PAVEMENT COURSE BITUMEN PERCENTAGE BY WEIGHT OF
TOTAL MIX INCLUSIVE OF TOLERANCES
--------------------------------------------------------------------------------------------
Base 3.2 to 4.4
Binder 3.4 to 4.4
Wearing 3.4 to 4.4
-----------------------------------------------------
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES
3/27.1 The mix approved for use in the works shall be designed using Marshall tests and field
trials with the following recommendations taken into account:-
- For base course the Marshall shall be modified by substituting all aggregate
sizes over 25 mm with an equal weight of aggregate sizes of 20/19 mm sieve.
3/17
- The combined aggregate gradation should be adjusted within the allowable
limits to achieve maximum stability whilst not going below the minimum
requirement for void content.
- The minimum bitumen binder content according to the results of the Marshall
Method of Mix Design should be used provided that it will still satisfy the
durability, the stability and the void content requirements.
- Prior to final approval, the proposed job mix, but with a bituminous content at
the upper percentage limits shall be compacted to refusal, (400 to 600 blows)
and the resulting voids in the mix shall not be less than 2% for asphaltic
concrete or 3% for DBM.
- The final job mix must display the Marshall characteristics specified in Table 8
for Asphaltic Concrete and Table 9 for Dense Macadam.
3/27.2 Determination of VIM, VMA & VFB shall be in accordance with DM 404.
3/27.3 At least thirty (30) days prior to the date he intends to begin production of plant-mix
"Bituminous Paving Course" Mixes, and after receiving approval of the aggregates and
bitumen from the Engineer the Contractor shall make a written request for the approval
of the job-mix formula from the Engineer. The job-mix formula will be prepared by the
Contractor under the supervision of the Engineer in the Laboratory. The job-mix design
and correction factor for the aggregate for the test ASTM D6307 shall be checked at
the Dubai Central Laboratory.
3/27.4 The laboratory job mix formula shall fix a single definite percentage of aggregate
passing each required sieve size, a single definite percentage of bitumen binder to be
added to the aggregate, a single definite temperature at which the mix is to be emptied
from the mixer, and a single definite temperature at which the mix is to be delivered to
the works site.
3/27.5 The laboratory job mix formula shall be used for the basis of approval of the job
standard mixture.
3/27.6 Trial areas having lengths of at least 30m and to the specified layer thickness shall be
laid outside the area of the permanent work by the Contractor for the Engineer's
approval, before the start of the permanent work. At least two samples of non-
compacted material from the trial area shall be taken in accordance with ASTM D979
and shall be analysed in the presence of the Engineer to determine the aggregate
grading, binder content, stability, flow, Marshall density and voids. The results shall be
submitted to the Engineer and shall be approved by him before further mixing or laying
is carried out.
3/27.7 Trial areas may form part of a temporary traffic detour subject to the approval of the
Engineer. The compaction trials according to sub-section 3/42 should be performed on
the trial mixes. If the trial areas form part of the temporary traffic detour they shall not
be paid for under the relevant Bill item.
3/27.8 Should the laboratory job mix formula after passing the mixing plant and laid and
compacted with approved plant fail to produce a satisfactory trial area, the mix
proportions may be modified by agreement with the Engineer, as necessary and within
the requirements of Table 7, 8 and 9 as applicable to produce a mix of satisfactory
workability and acceptable surface finish subject to the mix being rechecked in
accordance with the proceeding clauses of 3/27. After approval of the trial area by the
3/18
Engineer this mix shall be designated the 'Job Standard Mix' and shall thereafter be the
approved mix.
3/27.9 All mixes produced shall conform to the Job Standard Mix approved by the Engineer,
within the ranges of tolerance specified in Table 7 (within the limits of Table 1, 6 and 8
for Asphaltic Concrete and Tables 2, 3, 4 and 9 for Dense Bitumen Macadam). Each
day the Engineer shall take as many samples of the materials and mix as he considers
necessary and minimum of one sample for every 200 tons laid or part thereof for
checking their required characteristics. When unsatisfactory results or changed
conditions make it necessary, the Engineer shall instruct the Contractor to establish a
new job-standard.
3/27.10 Should a change in a material be encountered or should a change in a source of

material be made, a new Job-Standard Mix shall be submitted by the Contractorand
approved by the Engineer before the mix containing the new material is delivered. Job
materials will be rejected if they are found not to have the characteristics required by
the approved Job Standard Mix.
TABLE 7
JOB MIX TOLERANCE
---------------------------------------------------------------------------------------------
Aggregate retained on 4.75mm sieve or next +/- 5%
large sieve
Aggregate passing 4.75mm sieve and retained +/- 4%

on 0.85mm sieve
Aggregate passing 0.85mm sieve and retained +/- 2%

on 0.075mm sieve
Aggregate passing 0.075mm sieve +/- 1.0%
Bitumen Binder +/- 0.2%
Temperature of mixing and placing +/- 10 deg.C
---------------------------------------------------------------------------------------------
3/19
TABLE 8
PROPERTIES OF MIX FOR ASPHALTIC CONCRETE
PROPERTIES BITUMINOUS BITUMINOUS BITUMINOUS

BASE BINDER WEARING TEST
COURSE COURSE COURSE METHOD
Number of Compaction 75 75 75 ASTM
blow at each end of D1559
specimen
Stability (Marshall) 10000 10000 12000 ASTM
Minimum N. D1559
After submerging
specimen at 60° C
for 30 minutes
Flow (Marshall) mm 2-4 2-4 2 - 4 ASTM
D1559
Stiffness, minimum 5 5 5 -
KN/mm
Percent air voids 4 - 8 4-8 4 - 8 DM404
Percent voids in 13 14 15 DM404
mineral aggregate,
minimum % (V.M.A)
Percent voids filled 50 - 65 50 - 70 50 - 70 DM404
with bitumen (V.F.B).
Loss of Marshall Max.25% Max. 25% Max. 25% DM405
Stability by submerging
specimens in water at
60° C for twenty four
(24) hours compared to
Stability measured after
submersion in water at
60°c for 30 minutes.
Filler/Bitumen Ratio 0.6 - 1.5 0.6 - 1.5 0.6 - 1.4
3/20
TABLE 9
PROPERTIES OF MIX FOR DENSE BITUMEN MACADAM
BASECOURSE WEARING COURSE TEST
DESCRIPTION ROADBASE METHOD
MIN. MAX. MIN. MAX.
Marshall specimens 75 - 75 - ASTM
No. of Comp. blow D1559
each end of specimen
Voids in Mix (%) 7 11 6 9 DM404
Voids in Mineral 14 20 14 20 DM404

Aggregate (%)
Minimum Stability 7500 - 10000 - ASTM

N.after submerging D1559
specimen at 60° C for
30 minutes
Flow (mm) 2 4 2 4 ASTM D1559
Minimum Stability/ 2.7 - 3.2 - -

Flow Ratio (KN/mm)
Bitumen Content(% of 3.2 4.0 3.5 4.1 ASTM D6307

total mix) using
Ignition
Method
Voids filled with 47 60 48 60 DM404

Bitumen (%)
Loss of Marshall Max.25% Max. 25% DM405

Stability by submer-
ging specimens in
water at 60° C for
twenty four (24) hours
compared to Stability
measured after submersion
in water at 60°c for
30 minutes.
3/21
3/27.11 Samples of bituminous paving course mixes shall be taken from the mixing plant and/or
behind the paver prior to compaction, as decided by the Engineer, to check compliance
with the approved job mix requirements including Tables 1, 6, 7 and 8 for asphaltic
concrete and Tables 2, 3, 4, 7 and 9 for Dense Bitumen Macadam.
3/27.12 The density of the compacted mixes shall be related to the daily Marshall Density which
shall be determined by making four Standard Marshall specimens from samples of the
mix taken from the mixing plant or paver. The density of each sample shall be
determined and compared with the mean value. Any individual result which varies from
the mean by more than 0.015 gm/cc shall be rejected. Marshall tests shall be repeated
on a daily basis to establish the daily Marshall Density for that particular day's
production. The daily Marshall Density shall not vary from the Job Mix Design Density by
more than ± 1.0%.
3/27.13 The assistance of the Engineer in the preparation of the job standard mix in no way
relieves the Contractor of the responsibility of producing a bituminous mix meeting the
requirements of the Specifications.
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS
3/28.1 Method statement and equipment list shall be according to the type and number outlined
in the Contractor's detailed Programme of Work, as approved by the Engineer.
Requirements for major plant are outlined in Clause 1/29 of these Specifications.
3/28.2 In addition to the above requirements, trucks used for hauling bituminous mix shall have
tight, clean, smooth metal beds which have been thinly coated with a minimal amount of
paraffin oil, lime solution, or other approved material to prevent the mix from adhering to
the beds. When required by the Engineer, each vehicle shall be equipped with a canvas
cover or other suitable material of such size as to protect the mix from the weather.
3/28.3 Rolling equipment shall be self-propelled. The wheels on the rollers shall be equipped
with adjustable scrapers and the rollers shall have water tanks and sprinkling apparatus,
which shall be used to keep the wheel wet and prevent the surface material from
sticking.
3/29 PREPARATION OF BITUMEN BINDER
3/29.1 The heating of the bitumen binder for mixing and compacting shall be in accordance
with ASTM D1559.
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX
3/30.1 i. Coarse and fine aggregate shall be stored at the asphalt plant in such a manner
that the separate stockpiles will not become intermixed. The stockpiles shall be
of sufficient size to provide a minimum quantity of one week's continuous
production of asphalt mix. Aggregates brought to the asphalt plant to supplement
stocks should be tested and approved prior to placing in the existing approved
stockpiles.
ii. The cold bins shall be calibrated with the materials to be used and the settings
shall be such as to produce a combined gradation in accordance with the job mix
formula. The proportioning shall be such that surpluses and shortages in the hot
bins will not cause breaks in the continuous operation. All the above shall be as
iii. The materials shall be thoroughly dried and heated so that their temperature is
within ±8 deg.C of the temperature needed to satisfy the viscosity requirements
3/22
of the asphalt cement. The moisture content of the heated and dried materials
shall not exceed 0.5 per cent. The quantity of materials fed through the drier
shall in all cases be held to an amount which can be thoroughly dried and heated
within the limits specified.
3/30.2 Immediately after heating, the aggregate or aggregates shall be screened into at least
five (5) sizes and conveyed into separate bins ready for batching and mixing with
bituminous material. When the aggregates supplied are of such size and grading that
separating into five (5) bins is impractical, the number of required separations may be
reduced to four (4) or to three (3) with the approval of the Engineer. The efficiency of
the screening operations shall be sufficient to produce, at plant operating capacity,
gradations in each of the sizes of heated and dried aggregates which are reasonably
uniform and result in the production of a mix complying with the limits specified for the
aggregate gradation.
3/31 PREPARATION OF BITUMINOUS MIX
3/31.1 Dried aggregate as specified and prepared as prescribed above shall be combined in
the plant conforming to ASTM D995 in the approved proportions. The bitumen binder
shall be introduced into the mix in the proportion specified by the job-mix formula.
3/31.2 The initial mixing time will be designated by the Engineer. Mixing time may be increased
by the Engineer if additional time is necessary to obtain a homogeneous mix and
satisfactory coating.
3/31.3 The batch plants, timing shall begin at the start of the introduction of the bitumen into the
pugmill.
3/31.4 The length of mixing time for continuous plants will be determined by the following
formula or other approved methods:-
Pugmill dead load capacity in Kg

Mixing time in seconds = ---------------------------------
Pugmill output in Kg/second
3/31.5 The temperature of the aggregate immediately prior to mixing shall be within + 8 deg.C
of the temperature of the asphalt cement and the temperature of the aggregate and
asphalt prior to mixing shall be approximately that of the completed mix as defined in the
job mix formula approved by the Engineer. The mix temperature shall be within the
limits set out in the job mix formula when emptied from the mixer.
3/32 SURFACE PREPARATION
3/32.1 When the Bituminous Mix is placed on a prepared roadbase and whether or not a prime
coat is designated on the Drawings, the Granular Roadbase shall be even and firm and
within the construction tolerances specified for the roadbase to the satisfaction of the
Engineer.
3/32.2 When the paving layer is constructed on an existing bituminous surface, the surface
shall be cleaned of all foreign material and broomed free of dust. In addition any loose,
broken or shattered bituminous material along the edges of the existing surface shall be
removed, and the exposed subgrade and a sufficient width of the shoulder adjacent to
the edge of the existing surface to receive the new bituminous mix shall be shaped,
bladed, compacted and broomed and primed to provide a uniform firm subgrade for the
new surface course.
3/23
3/32.3 The existing bituminous surface, base, or subgrade shall be removed if broken,
shattered, or unstable. The areas shall be excavated to a depth as directed by the
Engineer, and refilled with the Bituminous Mix according to the Specifications.
3/32.4 Prior to the placing of the mix, when designated on the Drawings or directed by the
Engineer, a prime coat or tack coat shall be applied to the roadbase or surface in
accordance with the Specification for Prime Coat or Tack Coat.
3/33 PLACING OF THE MIX
3/33.1 All bituminous mixes shall be introduced to the paver at a temperature not less than
135° C and not more than 163° C. Mixes outside this temperature range shall be
discarded.
3/33.2 The bituminous mix shall be spread and finished to crown and grade by automatically
controlled bituminous paver. Bituminous mix may be spread and finished by hand
methods only where machine methods are impractical as determined by the Engineer.
3/33.3 The automatically controlled paver shall lay the bituminous mix without tearing the
surface and shall strike a finish that is smooth, true to cross-section, uniform in density
and texture, free from hollows, transverse corrugations and other irregularities.
3/33.4 The paver shall be operated at a speed which will give the best results for the type of
paver being used and which co-ordinates satisfactorily with the rate of delivery of the
mix to the paver, to provide a uniform rate of placement without intermittent operations
of the paver.
3/33.5 The mix shall be delivered to the paver in time to permit completion of spreading,
finishing and compaction of the mix during daylight hours.
3/33.6 The longitudinal joints in successive layers shall be offset not less than fifteen (15)
centimetres. The width of surface or top course placements shall conform to traffic lane
edges as shown on the Drawings.
3/33.7 The leading half of half roadway paving shall not get ahead of the trailing half of the
pavement by more than one (1) average full-day of paving and, in no case, shall the
leading half be more than one half (1/2) kilometre ahead of the trailing half without the
written permission of the Engineer. If the Contractor fails to comply with this
requirement, the Engineer may suspend paving on the leading half until such time, as
the Contractor shall pave the trailing half to a point approximately even with the leading
half.
3/33.8 Unless otherwise directed by the Engineer, where successive layers are to be placed,
the surface of the existing layer shall be swept clean with a power broom, or by other
means as approved by the Engineer, and a tack coat applied. Tack coat may not be
required where the delay between courses laying is less than 48 hours and when the
surface is fresh and clean and at the discretion of the Engineer. The rate of application
2
of tack coat to be between 0.2 to 0.6 l/m .
3/33.9 Asphaltic concrete mixes, except levelling courses shall be laid at an uncompacted
thickness such that, after rolling the thickness of the compacted layer shall be:-
Base Course : Min. 6 cm Max. 10 cm

Binder Course : Min. 5 cm Max. 8 cm
Wearing Course : Min. 4 cm Max. 6 cm
However, DBM thicknesses shall be as specified in Tables 3 and 4.
3/24
3/33.10 The maximum thickness for layers may be increased slightly when such increase is
more adaptable to total pavement thickness and when in the opinion of the Engineer it is
not detrimental to placement and rolling conditions.
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE
3/34.1 The Contractor shall make the necessary survey required for the reference grade. When
the survey is approved by the Engineer, the Contractor shall erect and maintain an
approved reference string line and operate the paver to conform to the reference string
line for the initial layer and/or any other layers as directed. Elevation control point stakes
for the first layer of bituminous paving course shall be set at a maximum spacing of
twenty (20) metres. For subsequent layers, control points shall be set at ten (10) metres
maximum spacing. The Contractor shall furnish and maintain an approved mobile string
line for all layers not laid with the erected string line. The string line shall be erected
parallel to the reference grade, and the bituminous mix shall be spread at a constant
elevation above, below or at the string line elevations as directed.
3/34.2 The use of the automatically controlled bituminous paver, to provide both longitudinal
and traverse control, shall include the furnishing and maintaining of a string line, fixed or
mobile, by the Contractor. The longitudinal and traverse controls shall operate
independently of each other, to the extent that the surface of the bituminous mix will
conform to the string line and will be uniform in cross-section and crown.
3/34.3 The Contractor shall establish the centre-line points and shall maintain the location of
the points until the completion of the surfacing or as directed. When directed by the
Engineer, the Contractor shall erect a string line, to be used as a guide for the finishing
machine, in order to maintain a uniform edge alignment. If any other method is proposed
by the Contractor, it shall first be approved by the Engineer.
3/35 BITUMINOUS LEVELLING COURSE
3/35.1 A levelling course, consisting of a layer of bituminous material of variable thickness may
be used to eliminate irregularities in existing surfaces or bases and to vary existing
cross-section elements of roadways.
3/35.2 In areas where levelling courses are required, as shown in the Drawings or determined
by the Engineer, the Contractor shall make a survey of the existing surface or base.
When the survey is approved, the Engineer will determine and inform the Contractor of
the precise locations and thickness of levelling course to obtain the smoothest possible
riding surface. Upon receipt of the locations and thickness from the Engineer, the
Contractor shall proceed with the placement of the Levelling Course.
3/36 THICKNESS CORES
3/36.1 The depth of each bituminous paving course shall be measured by cored samples. The
Contractor shall furnish and operate an approved core drill for cutting samples from the
compacted mix on the road. The equipment shall be capable of cutting the mix without
shattering the edges of the specimen or otherwise disturbing the density of the
specimen. Cored samples shall be ten (10) centimetres in diameter for binder course
and wearing course and fifteen (15) centimetres in diameter for base course and road
base.
3/36.2 Cores extracted for thickness measurement may be used for density determination and
density samples may be used for thickness measurements.Determination of thickness
and density of core samples shall be determined in accordance with ASTM D3549 and
ASTM D 1188 or ASTM D 2726 respectivelyand as required by the Engineer.
3/25
3/37 COMPACTION OF BITUMINOUS LAYERS
3/37.1 After spreading and strike off, and as soon as the mix conditions permit the rolling to be
performed without excessive shoving or tearing, the mixture shall be thoroughly and
uniformly compacted. Rolling will not be prolonged to an extent that cracks appear.
3/37.2 Rollers shall be of the steel-wheel and pneumatic tyre type and shall be in good
condition, capable of reversing without backlash, and shall be operated at speeds slow
enough to avoid displacement of the bituminous mix. The number and weight of rollers
shall be sufficient to compact the mix to the required density while it is still in a workable
condition. The use of equipment which results in excessive crushing of the aggregate
will not be permitted. A minimum of three (3) rollers, two (2) steel-wheel and one (1)
pneumatic-tyre type, shall be used with each spreading operation for each lane.
3/37.3 The Contractor shall provide adequate back-up equipment for use in the event of
mechanical failure, all to the satisfaction of the Engineer.
3/37.4 Initial or breakdown rolling shall be done by means of either a tandem power steel roller
or three-wheel roller followed by a pneumatic-tyre roller or as agreed by the Engineer.
Rolling shall begin as soon as the mix will bear the roller without undue displacement.
Rolling shall be longitudinal, beginning at the low side of the spread of material and
proceeding toward the high side, overlapping on successive passes by at least one half
(1/2) the width of the near wheels. Alternate passes of the roller shall be of slightly
different lengths.
3/37.5 The motion of the roller shall at all times be slow enough to avoid displacement of the
mix. To prevent adhesion of the mix to the rollers, the wheels of the rollers shall be kept
properly moistened with water, but an excess of water will not be permitted. Under no
circumstances shall the use of diesel fuel or any other asphalt stripping agent be used
for preventing adhesion of the asphalt to the roller wheels.
3/37.6 Final compaction and finish rolling shall be done by means of a tandem power steel
roller, unless otherwise directed. When the specified density is not obtained, changes in
the size and/or number of rollers shall be made as corrective measures, to satisfy the
density requirements.
3/37.7 Rollers shall be operated by competent and experienced roller men and shall be kept in
operation continuously if necessary, so that all parts of the pavement will receive
substantially equal compaction at the time desired. The Engineer will order the mixing
plant to cease operation at any time proper rolling is not being performed.
3/37.8 The road density requirements shall be equal to or greater than ninety eight (98) percent
of the average Marshall density of each day's production for wearing course and ninety
seven (97) percent of the average Marshall density of each day's production for
basecourse and binder course. However, densities in excess of 101.8% shall not be
permitted.
3/37.9 Any mix that becomes loose, broken, mixed with foreign material, or which is in any way
defective in finish or density, or which does not comply in other respects with the
requirements of the Specification shall be removed, replaced with new materials, and
finished in accordance with the Specifications.
3/37.10 After laying and compacting the asphalt mix, coring to be done after 24 hours of
completion of compaction.
3/38 RE-ROLLING OF BITUMINOUS COURSES
3/26
3/38.1 Should any bituminous course fail to achieve the specified density, at the discretion of
the Engineer rerolling may be allowed subject to the following conditions:-
a. The densification to be achieved shall be 1% or less.
b. Only PTR's to be used weighing no greater than 18 tons.
c. Re-rolling to take place within 72 hours from the time of the initial rolling of the
asphalt.
d. Re-rolling to take place at the time of the day when the asphalt has attained
its maximum natural temperature.
e. Re-rolling to be applied for a maximum of two hours.
f. Re-rolling to be carried out in the presence of the Engineer's Representative.
g. The section of the works in question shall be cored for density determination
immediately after the completion of re-rolling.
h. If after re-testing, the density achieved is 0.5% below the specified density,
the asphaltic material will be accepted in the works subject to a 20% reduction
to the billed rates. If, on the other hand, the density is greater than 0.5%
below the specified density, the asphaltic material shall be removed and new
material to the specification laid at the Contractor's cost.
3/39 CONTACT SURFACES
3/39.1 Contact surfaces between the bituminous paving and of kerbing, gutters, manholes, and
other appurtenances shall be painted with a thin uniform coating of tack coat as
3/40 JOINTS IN BITUMINOUS PAVING
3/40.1 Joints between old and new pavement or between successive day's work shall be made,
to ensure thorough and continuous bonding between the two. All construction joints in
previously laid material shall be constructed by cutting the material back vertically for its
full depth to expose a fresh surface.
3/40.2 Before placing the fresh mix against a cut joint or against old pavement, the contact
surface shall be sprayed or painted with a thin uniform coat of tack coat. Where a
finishing machine is used the longitudinal joint shall be made be overlapping the screed
on the previously laid material for a width of at least three (3) centimetres and depositing
a sufficient amount of mix so that the joint formed will be smooth and tight.
3/41 PROTECTION OF COMPACTED LAYER
3/41.1 The Contractor shall protect all sections of newly compacted pavement from traffic until
they have hardened sufficiently to the approval of the Engineer. On heavily trafficked
roads during the summer months a minimum period of 7 days must elapse before the
newly compacted pavement is trafficked.
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES
3/27
3/42.1 Prior to the commencement of the bituminous paving operations, the Contractor shall
construct trial lengths, of at least 30 metres. The materials used in the trials shall be
those approved for use in the bituminous paving courses and the equipment used shall
be that according to the Contractor's approved detailed Method Statement and
equipment list and the programme of work.
3/42.2 The object of these trials is to determine the adequacy of the Contractor's equipment,
the loose depth measurements necessary to result in the specified compacted layer
depths and the relationship between the number of compaction passes and the
resulting density of the material.
3/42.3 The Contractor may proceed with the bituminous paving operations only after the method
and procedures established by the compaction trials have been approved by the
Engineer.
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES
3/43.1 At final compaction the finished surfaces of the individual layers shall fall within the
following maximum tolerances, measured with a 3 m straightedge laid in any direction.
- Base Course 6 mm
- Binder Course 6 mm
- Wearing Course 4 mm
3/43.2 i. The rideability of the finished wearing course when tested with a Laser Road
Surface Testing Machine shall have and IRI (International Roughness Index) not
exceeding the following values:
Average value over a 400 metre section < 0.90
Peak value over a 25 metre section < 1.5

(not more than 2 values per 400 metres)
ii The amplitude of the longitudinal profile of the road, filtered between (a) 1 metre and
3.3 metres and (b)3.3 metres and 13 metres shall not exceed the following values:
1m - 3.3m <1.8 mm
3.3m - 13m <3.5 mm
3/43.3 All humps and depressions exceeding the specified tolerance shall be corrected by
removing the defective work and replacing it with new material as directed by the
Engineer at the Contractors cost.
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS
3/44.1 The thickness of the bituminous paving courses shall be determined in accordance with
ASTM D3549.
3/44.2 For the purpose of establishing an adjusted unit rate for bituminous paving courses,
units to be considered separately are defined as three hundred (300) linear metres in
each traffic lane. The last unit in each lane shall be three hundred (300) metres plus the
fractional part of three hundred (300) metres remaining. At least three cores shall be
taken randomly from each unit being sampled.
3/44.3 Other areas such as intersections, entrances, crossovers, ramps, etc. will be considered
as one unit and the thickness of each unit shall be determined separately. Small
3/28
irregular unit areas may be included as part of another unit. At such point as the
Engineer may select in each unit, one core shall be taken for each seven hundred fifty
(750) square metres of bituminous paving course.
3/44.4 If the core so taken is not deficient by more than three (3) millimetres from the specified
thickness, full payment will be made. If the core is deficient in thickness by more than
three (3) millimetres, from the specified thickness, two (2) additional cores shall be taken
from the area represented and if the average of the three (3) cores is not deficient by
more than three (3) millimetres from the specified thickness, full payment will be made.
If the average thickness of three (3) cores is deficient by more than three (3) millimetres,
but not more than ten (10) millimetres, or fifteen (15) percent (whichever is less), from
the specified thickness, an adjusted unit price as provided in the Bill of Quantities will be
paid for the area represented by these cores.
3/44.5 In calculating the average thickness of each bituminous paving course, measurements
which are in excess of the specified thickness by more than three (3) millimetres will be
considered as the specified thickness plus three (3) millimetres, and measurements
which are less than specified thickness by more than ten (10) millimetres or fifteen (15)
percent (whichever is less), will not be included in the average.
3/44.6 When the measurement of any core is less than specified thickness by more than ten
(10) millimetres, or fifteen percent (whichever is less), the actual thickness of the
bituminous paving course in this area will be determined by taking additional cores at not
less than three (3) metre intervals parallel to the centre-line in each direction from the
affected location until, in each direction, a core is found which is not deficient by more
than ten (10) millimetres, or fifteen (15) percent (whichever is less). Asphalt areas which
are deficient by more than ten (10) mm or 15% (whichever is less) shall be removed and
replaced at the Contractor's expense. Exploratory cores for deficient thickness may be
used in average for adjusted unit price. (Refer to the Bill of Quantities - Preambles for
Pavement Construction for price adjustments).
3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES
3/45.1 The density of the mix as placed and compacted on the road shall be determined from
cores cut from the compacted courses on the road at locations specified by the
Engineer. Samples shall be obtained in accordance with ASTM D979 in sets of two (2)
from the same location on the road. The frequency of testing shall be three (3)
specimens per traffic lane per three hundred (300) linear metres per layer or a minimum
of one (1) set per day for shorter runs, and such additional tests to determine limits of
area deficient in density, or for recheck. The density of these samples will be referred to
as "Road Density".
3/45.2 The Contractor shall cut the samples with an approved core drill in the presence of the
Engineer. The equipment shall be capable of cutting the material without shattering the
edges of the specimen. Samples shall be ten (10) centimetres in diameter for binder
course and wearing course and fifteen (15) centimetres in diameter for base course and
road base.
3/45.3 All test holes shall be filled and made good with approved material by the Contractor at
his expense.
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS
3/29
3/46.1 Hot bituminous mix shall be placed when the air temperature is eight (8) degrees C or
above, and when the weather is not dusty, foggy or rainy and when the existing surface
is free from moisture. Bituminous mix shall not be placed during sand storms.
3/46.2 No paving operations shall be started if rain is imminent.
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES
3/47.1 Bitumen material: One sample shall be tested for penetration and ring ball test every 80
tons.
3/47.2 Aggregate:One sample for each stockpile every 2,000 cu.m. shall be taken and all the
required tests shall be performed.
3/47.3 Bituminous mix : One sample of mix shall be obtained from at least every 300 tons or
part thereof and tested for bitumen content as per Ignition Method ASTM D6307 or as
directed by the Engineer, grading (ASTM C117 & C136), density (ASTM D1188 or
D2726), stability (ASTM D1559) and voids.
3/47.4 Loss of Marshall stability shall be tested for at least every 7,000 tons.
3/47.5 Thickness cores and compaction cores shall be taken as specified in Clause 3/44 and
3/45 respectively.
3/48 BITUMINOUS PRIME COAT
3/48.1 Bituminous Prime Coat shall consist of supplying and applying liquid asphalt to a
previously prepared and approved subgrade, subbase, aggregate base course or wet
mix road-base in accordance with this Specification.
3/48.2 Material for Prime Coat shall be:-
LIQUID ASPHALT for prime coat shall be medium curing cut back asphalt MC-70 to the
requirements of ASTM D2027 as modified by Table 10 or as directed by the Engineer.
The sampling method shall be in accordance with ASTM D140.
TABLE 10
MEDIUM CURING LIQUID

ASPHALT MC 70
TEST TEST METHOD MIN. MAX.
ASTM
Saybolt Furol Viscosity at
50 deg.C. sec. D88 60 120
Flash Point, Tag open Cup,
deg.C. D3143 38 -
Distillation : D402
- Distillate (% of total
distillation to 360 deg.C)
To 225 deg. C - 20
3/30
To 260 deg. C 20 60
To 315 deg. C 65 90
Residue from distillation
to 360 deg.C, percent by
volume difference 55 -
Tests on residue from
distillation :
- Penetration 25 deg.C, 100g D5 120 250
5 sec.
- Ductility 25 deg.C, cm D113 100 -
- Solubility in trichloro-
ethylene % D2042 99 -
Water percent D95 - 0.2
3/48.3 Prime coat shall be applied at a rate of not less than 0.7 litres per square metre and not
more than 1.5 litres per square metre.
3/48.4 The exact rate of application, which may be varied to suit field conditions, will be
determined by the Engineer following trials to be carried out by the Contractor.
3/48.5 The surface to be prime coated shall be uniformly smooth and firm and true to the
grades and cross-sections shown on the drawings within specified tolerances, and so
maintained throughout prime coating. Prime coat shall not be placed on a soft, uneven
base. Any holes, depressions or irregularities shall be repaired by the removal of loose
and unsuitable material and its replacement with suitable material compacted to produce
a dense, even surface of uniform texture. When required, the surface to be primed shall
be lightly bladed and compacted and the Engineer may instruct a light application of
water to facilitate penetration. Priming will not be permitted when the surface is wet.
3/48.6 Prime coat shall not be applied when the ambient temperature is less than 13° C or
during rain, fog, dust storms or other unsuitable weather. The application temperature
for MC-70 liquid asphalt shall be between 50° C and 80° C as approved by the
Engineer. It shall be applied to one lane of the carriageway width at a time. When
applied in two or more lanes there shall be a slight overlap along adjoining edges.
Overlapping will not be permitted at transverse joints and thick paper shall be used to
protect the previous application.
3/48.7 Traffic shall be kept off the prime coat until it has penetrated the subgrade or roadbase
and fully cured. It should be left undisturbed for a period of 48 hours or as otherwise
3/48.8 The Contractor shall furnish and spread at his cost sufficient clean fine sand, of an
approved quality, to blot up areas which show an excess of prime coat.
3/48.9 The primed surface shall be maintained in a good, clean condition at all times until the
next course is placed. Any surface irregularities or holes in the primed surface, however
caused, shall be repaired and corrected to the Engineer's satisfaction.
3/49 BITUMINOUS TACK COAT
3/31
3/49.1 Bituminous tack coat shall consist of supplying and applying emulsified asphalt diluted
with an equal quality of water (1:1) to a previously prepared bituminous base course or
binder course or to an existing bituminous surface, in accordance with this specification.
3/49.2 The material for bituminous tack coat shall be slow setting emulsified asphalt, grade SS-
1h (anionic) conforming to the requirements of ASTM D977.
3/49.3 The tack coat (diluted emulsion) shall be applied in quantities of not less than 0.3 litres
per square metre and not more than 0.6 litres per square metre.
3/49.4 Immediately before applying the tack coat, all loose material, dirt, clay or other
objectionable material, shall be removed from the surface with a power broom or blower
supplemented with hand brooms, as directed by the Engineer. After the cleaning
operation, and prior to the application of the tack coat, an inspection of the area to be
coated will be made by the Engineer.
3/49.5 The application temperature for the tack shall be between 10°C and 60°C as directed
by the Engineer. The material should not be applied when the ambient temperature is
less than 13°C or during rain, fog, dust storms or other unsuitable weather.
3/49.6 After application the surface shall be allowed to dry to the proper condition of tackiness
to receive the following pavement course. Tack coat shall be applied only so far in
advance to pavement courses to obtain the proper condition of tackiness and the
Contractor shall protect the tack coat from damage during this period.
3/49.7 If the completed tack coat is damaged by rain or dust, it shall be allowed to dry, cleaned
by power broom or blower and, if required by the Engineer, an additional light
application of tack coat shall be applied. No additional payment shall be made for this
work.
3/49.8 Where, in the opinion of the Engineer, a tack coat is not necessary, the Contractor shall
clear, at his expense the existing surface free of dust and other deleterious material as
paragraph 4 above.
3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT
3/50.1 A self-powered pressure distributor should be used for applying asphalt mixture. The
distributor shall have pneumatic tyres of such width and number that the load produced
on the base surface shall not exceed 110 Kg per centimetre of tyre width, and shall be
so designed and equipped as to distribute the bituminous material uniformly at even
heat on variable width of surface at readily determined and controlled rates from 0.2 to
7.5 litres per sq.m. with a pressure range of 1.25 Kg to 5.2 Kg per sq.m. and with an
allowable variation from any specified rate not exceeding 5 percent. Distributors and
booster tanks shall be so maintained at all times that no dripping of bituminous material
will occur from any part of the equipment.
3/50.2 Distribution equipment shall include an independently operated bitumen pump,

technometer pressure gauges, volume measuring devices, a thermometer for reading
the temperature of tank contents, and a hose attachment for applying bituminous
material to spots unavoidably missed by the distributor. The distributor shall be equipped
for circulation and agitation of the bituminous material during the heating process.
3/50.3 The equipment for heating shall consist of steam coils and equipment for producing
steam, so designed that steam will not be introduced into the material. In the event of
storage tanks being used, an armoured thermometer with a range from 10 deg.C to 150
deg.C shall be fixed to the tank so that the temperature of the bituminous material may
be determined at all times.
3/32
3/50.4 Other heating facilities may be used subject to the approval of the Engineer.
3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION
3/51.1 This work shall consider of a wearing surface composed of a bituminous prime followed
by two (2) applications of bituminous seal coats with each seal coat receiving an
application of cover material in accordance with the Specifications and in conformity with
the lines shown on the drawings or established by the Engineer.
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/52.1 PRIME COAT
The prime coat shall be medium curing cut-back asphalt grade MC-70. The rate of
application shall be between 1.00 to 1.75 litres per square metre as specified by the
Engineer.
3/33
3/52.2 SEAL COAT
The seal coat shall be 85/100 penetration grade bitumen. The bitumen may be cut back
with up to 2% by weight of kerosene to improve adhesion to the stone. The
characteristics of the bitumen are shown in the following table:-
85/100 PENETRATION GRADE BITUMEN
TEST METHOD MIN. MAX.

(ASTM)
Penetration at 25
deg.C, 100 g, 5 sec. D5 85 100
Flash Point,
Cleveland Open Cup,
deg.C D92 232 -
Ductility at 25 deg.
C, cum D113 100 -
Solubility in
trichloro ethylene,% D2042 99 -
Thin film oven test

3.2mm, 163 deg.C
5 hour loss on
heating, percent D1754 - 1.0
Penetration of
residue percent
of original D5 47 -
Ductility of residue
at 25° C 5cm/min. cm D113 75 -
3/52.3 COVER MATERIAL
Aggregate for cover material shall be screenings of crushed stone which are clean,
tough, durable and free from dirt and other objectionable matter. The percentages of
wear shall not be more than thirty (30) as determined by ASTM C131 & C535. When
subjected to five (5) cycles of magnesium sulphate soundness testing, as determined by
ASTM C88, it shall have a weight loss not greater than ten (10) percent and a flakiness
index of 30% (BS 812:Part 105.1 latest edition) and ACV of 20% (BS 812:Part 3 Test 6
latest edition). No less than sixty (60) percent by weight of crushed stone shall consist of
crushed pieces having two or more faces produced by fracture when tested by DM
standard test method DM 301. Aggregate shall conform to the following gradations and
3/34
DOUBLE BITUMINOUS SURFACE TREATMENT
3/4" 1/2" 3/8" 1/4" No.4 No.10 No.30 No.200
First 100 70-90 0-15 - 0-2 - - -

Course
Second - - 100 90-100 60-85 0-25 0-5 0-2

Course
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/53.1 The equipment used by the Contractor shall include a power broom or a power blower,
or both; a self propelled, pneumatic-tyred roller, or steel-wheeled tandem roller (4 to 8
tons) or both; self-propelled aggregate spreading equipment that can be adjusted to
spread accurately the specified amount per square metre; a bitumen distributor and
equipment for heating the asphaltic materials.
3/53.2 Other equipment may be used in addition to the specified equipment when approved or
requested by the Engineer.
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/54.1 HEATING OF BITUMINOUS MATERIALS shall be with the equipment as specified. The
use of any method or agitation or heating that introduces free steam or moisture into the
bituminous material is prohibited. Materials heated to temperatures above twenty eight
(28) degrees C higher than the maximum application temperature specified shall be
considered as overheated and shall be rejected until the material can be resampled and
retested. The reacceptance or final rejection will be made by the Engineer on the same
requirements under which the material was originally tested.
5/54.2 If aggregates are deemed by the Engineer to be dusty or dirty they shall be washed
after which their use shall not be permitted until all free water has evaporated or been
drained.
3/55 APPLICATION OF DOUBLE BITUMINOUS SURFACE TREATMENT
3/55.1 After the prime coat has been applied and has thoroughly penetrated the surface and
cured as specified, the Contractor shall apply 80/100 penetration bitumen and shall
apply the cover material and roll and manipulate the surface, all in accordance with the
requirements specified hereinafter. The material shall be uniformly applied at the rate
designated to the surface being sealed.
3/55.2 Bituminous material shall be applied by means of a pressure distributor in a uniform,

continuous speed over the section to be treated and within the temperature range
specified. The quantity of bituminous material to be used per square metre shall be
within the limits hereinafter specified and as directed by the Engineer.
3/55.3 A strip of building paper, at least one (1) metre in width and with a length equal to that of
the spray bar of the distributor plus thirty (30) centimetres, shall be used at the
beginning of each spread. The paper shall be removed and disposed of in an approved
manner. The distributor shall be moving forward at proper application speed at the time
the spray bar is opened. Any skipped areas or deficiencies shall be corrected in an
approved manner. Junctions of spreads shall be carefully made to ensure a smooth
riding surface.
3/35
3/55.4 The length of spread of bituminous materials shall not be in excess of that which trucks
loaded with cover coat material can immediately cover.
3/55.5 The spread of bituminous material shall not be more than fifteen (15) centimetres wider
than the width covered by the cover coat material from the spreading device. Under no
circumstances shall operations proceed in such manner that bituminous material will be
allowed to chill, set up, dry or otherwise impair retention of the cover coat.
3/55.6 The distributor, when not spreading, shall be so designed that the spray bar or
mechanism will not drip bituminous material on the surface of the travelled way.
3/55.7 Distribution of the bituminous material shall be so regulated and sufficient bituminous
material must remain in the distributor at the end of each application so that there will be
a uniform distribution of bituminous material. In no case shall the distributor be allowed
to expel air with the bituminous material thereby causing uneven coverage.
3/55.8 The angle of the spray nozzles and the height of the spray bar shall be so adjusted and
frequently checked so that uniform distribution is ensured. If the raise of the spray bar as
the load is removed is excessive and contributes to drilling and streaking of the seal
course, the frame of the distributor shall be blocked or snubbed to the axle of the truck
to maintain a constant height of the spray bar above the road surface. The distribution
shall cease immediately upon any clogging or interference of any nozzle and corrective
measures shall be taken before distribution is resumed.
3/55.9 APPLICATION OF AGGREGATE
Immediately following the application of the bituminous material, cover material shall be
spread with an approved aggregate spreader in quantities as specified by the Engineer and
within the limits specified herein. Spreading shall be accomplished in such a manner that
the tyres of the trucks or aggregate spreader at no time contact the uncovered and newly
applied bituminous material.
3/55.10 The operations of distributing bituminous material shall not be in excess of one hundred
(100) linear metres ahead of the spreading of the aggregate.
3/55.11 Procedures of starting, stopping or turning of any piece of equipment which results in
displacement of the cover material or damage to the seal courses shall be prohibited.
3/55.12 The spreading equipment shall be of such width and arrangement that as the aggregate is
placed, complete coverage will be obtained. No brooming, dragging or blading of the cover
material shall be permitted prior to initial rolling. Any rearrangement of the cover material
shall be done by hand methods. Overlapping the applications of cover material shall be
avoided and all spillage shall be removed from the surface. Before rolling, the bituminous
material shall be uniformly covered.
3/55.13 The rates of application for bituminous material and aggregate for "Double Bituminous
Surface Treatment" shall be within the following limits:
RATES OF APPLICATION OF ASPHALT AND AGGREGATE FOR DOUBLE

BITUMINOUS SURFACE TREATMENT
85/100 AGGREGATE
PENETRATION KG/SQ.M.
KG/SQ.M.
MIN. MAX. MIN. MAX.
3/36
First application 0.70 1.10 12.5 15.00
(Course)
Second application 0.70 0.90 6.5 8.5

(Course)
3/55.14 MANIPULATION
Immediately after the application of bituminous material and aggregate to the road
surface and after the aggregate has been rearranged as may be necessary to provide
uniform and complete coverage, the surface shall be sufficiently rolled with an approved
pneumatic-tyred roller to embed the aggregate thoroughly into the bituminous material.
Sufficient rollers shall be provided such that the initial rolling consisting of a single pass
of a 10 - 12 ton tandem steel wheel roller followed by at least two (2) complete
coverages with the pneumatic-tyred roller shall be completed within thirty (30) minutes
after the cover material is applied. The rollers shall be operated on each coverage so
that each succeeding trip of the roller will overlap at least fifty (50) percent of the width
of the previous trip. No blading or dragging of the aggregate will be permitted for the first
seal coat. Any rearrangement of the cover material before or during the initial rolling
shall be done by approved hand methods. Rolling shall be continued after the rolling
specified above is completed until a maximum amount of the aggregate is satisfactorily
embedded in the bituminous material. Pneumatic-tyred rollers shall be operated at a
maximum speed of eight (8) kilometres per hour.
3/55.15 SECOND SEAL COAT
Unless otherwise designated on the drawings, or directed by the Engineer, the second
seal coat shall not be applied for 48 hours after the application of the first seal coat.
3/55.16 Immediately prior to the second application of bituminous material for sealing, the
surface shall be cleaned in an approved manner of all dust and excess cover material
which is not embedded in the first application of bituminous material for sealing. Care
shall be exercised not to dislodge any cover material which is embedded in the
bituminous material. The second seal coat shall be applied as previously specified.
Brooms or drag brooms shall not be used to shift the cover material until the initial rolling
with the pneumatic-tyred roller is completed and until the bituminous material has cooled
and set up sufficiently to hold the cover material, preferably not earlier than the day
following the application of the second seal coat. Any rearrangement of the cover
material during the initial rolling shall be done by approved hand methods.
3/55.17 The rolling shall be longitudinal and shall commence at the outer edge of the shoulder
and then progress towards the inner edge. Rolling shall continue until the entire surface
has been completely covered at least three (3) times with a pneumatic tyred roller.
Maximum speed of rollers shall be as previously specified.
3/55.18 ADDITIONAL MANIPULATION OF COMPLETED SURFACES
The Contractor shall manipulate the surface for a period of five (5) days after the second
seal coat has been applied. The manipulation shall consist of the application of
additional aggregate or additional dragging and rolling or all of these operations to
portions of the surface that, as determined by the Engineer, require such additional
treatment. The manipulation shall also include the dragging and one (1) complete rolling
over the entire surface each day from the time the surface is completed until and
including the fifth (5th) day after. A light blade equipped with a broom drag shall be
operated immediately ahead of the roller throughout all rolling during the manipulation
period. The daily dragging and rolling under manipulation may be omitted, if in the
3/37
opinion of the Engineer, the weather and roadbed conditions are such that the dragging
and rolling would not be beneficial to the surface.
3/55.19 Aggregate and additional manipulation ordered by the Engineer, in this work, will not be
paid for separately but will be considered subsidiary to the item of 'Double Bituminous
Surface Treatment" included in the "Bill of Quantities".
3/55.20 Except for times when it is necessary for hauling equipment and/or pilot trucks to travel
on the newly applied seal coat, traffic of all types shall be kept off the seal coat until it
has had time to set properly. The minimum traffic free period shall be 24 hours.
3/55.21 WEATHER LIMITATIONS
Surface treatment operations shall be carried on only when the surface is dry, when the
atmospheric temperature is above fifteen (15) degrees C, and when the weather is not
dusty, foggy or rainy. The above requirements may be waived, but only when so
directed and in writing by the Engineer.
3/56 PROTECTION OF ADJACENT STRUCTURES FROM BITUMEN SPLASHING
3/56.1 When bituminous materials are being applied, the surface of all structures, wheel
guards, guard rail, kerbs and gutters, and other roadway appurtenances shall be
protected in an approved manner to prevent them from being splattered with bituminous
material or marred by equipment operation. In the event that any appurtenances
become splattered or marred, the Contractor shall at his own expense, remove all traces
of bituminous materials, and repair all damage, and leave the appurtenances in an
approved condition.
3/38
SECTION 4 - CONCRETE WORKS
Concrete work shall consist of furnishing all materials and constructing structures of the
forms, shapes and dimensions shown on the Drawings or as directed in accordance with the
details shown on the Drawings and these Specifications.
4/1 CEMENT
SULPHATE RESISTING CEMENT
4/1.1 Sulphate Resisting Cement shall comply with BS 4027 of latest edition or ASTM
C150 Type 5. In addition the cement shall comply with the following:-
- The acid soluble alkali level measured as (Na2 O+0.658 K2 O) shall not
exceed 0.6% by weight determined in accordance with BS EN-196 Part 21.
- The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in
accordance with BS 4550 : Part 3 Section 3.8.
- The specific surface shall be not greater than 325 sq.m/Kg and not less than
225 sq.m/Kg when tested in accordance with BS EN-196 : Part 6.
Chloride content shall be < 0.01% by mass of cement when tested in

accordance with BSEN-196 : Part 21 - 1992 Clause 4.
For 25/20 & 30/20 class of concrete, the standard strength class of cement
shall be 32.5N and for 40/20 class of concrete the strength class of cement
shall be 42.5N when tested according to BS EN 196 Part 1.
ORDINARY PORTLAND CEMENT
4/1.2 Ordinary Portland Cement shall conform to the requirements of BS 12 of latest

edition or ASTM C150 Type 1 with the following amendments:-
- The acid soluble alkali level measured as Na2 O+0.658 K2O shall not exceed
0.6% by weight determined by the test method described in BS EN 196 Part
21.
- The tricalcium aluminate content shall lie within the range of 4% to 13%.
- The specific surface (fineness) shall not be greater than 325 sq.m/Kg and not
less than 225 sq.m/Kg when tested as described in BS EN 196 : Part 6.
- Heat of hydration should not exceed 290 KJ/kg at 7 days when tested in
accordance with BS4550 : Part 3 Section 3.8.

For 40/20 and 45/20 class of concrete the standard strength class of cement
shall be 42.5N when tested in accordance to BS EN 196 Part 1.
MODERATE SULPHATE RESISTING PORTLAND CEMENT
4/1
4/1.3 Moderate sulphate resisting Portland Cement shall comply with BS12 but
containing not less that 4% and not more than 8% proportion by weight of
tricalcuim aluminate, or cement complying with ASTM C150 Type 2 with the
following amendments. In either case the cement shall not contain more than
2.7% proportion by weight of sulphur trioxide.
- Heat of hydration should not exceed 290 KJ/kg at 7 days when tested in
accordance with BS4550 : Part 3 Section 3.8.
- The acid soluble alkali level measured as Na2 O+0.658 K2O shall not exceed
0.6% by weight determined by the test method described in BS EN 196-21.
- The specific surface (fineness) shall not be greater than 325 sq.m/Kg and not
less than 225 sq.m/Kg when tested as described in BS EN 196 : Part 6.

For 40/20 and 45/20 class of concrete the standard strength class of cement
shall be 42.5N when tested in accordance to BS EN 196 Part 1.
GENERAL
4/1.4 Each cement batch shall bear manufacturer's name and batch number. Type of
cement shall be the same as mentioned in the approved analysis report. Each
separate consignment of cement shall be tested by the manufacturer before
delivery and certified copies of such tests shall be supplied to the Engineer
before any part of the consignment is used in the works. The Engineer reserves
the right to order a re-test of cement at any time. Approval of cement does not
relieve the Contractor of the responsibility to produce concrete of the specified
strength.
4/1.5 Cement shall be delivered to site in bulk, or with the Engineer's approval, may be
supplied in sealed bags which shall bear the manufacturer's name and the date
of manufacture. Each consignment shall be accompanied by a copy of the
manufacturer's batch test certificate and certificate of guarantee.
4/1.6 Each consignment of cement shall be kept separate, identified and used in order
of delivery.
4/1.7 Any consignment not used within 2 months from the date of manufacture will not
be allowed to be used in the works.
4/1.8 One brand only of cement as approved by the Engineer shall be used throughout
the works unless otherwise authorised by the Engineer in writing.
4/2 AGGREGATES GENERAL REQUIREMENTS
4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 "Concrete aggregates
from natural sources" and shall also comply with Dubai Municipality
Administrative Order No. 143/91.
4/2.2 The aggregates used in the permanent works shall be naturally occurring or
4/2
crushed materials obtained only from approved sources.
4/2.3 Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.
4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works. Part of
each sample will be required for concrete trial mixes and part shall be retained for
comparison with subsequent deliveries.
4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102.
4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the member for which the concrete is to be used and
not larger than 3/4 of the maximum clear distance between reinforcing bars.
4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry approved
by the Engineer.
4/2.9 Unless otherwise authorised by the Engineer coarse aggregate shall be delivered
to site in separate sizes according to the maximum specified aggregate size for
each grade of concrete.
4/2.10 Aggregates shall meet the requirements of Table 4.1.
4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.2.
4/3
TABLE 4.1
LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL

PROPERTIES OF AGGREGATES FOR CONCRETE
________________________________________________________________
____
TEST METHODS PERMISSIBLE LIMITS
IN
SR. KIND OF REQUIREMENT ----------------------- ------------------------------
NO BS812: ASTM: FINE COARSE
AGGREGATES
AGGREGATES
---------------------------------------------------------------------------------------------------------
1. Grading Part 103 (dry) Standard Standard
2. Material finer
than 0.075 mm Part 103 (wet)
Natural, uncrushed max.3% max.1%
Crushed rock max.7% max.1%
3. Clay lumps and

friable particles C142 max.1% max.1%
4. Light weight pieces C123 max.0.5% max.0.5%
5. Organic impurities C40 The colour of the super-

for fine aggregate natant liquid is lighter
than standard colour
solution
6. Water absorption C128/C127 max.2.3% max.2%
7. Specific Gravity C128/C127 min.2.6 min.2.6

(apparent)
8. Shell content in aggregates Part 106

Coarser than 10mm max.5%
Between 5mm & 10mm max.15%
9. Particle shape
Flakiness index Part 105.1 max.25
Elongation index Part 105.2 max.25
(If the coarse aggregates are stockpiled

separately, then the indices of each stockpile
shall be determined and result combined in
proportion of their weight as per design to
compare with the specified value provided no
individual stockpile shall have indices more than
30).
Partially crushed 100% with at least

faces of aggregate DM301 one crushed face
4/4
TABLE 4.1 (CONT'D)
LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL
PROPERTIES OF AGGREGATES FOR CONCRETE
________________________________________________________________
____
TEST METHODS PERMISSIBLE LIMITS
SR. KIND OF REQUIREMENT ----------------------- ------------------------------
NO BS812: ASTM: FINES COARSE
---------------------------------------------------------------------------------------------------------
10. Acid soluble Part 117,

Chlorides, CL Appendix C
For reinforced
concrete made with
SRPC cements max.0.03% max.0.01%
OPC & MSRPC cements max.0.03% max.0.02%
For mass concrete

made with SRPC cements max.0.03% max.0.02%
OPC & MSRPC cements max.0.03% max.0.04%
For prestressed
concrete & steam
cured structural concrete max.0.03% max.0.01%
11. Acid soluble

sulphates, S03 Part 118 max.0.3% max.0.3%
12. Soundness, MgS04

(5 cycles) C88 max.12% max.12%
13. Mechanical strength

10% fines value Part 111 min100KN
or Impact value Part 112 max.30%
Loss Angeles Abrasion C131/C535 max.30%
14. Drying Shrinkage Part 120 max.0.05%
15. Potential reactivity,

Note 2
Of Aggregates,
Chemical Method C289 Innocuous Innocuous
Of Cement-Aggregate
Combination C227 6 month expansion
0.10% max.
---------------------------------------------------------------------------------------------------------
Note 1 : There is no requirement of shell content in sands passing 5 mm sieve
size.
Note 2 : Aggregates may initially be assessed for its reactivity in accordance
with ASTM C289 and if potential reactivity is indicated, then mortar bar
tests in accordance with ASTM C227 shall be carried out.
4/5
TABLE 4.2
FREQUENCY OF ROUTINE TESTS ON AGGREGATES

________________________________________________________________
_
SR. KIND OF REQUIREMENT - TEST METHOD TEST FREQUENCY RATE
NO.
--------------------------------------------------------------------------------------------------
1. Grading - BS 812 Part 103 Every 1000 m3 for

each stockpile
2. Material finer than 0.075 mm - Every 1000 m3 for

BS 812 Part 103 each stockpile
3. Clay lumps and Friable Particles Every 1000 m3 for

- ASTM C 142 each stockpile
4. Organic impurities ASTM C 40 Every 1000 m3 for

each stockpile
5. Water absorption - ASTM C128/C127 Every 1000 m3 for

each stockpile
6. Specific Gravity - ASTM C128/C127 Every 1000 m3 for

each stockpile
7. Shell content - BS 812 Part 106 Every 1000 m3 for

each stockpile
8. Particle shape BS 812 Part 105.1 Every 1000 m3 for

105.2 each stockpile
9. Acid soluble chlorides, CL
Qualitative-BS 812 Part 117 On each delivery

Appendices A/B to site
Quantitative-BS 812 Part 117 Each 6 concrete

Appendix C days if result is
more than 75% of
the limit and each
month if result is
less than 75% of
the limit.
10. Acid soluble sulphates, On each delivery

S03 - BS 812 Part 118 to site.
4/6
TABLE 4.2 (CONT'D)
FREQUENCY OF ROUTINE TESTS ON AGGREGATES

________________________________________________________________
_
SR. KIND OF REQUIREMENT - TEST METHOD TEST FREQUENCY RATE
NO.
--------------------------------------------------------------------------------------------------
11. Soundness, Mg S04 (5 cycles) Each 48 concrete
ASTM C88 days
10% Fines or impact value Each 72 concrete

- BS 812 Parts 111, 112 days
Los Angeles abrasion - - do -

ASTM C 131/C 535
13. Moisture variation in sand - by Twice daily

Moisture Meters
14. Drying Shrinkage At the start of the project

BS812 Part 120 and whenever there is a
change in the source of
supply.
15. Potential Reactivity: At the start of the project

of aggregates and wherever there is a
(ASTM C295, C289) change in the source of
supply
of Carbonate (ASTM C586)
of Cement aggregate
combination
(ASTM P214 and C227)
--------------------------------------------------------------------------------------------------
Note : Drying Shrinkage and potential reactivity of aggregates shall be
determined initially at the start of the project or whenever there is a
change in the source of supply.
4/3 FINE AGGREGATES
4/3.1 The gradation of fine aggregate shall be in accordance with BS 882 latest edition
excluding grading designation F.
4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to allow
inspection and tests to be carried out.
4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand and shall be
within BS882 zones c and m only.
4/7
4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
4/4 COARSE AGGREGATE FOR CONCRETE
4/4.1 Coarse aggregate shall be prepared by blending two or more single sized
aggregates. Combined grading of thus blended coarse aggregate shall conform
to the grading limits given in BS 882 : 1992 Table 3..
4/4.2 Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall not be used.
4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
4/5 COMBINED AGGREGATE
4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions as specified in BS 882 and as approved by the Engineer. However,
in no case shall materials passing the 0.075mm, sieve exceed three (3) percent
by weight of the combined aggregate.
4/5.2 The combined aggregate gradation used in the work shall be as specified, except
when otherwise approved or directed by the Engineer. Changes from gradation to
another shall not be made during progress of the work unless approved by the
Engineer.
4/6 WATER FOR CONCRETE
4/6.1 The Contractor shall make his own arrangement and obtain approval for the
supply of water.
4/6.2 The mixing water should be clear, apparently clean and free from matter harmful
to concrete in its fresh or hardened state. Potable water can be used. Water of
questionable quality should comply with the physical tests of Table 4.3 and
chemical limitation listed in Table 4.4. Water shall also meet the requirements of
BS 3148 of latest edition.
4/6.3 The temperature of water for concrete should not be less than 5 degree celsius
nor more 25 degree celsius. Water may be cooled to not less than 5 degree
celsius by the gradual addition of chilled water or ice but on mixing, no ice
particles should be present in the mix. Alternatively, flaked ice may be used. The
ice to be used should be crushed and should be the product of frozen water
which complies with acceptance criteria of Tables 4.3 and 4.4.
4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to
cause discolouration of the concrete. Sources of Water shall be maintained at
such depth and the water shall be withdrawn in such a manner as to exclude silt,
mud, grass and other foreign matter.
4/8
TABLE 4.3
ACCEPTANCE CRITERIA AND PHYSICAL

TESTS FOR MIXING WATER
--------------------------------------------------------------------------------------------------
Limits ASTM Test
--------------------------------------------------------------------------------------------------
Compressive strength,min.% 90 C 109

control at 7 days
Setting time, deviation from 1:00 early

from control,h:min. to 1:30 later C 191
--------------------------------------------------------------------------------------------------
TABLE 4.4 - CHEMICAL LIMITATIONS FOR MIXING WATER
--------------------------------------------------------------------------------------------------
Max.Concentration, Limit,ppm Test Method
--------------------------------------------------------------------------------------------------
1. Chloride as C1 250 ASTM D 512
2. Sulphates as SO4 350 ASTM D 516
3. Alkali carbonates 500 ASTM D 513

and bicarbonates
4. Total dissolved
ions, including
1, 2 & 3 above 2000 BS 1377 : Part 3:
Test 8
5. pH min.7/max. 9 ASTM D1293

--------------------------------------------------------------------------------------------------
4/7 APPLICABLE TESTS AND CODES
4/7.1 All concrete, aggregate, cement and water shall be sampled and tested during
construction as frequently as deemed necessary by the Engineer. All test
samples shall be supplied by the Contractor at his expense. Samples shall be
obtained in accordance with BS 812, BS 3148, BS 1881 and BS EN 196. Testing
shall be at the frequencies stated in the Specifications or relevant standards. All
sampling shall be carried out by the Engineer.
4/7.2 WORKABILITY
Workability shall be assessed by the following tests the requirements for which
shall be as specified elsewhere in the documents.
Slump test shall be performed according to BS 1881 Part 102
Compaction factor shall be performed according to BS 1881 Part 103.

4/9
Vebe time shall be performed according to BS 1881 Part 104
Flow test shall be performed according to BS 1881 Part 105.
4/7.3 COMPRESSION TEST
The Compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS 1881 Part 116. Sampling, making test cubes and curing of
cubes shall be in accordance with BS 1881 Parts 101, 108 and 111 respectively.
4/8 REINFORCEMENT BARS
4/8.1 All reinforcement bars shall be of a deformed type in accordance with BS 4449,
except that plain bars may be used where specifically indicated on the Drawings.
Plain bars shall be in accordance with BS 4449 of latest edition.
4/8.2 All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars grade 460 Type 2, unless otherwise shown on
the Drawings or specified by the Engineer.
4/8.3 Certification. Three (3) copies of a mill test report shall be furnished to the
Engineer for each lot of steel reinforcement bars proposed for use on the project.
4/8.4 Identification. The bars in each lot shall be legibly tagged by the manufacturer
and/or fabricator before being offered for inspection. The tag shall show the
manufacturer's test number and lot number and other applicable data that will
identify the material with the certificate issued for that lot of steel.
4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the
heat number or numbers from which each size of bar in the shipment was
fabricated.
4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site. The Contractor shall provide a certificate
confirming that samples taken from the bars delivered to the works pass all the
tests including the rebend test. The frequency of sampling and the method of
quality control shall be in accordance with Table 5 and Clause C 3.2 of BS 4449
of latest edition.
4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,
paint, grease, oil or other foreign substance, fins, or tears. There shall be no
evidence of visual flaws in the bars, test specimens or on the sheared ends of the
bars.
4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil,
grease, salt and other deleterious materials and where pitting has occurred the
causes and products thereof. Repeated blasting may be required when the
reinforcement is in position, or partially cast in. Partially set concrete adhering to
exposed bars during concreting operations shall be removed.
4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown on

the drawings. Only approved concrete spacers shall be used. The concrete shall
be of similar grade to the main concrete and shall have non metallic ties.
4/9 BAR SCHEDULES AND SHOP DRAWINGS.

4/10
4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules
and adjust them if necessary to the approval of the Engineer. Bar schedules shall
show the weight of each bar, the total weight of each bar size and the total weight
of bars, and bending diagrams for bars in accordance with BS 4466.
4/9.2 The Contractor shall provide and submit to the Engineer for approval any working
drawings additional to the Contract Drawings which may be found necessary for
the production of revised bar schedules or for the completion of the works.
4/9.3 The approval of working drawings, or revised bar schedules by the Engineer shall
in no way relieve the Contractor of responsibility for the correctness of such
drawings or schedules.
4/10 BAR CUTTING AND BENDING
4/10.1 Reinforcement shall be cut and bent in accordance with B.S. 4466. Cutting or
bending by the application of heat is not permitted. Welding of reinforcement shall
only be permitted when approved in writing by the Engineer. If such approval is
given then the workmanship shall be in accordance with BS 5135. The Contractor
shall submit full technical details of his proposed procedures prior to seeking
approval.
4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.
4/10.3 Stockpiles of cut and bent steel shall be well protected from weathering action as
4/11 PLACING AND FIXING REINFORCEMENT
4/11.1 Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar
intersections shall be tied together using 1.2mm diameter steel wire or No. 18
gauge stainless steel wire as indicated on the drawings and the ends of the tying
wire shall be turned into the main body of the concrete.
4/11.2 Metal supports, approved by the Engineer, shall be provided and used to retain
the reinforcement at proper distances from the forms. Supports under horizontal
bars at the bottom of base slabs shall be spaced at not more than eighty (80)
diameters of the bar. All reinforcement shall be so rigidly supported and fastened
that displacement will not occur during construction. Reinforcing steel shall be
inspected in place and must be approved by the Engineer before any concrete is
deposited.
4/11.3 No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.
4/11.4 Reinforcement temporarily left projecting from the concrete at construction or

other joints shall not be bent out of position during the periods in which concreting
is suspended, except with the approval of the Engineer.
4/12 WELDED WIRE FABRIC

4/11
4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform to
the following requirements:
- Dimensions. Welded steel wire fabric shall conform to the size and
dimensions shown on the Drawings.
- Properties. Wire fabric furnished under this specification shall conform to the
requirements for "Welded Steel Wire Fabric for Concrete Reinforcement"
AASHTO M 55-81 or to BS 4483.
4/13 SPACER BLOCKS
4/13.1 Spacers as approved by the Engineer shall be of such material and design as will
be durable, not lead to corrosion of the reinforcement and not cause spalling of
the concrete cover.
4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the mix
proportions of the surrounding concrete so far as is practicable with a view to
being comparable in strength, durability and appearance.
4/14 ADMIXTURES
4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used.
4/14.2 Where the use of admixture had been agreed by the Engineer, they shall conform
to the requirements of Type A, Type D, Type F or Type G as specified in ASTM
C494 and shall be used in strict accordance with the manufacturer's instructions.
Preliminary tests of cube strength and other tests shall be carried out using the
combination of aggregates cements and admixtures proposed for use.
4/14.3 The Contractor shall be entirely responsible for the use of any approved
admixtures.
4/14.4 Approved methods and equipment shall be used for dispensing and incorporating
the admixture into the concrete. The dispensing unit shall be designed so that the
discharge of the admixture is visible.
4/15 CONCRETE MIX SPECIFICATION
4/15.1 Concrete shall be as shown in the Table of 4.5. The number of mixes may
require to be increased.
The criteria given in the Table are designed to produce concrete of the required
strength and durability.
If the maximum aggregate size is 10 mm then the cement content stipulated for
the class of concrete given in table 4.5 shall be increased by 40 Kg per m3.
4/12
TABLE 4.5
TABLE OF MIXES
--------------------------------------------------------------------------------------------------
Concrete Max. Min. Max. Characteristic

Class Size Qty. Free Cube Strength
Agg of Water/ CCS
Cement Cement
Ratio 7-day 28-day
mm. kg.per m3 N/mm2 N/mm2
--------------------------------------------------------------------------------------------------
45/20 20 400 0.425 33 45

40/20 20 370 0.475 30 40
37/20 20 350 0.50 26 37
35/20 20 330 0.525 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15
--------------------------------------------------------------------------------------------------
The CCSs are for concrete which has been cured at a temperature of 23 degrees
C + 2 degree C, and are the values below which no more than 5% of the test
results fall. The 7-day strengths shall be used only as a guide.
4/15.2 Concrete shall comply with BS 8110 except where BS 8007 or this specification
differs. Sampling for test purposes shall comply with BS 1881 Part 101 (on site) &
Part 125 (in laboratory).
If air-entertainment is specified the average air content at the time of placing

measured in accordance with BS 1881 PART 106 shall be:
Concrete containing 20mm

Maximum size aggregate 5% + 1%
Concrete for water-retaining shall be watertight and shall comply with the
recommendations of BS 8007.
Concrete for paving or precast units shall be tested to BS 1881 Part 118 and
shall have a minimum flexural beam strength of 3.5N/mm2 at 28 days. If the
concrete has a specified CCS of 40N/mm2 or greater, then the minimum flexural
strength shall be 4N/mm2.
If concrete specimens are cured at higher temperatures or for longer periods than
BS 1881 Part 111 requires, the adjusted CCS shall be calculated as follows:
100f'/f = A + B log {24D (T+12)/1000}
f' = adjusted CCS

f = specified CCS
T = curing temperature
D = age at testing in days
A&B = are coefficients given in the
4/13
following table.
The above equation applies only to OPC, MSRPC and SRPC.
--------------------------------------------------------------------------------------------------
Recorded Cube Strength N/mm2 A B
--------------------------------------------------------------------------------------------------
Less than 15 10.0 67.5
15 to 35 20.0 60.0
Greater than 35 30.0 52.5
--------------------------------------------------------------------------------------------------
This calculation may be applied for curing at temperatures up to 27 degrees C .
Before placing concrete the Contractor shall obtain approval of the mixes
proposed for each class of concrete and the average target strengths. The mixes
shall be designed to achieve the minimum workability for the Contractor to place
and compact the concrete with the equipment proposed for use.
The mean strength shall exceed the CCS by a margin of 1.64 times the standard
deviation expected from the concreting plant, except that no standard deviation
less than 3.5 N/mm2 shall be used as a basis for designing a mix. Unless
otherwise approved a standard deviation of 7 N/mm2 shall be used for initial
mixes.
4/15.3 The ultimate compressive strength of the concrete shall be determined on test
specimens obtained and prepared in accordance with B.S. 1881. Part 108.
4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of
concrete (shown on the drawings) is denoted by the 28 day characteristic cube
strength and the maximum size of aggregate.
4/15.5 The chloride and sulphate levels in the concrete mix shall comply with the
following requirements:-
Maximum Limits of acid soluble Chloride and Sulphate content as a percentage

by Weight of Cement in the Mix.
--------------------------------------------------------------------------------------------------
TYPE OF CONCRETE CHLORIDES SULPHATES
AS Cl AS SO3
ACCORDING TO BS-1881 PART 124
---------------------------------------------------------------------------------------------------
a. For reinforced concrete

if made with OPC/MSRPC 0.30 3.70
b. Prestressed concrete & Heat- 0.10 3.70

cured reinforced concrete
c. For mass concrete

if made with OPC/MSRPC 0.60 3.70
--------------------------------------------------------------------------------------------------
4/14
Note : The OPC and MSRPC cements can also contain chlorides, the relevant
standard BS 12 allows upto 0.1% Cl. Therefore any chloride content
present in the cement has to be taken into account while computing total
Cl in the mix. In case the cement contains the maximum limit of 0.1%
Cl, then the aggregates, water and admixtures used for prestressed
concrete or heat cured reinforced concrete should be absolutely free of
chlorides.
4/16 CONCRETE MIX DESIGN
Trial Mixes
4/16.1 Preliminary laboratory tests shall be carried out to determine the mixes to satisfy
the specification with the approved materials.
Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:
a) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed

0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5.
c) Air content if applicable BS 1881 Part 106.
d) Free water/cement ratio
e) Workability BS 1881 Part 102.
f) Fresh and hardened concrete densities BS 1881 Parts 107 and 114
respectively.
g) Compressive strength BS 1881 Part 116
h) Water Permeability DIN 1048

(maximum 10 mm at 28 days)
(maximum 15 mm at 7 days)
i) Chloride Permeability ASTM C-1202 (max. 2000 coulombs)
If the values obtained are unacceptable, the mixes shall be re-designed.
4/16.2 At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS 1881.
Samples of concrete incorporating the reinforcing details to be used shall be cast

and examined, before hardening using hand tools, and after hardening by coring
to assess the mixes. Cores shall be taken in accordance with BS 1881 Part 120.
Trial mixes shall be made on each of three days; the workability shall equate to
the designed target value. Six cubes from each mix shall be taken, three for test
at 28 days.
Further trial mixes shall be made if the range (the maximum minus the minimum
of the three cube results in any batch) exceeds 15% of the average of that batch,
or if the range of the three batch averages exceeds 20% of the overall average of
the batches.
4/15
The mixes shall be tested to determine the following properties:
a) Bleeding in accordance with ASTM C232
b) Air content if applicable BS 1881 Part 106.
c) Free water/cement ratio
d) Tensile strength in accordance with BS 1881 Parts 117 and 118.
The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be acceptable
before the mix is approved. Otherwise the mix shall be re-designed.
4/16.3 The Engineer will review the Contractor's trial-mixes and crush the test cubes at
seven (7) and twenty-eight (28) days. The Engineer will then determine which of
the trial mixes shall be used. If none of the trial mixes for a class of concrete
meets the Specifications, the Engineer will direct the Contractor to prepare
additional trial-mixes. No class of concrete shall be prepared or placed until its
job-mix proportions have been approved by the Engineer.
4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements of these
Specifications.
4/16.5 The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face intended
for use in the works.
4/16.6 All costs connected with the preparations of trial-mixes and the design of the job-
mixes shall be borne by the Contractor.
4/16.7 Mix designs of concrete of each grade shall be verified by DCL.
4/17 QUALITY CONTROL
4/17.1 Test Cubes
Cubes shall be manufactured in an on-site laboratory, specially equipped for the

purpose, in controlled conditions. They shall be made, cured, stored, transported
and tested to BS 1881 Parts 108,111 and 116. The method of compacting cubes
shall be as approved and shall be means of vibrating table in the laboratory or
25mm vibrating poker on site.
4/17.2 Sampling Cubes
A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each day.
The standard deviation shall be calculated from at least 40 individual cube results
each representing separate batches of similar concrete produced by the same
plant under the same supervision. The current margin for the plant shall be thus
established as 1.64 times the standard deviation.
4/16
Thereafter one sample shall be taken at random for each class of concrete in
accordance with Clause 4/31 of the Specification.
In addition to the above requirements, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of a
single pour.
From each sample three cubes shall be made for testing at 28 days and three for
testing at 7 days for control purposes.
Samples shall also be taken and six cylinders cast to determine the split tensile
strength of the concrete at 7 days (using three cylinders) and at 28 days (using
three cylinders) as specified in BS 1881 Part 117. These samples shall be taken
from every 100 batches, but at least once a week during concreting operations
and shall coincide with samples taken for test cubes.
The frequency of sampling may be required to be varied if directed by the

Engineer.
The procedures shall be repeated when materials or design mixes are changed.
4/17.3 Cube Strength Results
The results will be acceptable if:
a) The average strength determined at the age of 28 days from a sample of

three of more cube test results exceed the specified CCS by 0.5 times the
current margin, or
b) No individual result of the sample is less than (Specified CCS minus 3
N/mm2) or,
c) Number of individual results in the sample below specified CCS is not
more than one.
If the above criteria is not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate :
i) Cutting and testing cores from placed concrete

ii) Non-destructive testing of placed concrete
iii) Load-testing relevant structural units
iv) Cutting out and replacing defective concrete
If the range of individual cube strengths made from the same sample
exceeds 15% of the mean, then the method of making, curing and testing
cubes shall be checked. In the event of a result having a range exceeding
20%, then the result shall be unacceptable and the Engineer may order
any of the following actions :
i) Changing the mix

ii) Improving quality control
iii) Cutting and testing cores from placed concrete
iv) Non-destructive testing of placed concrete
In the event cutting and testing of cores are required, the contractor shall
cut cores from approved locations, and test them to BS 1881 as modified
by BS 6089.
4/17.4 Durability Tests

4/17
Concrete shall be tested for durability properties by undertaking absorption and
permeability tests where appropriate, or directed by the Engineer, as directed
below:
Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out between
28 and 32 days in accordance with BS 1881 Part 122. The upper acceptable limit
for absorption after 30 minutes shall be 2%.
Effective permeability tests in accordance with the method described in DIN 1048
shall be carried out. The maximum acceptable penetration at twenty-eight days
shall be 10 mm.
Durability tests for concrete are applicable only to reinforced concrete.
4/17.5 Other Tests
When instructed by the Engineer concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and tested
in accordance with Test 5 of BS 1881 (1970) Part 5 or BS6073 Part 1 Appendix
D. The maximum acceptable limits shall be:
Drying Shrinkage : 0.05%

Wetting Expansion : 0.03%
Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.
The air content of air-entrained concrete shall be determined (ASTM C231) for
Compaction factor, slump, vebe or other workability tests shall be carried out as
required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree of workability shall be as for the
trial mixes; permitted tolerances shall be in accordance with BS 5328.
4/18 CONCRETE DESIGN LIMITS
4/18.1 The following will be designated by the Engineer within the limits of the
Specifications.
a) The minimum Cement content in kg. per cubic metre of concrete.
b) The maximum allowable water/cement ratio including surface moisture, but

excluding water absorbed by the aggregates.
c) Slump or Slumps designated at the point of delivery.
d) Changes requested by the Contractor in mix proportioning previously

approved shall be made only with the agreement of the Engineer.
e) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as
directed by the Engineer. No additional payment shall be made for the
added cement.
4/18
f) Failure of the mixed concrete to meet specifications as determined by the
Engineer will be grounds for the Engineer to reject the concrete.
g) Bleeding limitations when tested in accordance with ASTM C232.
4/19 CONSISTENCY OF CONCRETE
4/19.1 The consistency of concrete shall be determined in the field by the Slump Test.
The consistency of concrete at the time of delivery will be designated by the
Engineer and shall not vary by more than 25mm from the designated
consistency.
4/19
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS
4/20.1 Cement
In the case of bagged cement it shall be measured as packed by the

manufacturer: a sack of cement shall weigh fifty (50) kilograms. Measurement for
proportioning all cement shall be accurate to within two (2) percent throughout
the range of use. Only full bags, undamaged or unbroken will be permitted.
4/20.2 Water
The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within one (1) percent throughout the range of
use.
4/20.3 Aggregate
The aggregates shall be measured by weight to an accuracy within two (2)

percent through-out the range of use.
4/21 ASSEMBLY AND HANDLING MATERIALS
Assembly
4/21.1 Aggregates shall be assembled in such quantities that sufficient material

approved by the Engineer is available to complete any continuous pour
necessary for any element. The batching site shall be of adequate size to permit
the stockpiling of sufficient, unsegregated materials, having proper and uniform
moisture content, to ensure continuous and uniform operation. Aggregates shall
enter the mixer in a manner approved by the Engineer and in such a manner to
ensure that no matter foreign to the concrete or matter capable of changing the
desired proportions is included. In the event two (2) or more sizes or types of
coarse or fine aggregates are used on the same project, only one (1) size or type
of each aggregate may be used on one continuous concrete pour.
Stockpiling of Aggregates
4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation of
material, to ensure a uniform moisture content and to provide uniform conditions
for proportioning plant control.
4/21.3 The use of equipment or methods of handling aggregates which result in the
degradation and contamination of the aggregates is strictly prohibited. Bulldozers
with metal tracks shall not be used on coarse aggregate stockpiles. All equipment
used for handling aggregates shall be approved by the Engineer.
4/21.4 Stockpiling of aggregates shall be in the manner approved by the Engineer, and
in addition, every precaution shall be taken to prevent segregation. Segregation
shall be prevented by making no layer higher than one and one-half (1.5) metres
and if two (2) or more layers are required, each successive layer shall not be
allowed to "cone" down over the next lower layer.
4/21.5 Aggregates shall not be stockpiled against the supports of proportioning hoppers
and weighing devices.
4/20
Segregation
4/21.6 Segregated aggregates shall not be used until they have been thoroughly
remixed and the resultant pile is of uniform and acceptable gradation at any point
from which a representative sample is taken. The Contractor shall re-mix
aggregate piles when ordered by the Engineer.
Transporting of Aggregates
4/21.7 If aggregates are to be transported from a central proportioning plant to the mixer
in batch-boxes or dump trucks, such equipment shall be of sufficient capacity to
carry the full volume of materials for each batch of concrete. Partitions separating
batches shall be approved by the Engineer and shall be adequate and effective
to prevent spilling from one compartment to another whilst in transit or being
dumped.
Cement
4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor or
in a silo and shall be delivered in quantities sufficient to ensure that there is no
suspension or interruption of the work of concreting at any time. If stored in
sheds, each consignment shall be kept separate and distinct.
4/22 MIXING CONCRETE
4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in BS
1305 and checked against accurate weights and volumes when required by the
Engineer.
4/22.2 The mass of cement and of aggregate indicated by the mechanism employed
shall be within a tolerance of 2% of the respective mass per batch agreed by the
Engineer. The mass of the fine and coarse aggregates shall be adjusted to allow
for the free water contained in them. The water to be added to the mix shall be
reduced by the quantity of free water contained in the fine and coarse
aggregates, which shall be determined by the Contractor by a method approved
by the Engineer immediately before mixing begins and further as the Engineer
requires.
4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch
type mixer manufactured in accordance with BS 1305. Where appropriate the
batch capacity, method of loading, mixing time and drum speed shall conform to
the details furnished in accordance with the requirements of BS 3963 for the mix
which corresponds most closely to the mix proportions being used. The mixing
blades of pan mixers shall be maintained within the tolerances specified by the
manufacturer of the mixer and the blades shall be replaced when it is no longer
possible to maintain the tolerance by adjustment. The period of mixing, judged
from the time that all the ingredients including water are in the mixing drum shall
be as ordered by the Engineer's representative but shall not be less than 2
minutes or 20 revolutions of the drum whichever is the longer.
4/22.4 Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before any fresh concrete is mixed.
4/22.5 The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.
4/21
4/22.6 The Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between its
discharge from the mixer and compaction in its final position. Precautions shall
include the shading of aggregate stockpiles and the use of chilled water.
4/23 READY MIXED CONCRETE
4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be used
only with the agreement of the engineer and shall comply with all requirements of
the Contract.
4/23.2 The Concrete shall be carried in purpose-made agitators, operating continuously,

or truck mixers. The concrete shall be compacted and in its final position within 1
hour of the introduction of cement to the aggregates, unless a longer time is
agreed by the Engineer. The time of such introduction shall be recorded on the
delivery note together with the weight of the constituents of each mix.
4/23.3 When truck mixed concrete is used, water shall be added under the supervision,
either at the Site or at the central batching plant as agreed by the Engineer but in
no circumstances shall water be added in transit.
4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing and
discharge performance shall comply with the requirements of BS 4251. Mixing
shall continue for the number and rate of revolutions recommended in
accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer's instructions, mixing shall continue for not less than 100
revolutions at a rate of not less than 7 revolutions per minute.
4/23.5 Pumping concrete through delivery pipes may be permitted but only with the prior
4/23.6 Re-mixing of concrete which has commenced to set shall not be allowed and in
no case shall such concrete be used in the Works.
4/23.7 Coarse aggregate shall be kept in indentified stockpiles from which samples can
be collected and tested as specified.
4/23.8 The concrete supplier is required to certify that the Cl content in the mix being
delivered is within the limits specified in Clause 4/15.5. The Cl and SO3 content
shall be checked at frequent intervals.
4/24 TRANSPORT AND PLACING
4/24.1 The method of transport and placing concrete shall be to the approval of the
Engineer. Concrete shall be so transported and placed that contamination,
segregation or loss of the constituent materials does not occur.
4/24.2 All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.
No concrete work shall be stopped or temporarily discontinued within forty-five

(45) centimeters of the top of any finished surface, unless such work is finished
with a coping having a thickness less than forty-five (45) centimeters in which
case the joint shall be made at the under edge of the coping.
4/22
Concrete in simple slab spans shall be placed in one (1) continuous operation for
each span, unless otherwise indicated on the drawings or approved by the
Engineer.
4/23
4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15
concrete shall be laid to a minimum of 75 mm thickness unless otherwise
specified on the drawings. This blinding shall be suitably cured prior to
subsequent concrete placement. The blinding shall be clean and free from any
dust or impurities prior to subsequent concrete placement.
4/24.4 No concrete shall be placed in a foundation until the extent of excavation and the
character of bearing material have been approved and no concrete shall be
placed in any structure until the placement of reinforcing steel and the adequacy
of the forms and falsework have been approved.
4/24.5 Concrete shall not be placed in any part of the Works until the Engineer's
approval has been given. If concrete has not started within 24 hours of such
approval being given, approval shall again be requested. Concreting shall then
proceed continuously over the area between construction joints. Fresh concrete
shall not be placed against in-situ concrete which has been in position for more
than 30 minutes unless a construction joint is formed in accordance with the
Specification. When the concrete has been in place for 4 hours, or less as
directed by the Engineer, further concrete shall not be placed against it for a
further 20 hours.
4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg. C
unless otherwise specified. Concrete shall be compacted in its final position
within 30 minutes of discharge from the mixer unless carried in purpose made
agitators operating continuously, when the time shall be within 1 hour of the
introduction of cement to the mix and within 30 minutes of discharge from the
agitator.
4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited in
horizontal layers to a compacted depth not exceeding 400mm where internal
vibrators are used or 300mm in all other cases.
4/24
4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 2m. When trunking or chutes are used they shall
be kept clean and used in such a way as to avoid segregation. Where steep
slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of the
movement. Chutes and the use of chutes must be approved by the Engineer. All
chutes shall be kept clean and free from coating of hardened concrete by
thoroughly flushing with water after each run. The water used for flushing shall be
discharged clear of the concrete already in place.
4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be

placed in position by tremies, or by pipeline from the mixer.
4/24.10 Full details of the method proposed shall be submitted in advance to the
Engineer and his approval obtained before placing begins. Where the concrete is
placed by the tremie, its size and method of operation shall be in accordance with
BS 8004. During and after concreting under water, pumping or dewatering
operations in the immediate vicinity shall be suspended until the Engineer permits
them to be continued.
4/24.11 Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement against
which concrete is to be placed shall be shielded against the direct rays of the sun
and shall be sprayed with water to prevent excessive absorption by the surfaces
of water from the fresh concrete.
4/24.12 A complete record shall be kept of the date, time, temperature and conditions of
placing the concrete in each portion of the work and shall be available for
inspection by the Engineer at any time.
4/24.13 Unless otherwise shown on the drawings all concrete placed below ground level
shall have a minimum protection to its outside faces as follows:
Underside - Protected by the laying of a grade 1000 approved polyethylene

sheeting on the blinding concrete. The sheeting shall be returned up the outside
faces of the concrete and suitably sealed.
Sides - Coated with 3 coats of an approved bitumen rubber latex emulsion

flexible damp and vapour-proof liquid membrane conforming to BRE Digest No.
54.
4/25 COMPACTION OF CONCRETE
4/25.1 All concrete shall be compacted to produce a dense homogeneous mass. Unless
otherwise agreed by the Engineer, it shall be compacted with the assistance of
vibrators. Sufficient vibrators in serviceable condition shall be on site so that
spare equipment is available in the event of breakdown. A 50mm diameter
internal vibrator shall be deemed capable of compacting 20 Cu. m./hr. Internal
vibrators shall be capable of producing not less than 10,000 cycles per minute.
4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion
vibrators are used, contact with reinforcement and all inserts shall be avoided.
4/25
4/25.3 Concrete shall not be subject to vibration between 4 and 24 hours after placing.
4/25.4 Vibrators shall be so manipulated as to work the concrete thoroughly around the
reinforcement and embedded fixtures and into corners and angles of the forms.
Vibrators shall not be used as a means to cause concrete to flow or its position in
lieu of placing. The vibration at any point shall be of sufficient duration to
accomplish compaction. After initial set of the concrete, the forms shall not be
jarred and no strain shall be placed on the ends of projecting reinforcement.
4/26 CONSTRUCTION JOINTS
4/26.1 The position and detail of any construction joints not described in the Contract
shall be subject to the approval of the Engineer and shall be so arranged to
minimise the formation of shrinkage cracks.
4/26.2 The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organised to ensure that the above mentioned interval shall not be exceeded.
4/26.3 When the continuous placement of concrete in any structural member is

interrupted or delayed, for any reason, for a period long enough for the previously
partially placed concrete to take its initial set, the Engineer shall declare such
joint a cold joint and the Contractor shall immediately remove the previously
partially placed concrete from the forms. No extra payment will be made for the
initial placement or the removal of concrete which is wasted because of a cold
joint. The Engineer may suspend all or any part of subsequent concrete work
until he deems the Contractor has corrected the cause for the cold joint
occurrence.
4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the
drawings, keys shall be as made by embedding water soaked beveled timbers in
soft concrete. The key shall be sized as shown on the details, or as directed by
the Engineer, which shall be removed when the concrete has set. In resuming
work the surface of the concrete previously placed shall be thoroughly cleaned of
dirt, scum, laitance or other soft material with stiff wire brushes, and if deemed
necessary by the Engineer, shall be roughened with a steel tool. The surface
shall then be thoroughly washed with clean water and painted with a thick coat of
neat cement mortar, after which the concreting may proceed.
4/26.5 Expansion joints shall be constructed at the locations, of the materials and to the
dimensions shown on the drawings.
4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal and if
the formwork extends above the joint on the exposed face, it shall be cleaned of
adhering concrete before the next lift is placed. The concrete placed immediately
above a horizontal construction joint shall not be the first batch through the mixer
and shall be thoroughly compacted and worked against the existing concrete.
4/26
4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand shall,
wherever possible, be well worked into them immediately before the fresh
concrete is placed.
4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting
above the lift being cast shall be adequately supported to prevent movement of
the bars during the casting and setting of the concrete.
4/26.9 Wherever possible laitance and all loose material shall be removed while the
concrete is still green and no further roughening shall then be required. Where
this is not possible, it shall be removed by mechanical means provided the
concrete has been in position for more than 24 hours. The roughened surface
shall then be washed with clean water.
4/27 CURING OF CONCRETE
4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be
protected from the harmful effects of weather, including rain and rapid
temperature changes, and from drying out. The methods of protection shall be
subject to the Engineer's approval. The Engineer's approval will be conditional
upon the proposed curing method proving to be satisfactory on site. Only water
curing shall be allowed for bridges and retaining walls which shall be continuously
cured for a minimum of 14 days.
4/27.2 The method of curing used shall minimise the loss of moisture from the concrete.
On concrete surfaces which are to be water-proofed, and for bridge
superstructures including piers, abutments, retaining walls and culverts curing
membranes shall not be used. Details of all curing methods to be used shall be
subject to the approval of the Engineer.
4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete
surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimise evaporation.
The hessian sheeting shall be maintained continuously damp for a minimum
period of 14 days after casting. The water used for this purpose shall be of the
same quality as that allowed in mixing the concrete.
4/27.4 Whenever approved by the Engineer, membrane curing of concrete with an

approved liquid may be used as an alternative to curing with water except that
membrane curing liquid shall not be applied to surfaces of concrete from which
the shuttering has been stuck, until the concrete has been inspected and
approved by the Engineer's representative.
4/27.5 Concrete curing compound shall be of an approved type which shall be readily
distinguishable upon the concrete surface for at least four hours after application.
The colour, if any, shall become inconspicuous within seven days after
application.
4/27
4/28 EARLY LOADING
4/28.1 Concrete shall at no time be subject to loading, including its own weight, which
will induce a compressive stress in it exceeding 0.25 of its compressive strength
at the time of loading or of the specified 28 day strength whichever is lower.
4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of the
Engineer.
4/28.3 No superstructure load shall be placed upon finished piers or abutments until the
Engineer so permits, but in no case shall any load of any kind be placed until the
curing has been completed. The Contractor shall not place any temporary loads
on deck slabs. Bridge deck slabs shall be opened to traffic or construction
equipment only when so permitted by the Engineer.
4/29 CONCRETING AT NIGHT
4/29.1 No concrete shall be mixed or placed when the light is insufficient, unless an
adequate and approved artificial lighting system is operated and such night work
is approved by the Engineer.
4/30 CONCRETING IN HOT WEATHER
4/30.1 When the rate of evaporation of surface moisture from concrete is expected to
approach 1 Kg/m2 per hour (estimated from following chart) or when the shade
air temperature is 35 deg. C and rising, precautions shall be taken, including the
following:-
a. Dampening the forms.
b. Reducing the concrete temperature to the lowest practical level by

procedures such as:-
i. Shading the aggregate.
ii. Cooling the mixing water before use.
iii. Screening the mixing plant and transporting vehicles from wind, rain
and sun.
c. Erecting wind breaks and sunshades at the concrete placing location.
d. Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.
e. Minimising evaporation (particularly during the first few hours subsequent

to placing the concrete) by suitable means such as applying moisture by
fog spraying.
4/28
4/30.2 All precautions to be taken shall be subject to the Engineer's approval and the
Contractor shall demonstrate that all approved precautions are available for use
prior to the Engineer granting approval to any concreting operation.
4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor shall
concrete be mixed or placed when the shade air temperature is 40 deg.C or
above, or is expected to reach such a level during concreting, without special
permission from the Engineer.
4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE
4/31.1 Any one set of 6 cubes for each class of concrete and for each particular
application represent a maximum quantity of concrete as shown in Table 4.6. The
point of sampling of fresh concrete shall be at delivery into the construction
unless otherwise directed by the Engineer. Each set of cubes shall be made from
a separate batch.
4/31.2 Portland Cement : One 2 Kg sample for quality test shall be taken from each
1,700 bags or equivalent weight. Sampling of cement shall be as per BS EN 196-
7.
4/31.3 Water: One 1 - gallon sample shall be obtained prior to use from each source and
at least once every week for quality testing.
TABLE 4.6 - SAMPLING RATES

------------------------------------------------------------------------------------------------
TYPE OF STRUCTURE SAMPLING TO REPRESENT
A VOLUME OF M3
------------------------------------------------------------------------------------------------
1. Critical structures
e.g. masts, cantilevers, columns 10
2. Intermediate structures
e.g. beams, slabs, bridge decks 50
3. Heavy concrete construction

e.g. breakwaters, solid rafts 100
------------------------------------------------------------------------------------------------
4/32 FORMWORK
CONSTRUCTION
4/32.1 Formwork shall include all temporary or permanent forms required for forming the
concrete, together with all temporary constructions required for their support.
4/32.2 All formwork shall be of such quality and strength as will ensure rigidity
throughout the placing, ramming, vibration and setting of the concrete without
visible deflection.
4/29
4/32.3 All formwork shall be so constructed that there shall be no loss of material from
the concrete. After setting, the concrete shall be in the position and of the shape
and dimensions prescribed. The finished surface of exposed concrete shall be of
a quality specified on the drawings and approved by the Engineer.
4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all
exposed edges shall be bevelled by using dressed, mill-cut, triangular molding,
having twenty (20) millimetres sides.
All curved surfaces shall be formed with approved plywood or steel.
The Contractor shall in all cases request the approval of the formwork by the
Engineer's representative in sufficient time to allow an inspection to be made and
shall not commence concreting until such approval is obtained. The period
between the Contractor's request for approval and his intention to commence
concreting shall be not less than one clear normal working day and the
Engineer's representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.
Such approval shall not absolve the Contractor of his responsibilities under the
Contract.
4/32.5 Where internal metal ties are permitted, they or their removable parts shall be
extracted without damage to the concrete and the remaining holes filled with
mortar. No permanently embedded metal part shall have less than 40 mm cover
to the finished concrete surface or the specified cover to the reinforcement
whichever is the greater.
4/32.6 The Contractor shall submit to the Engineer for his approval strength and
deflection calculations and drawings of the formwork he proposes to use. The
Contractor shall ensure that adequate time is given to enable the Engineer to
examine the calculations and drawings and also to inspect the formwork before
concrete is placed within it.
FALSEWORK
4/32.7 Detailed drawings for falsework and centering shall be prepared by the
Contractor and submitted to the Engineer for approval. The drawings must be
approved by the Engineer before the work is started.
4/32.8 The Contractor shall submit to the Engineer for approval at least one (1) month
before commencing work, details of his proposed system of falsework, including
detailed drawings and calculations. Falsework shall be capable of
accommodating temperature changes without causing damage to the concrete.
4/30
4/32.9 Falsework and centering shall be designed and constructed to provide the
necessary rigidity to support all loads placed upon it without appreciable
settlement or deformation. Falsework columns shall be supported on wood or
metal bases to support all falsework that cannot be founded on rock, shale or
thick deposits of other compact material in their natural beds. Falsework shall not
be supported on any part of the structure, except the footings, without the written
permission of the Engineer. The number and spacing of falsework columns, the
adequacy of sills, caps and stringers and the amount of bracing in the falsework
framing shall be subject to approval of the Engineer.
4/32.10 All timber shall be of sound wood, in good condition and free from defects that
might impair its strength. If the vertical members are of insufficient length to cap
at the desired elevation for the horizontal members, they shall preferably be
capped and frames constructed to the proper elevation. Ends of the vertical
members shall be cut square for full bearing to preclude the use of wedges. If
vertical splices are necessary, the abutting members shall be of the same
approximate size, the ends shall be cut square for full bearing, and the splices
shall be scabbled in a manner approved by the Engineer.
4/32.11 All steel members shall be in good condition, free from damage, kinks, corrosion
or any other defect which might impair their strength.
4/32.12 The Contractor shall compute the form settlement and deflection required for
bridges so that when the final settlement is complete, the structure will conform to
the required camber, section and grade as shown on the drawings.
4/32.13 The Engineer will check and approve the Contractor's computations. Long,
tapered hardwood wedges or screw jacks shall be used in all falsework
construction and shall be so placed that they can be adjusted to give proper form
alignment. The Contractor shall, if required by the Engineer, provide means for
adjusting forms to offset any excessive settlement, if screw jacks are used, they
shall be adequately braced and secured in such a manner that will prevent
tipping of the jacks in any direction.
4/32.14 The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent observer
to observe and correct the settlement.
4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In

computing vertical loads, a weight of twenty four hundred (2,400) kilograms per
cubic metre shall be assumed, and not less than thirteen hundred and sixty
(1,360) kilograms per cubic metre shall be assumed in computing horizontal
pressure.
4/32.16 The Engineer may refuse permission to proceed with other phases of the work if
he deems the falsework unsafe or inadequate to support properly the loads to
which it will be subjected.
4/32.17 The review or approval of falsework drawings by the Engineer or permission to

proceed with the work shall not relieve the Contractor of the responsibility for
successful erection or satisfactory results.
4/31
TOLERANCE
4/32.18 The formwork shall be set to such lines and levels as to ensure that the following
tolerances are not exceeded in the structures as cast.
- For all buried concrete. + 25mm - 12mm
In addition, for concrete surfaces that are to

be waterproofed, abrupt irregularities in the
surface finish shall not exceed 3mm.
- For soffit edge beams and +/- 3mm but not more
sides of parapet plinths than 3mm in 3.5m.
- For all other concrete +/- 6mm but not more than 3mm in 3.5 m.
PREPARATION OF FORMWORK BEFORE CONCRETING
4/32.19 The inside surfaces of forms shall, except for permanent formwork, or unless
otherwise agreed by the Engineer, be coated with a release agent approved by
the Engineer. Release agents shall be applied strictly in accordance with the
manufacturer's instructions and shall not come into contact with the
reinforcement. Different release agents shall not be used in formwork to concrete
which will be visible in the finished works. A panel shall be constructed utilising
the proposed release agent for the Engineer's approval. The surface of the panel
shall not exhibit discolouration or any significant retard of the surface mortar
strength.
4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All
formwork shall be inspected and approved by the Engineer before any concrete
is placed in it but such approval shall not relieve the Contractor of his
responsibilities for the safety, accuracy or efficiency of the work.
REMOVAL OF FORMWORK
4/32.21 The Engineer shall be informed in advance when the Contractor intends to strike
any formwork.
4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and
strength for it to withstand the effects of striking, including the effect of thermal
shock or the loss of surface durability upon premature exposure, and to be able
to withstand the resulting stresses without adverse effects.
4/32.23 The time at which the formwork is struck shall be the Contractor's responsibility
but the minimum periods between completion of placing concrete in a section of
the works and the removal of forms shall be as follows:-
Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days
Removal of props (beams and slabs) 14 days
Soffits of precast beams 7 days
4/32.24 Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props are to be left in place
when the soffits forms are removed, these props shall not be disturbed during the
striking.
4/32
4/32.25 Formwork shall be removed without damage to the concrete.
4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and made
good to the satisfaction of the Engineer.
4/33 CLASSES OF FINISH
FORMED SURFACES
4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.
4/33.2 Class F1 : As struck.
4/33.3 Class F2 : The irregularities in the finish shall be no greater than those obtained
from the use of wrought thicknessed square edged boards arranged in a uniform
pattern. The finish is intended to be left as struck but imperfections such as fins
and surface discolouration shall, if required, be made good by methods approved
by the Engineer.
4/33.4 Class F3 : The formwork shall be lined with a material approved by the Engineer
to provide a smooth finish of uniform texture and appearance. This material shall
leave no stain on the concrete and shall be so joined and fixed to its backing that
it imparts no blemishes. It shall be of the same style and obtained from only one
source throughout.
4/33.5 The Contractor shall make good any imperfections in the finish as required by the
Engineer. Internal ties and embedded metal parts will not be allowed.
4/33.6 Class F4 : The requirements for Class F4 are as for class F3 except that internal
ties and embedded metal parts will be permitted. The ties shall be positions as
described in the Contract or as agreed by the Engineer.
4/33.7 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish shall be
protected from rust and stains of all kinds.
4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed
surfaces of concrete to Class F2, F3 and F4 finish shall form a regular pattern
with horizontal and vertical lines continuous throughout each structure and all
construction and movement joints shall coincide with these horizontal or vertical
lines.
4/33.9 REMEDIAL TREATMENT OF SURFACES
An inspection of the concrete surface shall be carried out immediately after

removing the formwork, and any remedial treatment to surfaces proposed by the
Contractor shall be submitted to the Engineer for approval and shall be carried
out without delay. Portions of the structure which can not be finished or properly
repaired to the satisfaction of the Engineer shall be removed.
4/33
4/33.10 Any concrete, the surface of which has been treated before being inspected by
the Engineer, shall be rejected.
UNFORMED SURFACES
4/33.11 Class U1 Finish. The concrete shall be uniformly levelled and screeded to
produce a plain surface as described in the Contract. No further work shall be
applied to the surface unless it is used as a first stage for a Class U3 finish.
4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent laitance
from being worked to the surface, a Class U1 finish shall be floated by hand or
machine sufficiently to produce a uniform surface free from screed marks.
4/33.13 Class U3 Finish. When the moisture has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a
Class U1 finish shall be steel-trowelled under firm pressure to produce a dense,
smooth uniform surface free from trowel marks.
4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved
waterproofing systems. The concrete shall be uniformly levelled and screeded to
produce a plain surface. When the concrete has sufficiently hardened to prevent
laitance being worked to the surface it shall be floated to produce a uniform
surface free from screed marks and exposed aggregate. Finally the surface shall
be textured by brushing or otherwise to the waterproofing manufacturer's
requirements as agreed by the Engineer. The accuracy of the finished surface
shall be such that it does not deviate from the required profile by more than + 5
mm over a 3 m gauge length or have any abrupt irregularities more than 3 mm.
SPECIAL FINISHES
4/33.15 Where special finishes are specified in the drawings or in a particular

specification the Contractor shall make trial panels for the formed finishes
specified for inspection and approval by the Engineer.
4/34 MORTAR
4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing

plasticisers shall not be overmixed. Mixers shall be kept clean at all times.
4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall not
be used in the work and shall be removed immediately from the site. Mortar shall
be prepared in the following proportions with the addition of a minimum quantity
of water for workability.
4/34.3 MORTAR (3:1)
Sand/Cement mortar (3:1) shall be composed of one part of cement to three

parts of sand by volume. This type of mortar shall be used in blockwork where
high strength is required.
4/34.4 MORTAR (4:1)
Sand/Cement with plasticiser mortar (4:1) shall be composed of one part of

cement to four parts of sand with a mixture of an approved plasticising agent,
added in accordance with the manufacturer's instructions.
4/34
4/34.5 The sand used in mortar must be dry when proportioning. Allowance for bulking
shall be made when gauging by volume. The mean compressive strength at 28
days for each mortar shall conform to BS 5628 : Part I.
4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both as
4/35 EXTENT OF POURS
4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimise thermal and shrinkage strains.
4/35.2 For walls, the length of panel placed at one time shall not exceed 6 m, adjacent
panels shall not be placed within 2 days, but shall be placed as soon as
practicable thereafter. Subsequent vertical lifts shall not be poured within 2 days.
4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
sequence of panels. 'Chequerboard' placing shall be avoided. Adjacent panels
shall not be placed within 3 days, and then only provided that the concrete in the
first pour has cooled down to below 38 degrees centigrade or ambient
temperature. Placing of adjacent panels shall take place as soon as practicable
after the above criteria have been satisfied. Panels shall be 5 m x 5 m and any
pour exceeding 25 m2 will only be considered for approval if substantiated by
calculations.
4/35
SECTION 5 - ANCILLARY WORKS
5/1 PAVING DESCRIPTION
5/1.1 This work shall consist of covering certain areas (footpaths, parking areas, etc..)
with paving blocks in accordance with the Specifications, the Drawings and the
Engineer's instructions.
5/2 PAVING BLOCKS
5/2.1 Paving blocks shall be concrete blocks, coloured where specified, laid on a sand
laying course. Their thickness shall be 6 cm on sidewalks and 8 cm on parking
areas unless otherwise shown on the Drawings or instructed by the Engineer.
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS
5/3.1 The materials, dimensions and tolerances, test for compressive strength, test for
water absorption and certificate of compliance for paving blocks shall conform to
the requirements of Local Order No.44/90. Water absorption and abrasion
resistance shall be carried out in accordance with the requirements of the
particular specification.
5/4 BLOCK LAYING REQUIREMENTS
LAYING COURSE
5/4.1 The laying course shall consist of sharp black sand containing not more than 3%
silt and clay by weight and not more than 10% retained on 4 mm sieve. The sand
shall be obtained from a single source, allowed to drain before use and shall be
covered with suitable sheeting to minimise moisture changes. Permissible
sulphate (as SO3) and chloride (as CL) shall not exceed 0.3% and 0.5%
respectively (expressed as a percentage by weight). Method for testing acid
soluble chloride content in laying course sand shall be BS812:Part 117 and for
acid soluble sulphate in sand shall be BS812: Part 118.
5/4.2 The profile of the laying course before compaction shall be similar to that of the
finished surface. During laying the sand shall be uniform in moisture content and
shall be carefully, screened to form a smooth compacted surface to receive the
paving blocks. The maximum deviation from the design levels shall be 5 mm.
5/4.3 The edge restraints to the paved area shall be laid in advance of the laying
course and all permanent obstacles within the area, such as manhole covers,
shall be adjusted to the correct finished levels.
SURFACE COURSE
5/4.4 The paving blocks shall be laid on the sand laying course in such manner as not
to disturb the blocks already laid. Each block shall be placed firmly against its
neighbour so that they fit closely together. The joints between blocks shall not
exceed 3 mm. Laying of the paving blocks shall commence at right angles to the
main pavement axis starting at one end of the area. The paving blocks shall be
laid in a herringbone pattern unless otherwise shown on the drawings or
instructed by the Engineer at 45° to the main pavement axis.
5/4.5 Where blocks do not fit the edge restraints or other obstructions such as
manholes or upstands the gaps shall be filled using cut blocks.
5/1
5/4.6 Blocks shall be cut using only a mechanical block splitter.
5/4.7 Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall
be checked after laying the first three rows of blocks and thereafter at regular
intervals. If joints begin to open the blocks shall be knocked together using a hide
mallet.
5/4.8 After each 20 sq.m. or such area that has been agreed with the Engineer, has
been laid the blocks shall be compacted to the required levels using a plate
vibrator.
5/4.9 The plate vibrator shall have a plate area of 0.20 to 0.35 sq.m. and have a
compaction force of 12-24 KN and a frequency of approximately 75 to 100 Hz.
5/4.10 A minimum of two passes of the plate vibrator shall be made in each direction,
i.e. at 90 degrees to each other. Vibration shall continue until no further
compaction of the sand layer is apparent. The laying course shall have a
compacted thickness of 50 mm. Fine dry sand with a particle size of 0.3mm shall
then be brushed over the paving, and further passes of the plate vibrator made in
each direction, until the sand is no longer absorbed into the joints.
5/4.11 The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.
5/4.12 No paving shall be left uncompacted overnight except for the 1 m strip at the
temporarily unrestrained edge.
5/4.13 On completion, the finished surface level, shall be within 5 mm of the design level
and the maximum deviation within the compacted surface, measured by a 3 m
straight edge shall not exceed 3 mm. The level of any two adjacent blocks shall
not differ by more than 1 mm. Any areas of paving which do not comply with
these tolerances shall be removed, the sand laying course adjusted and the
paving blocks relaid to the correct levels.
5/5 KERBS DESCRIPTION
5/5.1 This work shall consist of the construction of kerbs in accordance with the
Specifications and in conformity with the lines, grades and typical sections shown
on the Drawings or established by the Engineer. These Specifications refer to the
following types of precast kerbs to be constructed: Non-Mountable Kerbs,
Dropped Kerb, Heel Kerb, Quadrants and Flush Kerb. All Kerbs and edgings
shall be hydraulically pressed and shall comply with the requirements of BS7263
Part 1. They shall be uniform in colour, free from cracks, flaws or other defects
and they shall have well defined arises.
5/6 MATERIALS AND MANUFACTURE OF KERBS
5/6.1 Materials shall conform to the requirements specified in Part 4 "Concrete" of the
Specifications and as specified herein.
5/6.2 Kerbs shall be prepared with a concrete mixture containing not less than 400
Kg/m3 of Sulphate Resisting Portland Cement. The aggregate shall meet the
requirements of the General Specifications and conform to the following
gradation.
5/2
ASTM SIEVE % PASSING BY WEIGHT
3/4" (19.00 mm) 100

1/2" (12.50 mm) 76 - 100
3/8" ( 9.51 mm) 60 - 80
No.4 ( 4.75 mm) 40 - 60
No.8 ( 2.36 mm) 22 - 42
No.16 ( 1.18 mm) 12 - 32
No.30 ( 0.60 mm) 7 - 23
No.50 ( 0.300 mm) 4 - 15
No.100 ( 0.150 mm) 2 - 10
No.200 ( 0.075 mm) 0 - 2
5/6.3 The 28 day characteristics cube strength of the concrete shall be 40 N/mm2
determined on cubes specimens, and not less than 75% of this figure after 7
days.
5/6.4 Non-Mountable Kerb, Dropped Kerb, Flush Kerb and Heel Kerb elements shall
only be precast from concrete produced in a fully automatic batching plant.
5/6.5 Tests shall be carried out on the concrete mix prior to commencement of
manufacture to ascertain the strength and surface finish requirements can be
met. If the required strength and surface finish is not obtained, then the Engineer
may order revisions to be made in order to achieve the specified requirements.
Mix design changes and any other work considered necessary to meet
requirements shall be subsidiary to the pay item.
5/6.6 Prior to approval of elements of commercial manufacture cores shall be taken

from a random sample to ascertain that the concrete strength is not less than 280
Kg/cm2 at 7 days. The Contractor shall submit samples of the various types of
concrete kerbs for approval by the Engineer before commencing this work.
5/6.7 Elements shall be manufactured to the dimensions shown on the Drawings.
5/6.8 Non-Mountable and Dropped Precast Kerbs shall be formed by elements 900
mm long where required to be laid in straight lines but may be reduced to 250
mm long where required to be laid to curves depending on the radii of the curves.
5/6.9 The finished product shall be of solid appearance with clean planar faces, be free
of segregation, honeycombing, pits, broken corners or other defects and there
shall be no evidence of external rendering.
5/6.10 Bull noses and curved faces shall be of constant radius with a smooth change
from radius to plain face.
5/6.11 Tolerances of manufacture shall be three (3) millimetres in any one dimension
and end faces shall be truly perpendicular to the base.
5/6.12 Transverse strength and water absorption requirements shall be in accordance

with BS 7263 Part 1 (latest edition).
5/7 KERB LAYING
5/7.1 Elements shall be set to the lines and grades shown on the Drawings. Under no
circumstances will it be permitted for levels to be set by direct measurement from
pavement layers.
5/3
5/7.2 Unless otherwise indicated, elements shall be laid either directly onto a wet
concrete base or on to a sand/cement (3:1) mortar bedding, two and half (2.5)
centimetres thick, on a previously laid concrete base on approved subgrade. The
dimensions of the base shall be as shown on the Drawings. The concrete base
shall be constructed of Concrete Class 25/20.
5/7.3 Unless otherwise indicated, after kerbs units have been laid a contiguous backing
of Concrete Class 25/20 shall be poured for the elements using steel forms.
5/7.4 No pavement layers shall be laid against kerbing until such time as the backing is
complete, back filled and approved by the Engineer.
5/7.5 Joints between radius kerbs, shall have a clear width of four (4) millimetres and
be filled with a sand/cement (3:1) mortar with one fifth (1/5) part hydrated lime
and sufficient water to make the mixture plastic and easily smoothed. A grooving
tool shall be used to produce a smooth, circular section groove not more than
three (3) millimetres deep in all joints. Grouted joints shall be cured by an
approved method to the Engineer's satisfaction. Joints between straight kerbs
shall not be filled.
5/7.6 Immediately after any concrete is in place and for 7 days thereafter the kerbs,
base backing and mortared joints shall be fully cured and protected from drying
out and against the harmful effects of weather, including rain and rapid
temperature changes. The method of protection shall be subject to the
Engineer's approval. The use of coloured curing membranes will not be
permitted. Concrete not properly cured and protected will be rejected and shall
be removed from the works.
5/7.7 At each 9 metres or as directed by the Engineer or shown on the Drawings, the
joint between kerbs shall be filled with an approved joint filler 10 mm thick to form
an expansion joint. The filler shall extend through the kerb, bed, backing and
channel, and shall be trimmed to the finished shape of the kerb and channel.
5/7.8 At access points the kerbs, including the bed backing shall be dropped to show a
face of 75 mm or as otherwise shown on the Drawings.
5/7.9 At the end of any kerb run, the end kerb section shall be sloped down to ground
level, if applicable, and angled away from the road at 30 degrees.
5/7.10 All kerbs shall be thoroughly cleaned of all extraneous material prior to approval.
5/7.11 Kerbs shall be laid within a tolerance of plus or minus three (3) millimetres, at
each end of an element, to the lines and grades given on the Drawings.
5/7.12 Where specified kerbs shall be painted.
5/7.13 Any excavated surface for the concrete bedding shall be watered and compacted
to a minimum of 95% maximum Dry Density (BS 1377 Part 9 Method 2.1).
5/8 PAVEMENT MARKING DESCRIPTION
5/8.1 This work shall consist of supplying thermoplastic road marking material for
marking of the pavement as outlined herein. It shall include the marking of the
centreline, the shoulder strip or edge, the barrier lines, the cross walks and any
other markings required on the pavement for the control and direction of the
traffic.
5/4
5/8.2 The pavement markings shall be painted on the road to the dimensions and in
the location as shown on the Drawings or as directed by the Engineer.
5/8.3 The Contractor shall set out the markings and obtain the Engineer's approval
before commencing the work.
5/9 MATERIALS FOR PAVEMENT MARKINGS
5/9.1 The material used shall conform to the B.S. (British Standard) Specification for
Road Marking Materials (Superimposed type) B.S. 3262, (Part I) 1989 except
where modified in this Specification. Ballotini shall be in accordance with BS
6088, 1981.
5/9.2 The road marking material shall consist of light coloured aggregate, pigment and
extender, bound together with hard wearing resins, plasticised with oil as
necessary in approximately the following proportions by weight:
Aggregate 40 parts)
Ballotini 20 parts)
Pigment and 20 parts)

Extender
Binder 20 parts)
5/9.3 The grading of various ingredients shall be such that the final product, when in a
molten state, can be sprayed on the surface in accordance with BS 3262:1989.
5/9.4 The aggregate shall consist of white silica sand, crushed calcite, calcined flint or
quartz, or other approved aggregate, and the colour shall comply with the
requirements laid down in paragraph 4b of BS 3262 (Part I).
5/9.5 Ballotini incorporated in the mixture shall be reasonably spherical, and free from
flaws and not less than 80 percent shall be transparent glass. The grading of the
ballotini shall be as stated in BS 6088 1981.
5/9.6 The pigment shall be titanium dioxide (in accordance with paragraph 6a (i) of
B.S. 3262 (Part I) and shall be not less than 10 percent by weight of the mix.
5/9.7 The extender shall be whiting (in accordance with paragraph 6b of BS 3262 (Part
I). The total content of pigment and extender shall be 18-22 percent (in
accordance with paragraph 6c of BS 3262 (Part I).
5/9.8 The binder shall not contain more than 5 percent of resin or other acidic material.
It shall consist mainly of hydrocarbon resins plasticised with mineral oil.
5/9.9 The resins used shall be of a colour at least as pale as Grade WG resin. It shall
have an acid value not greater than 2, and must pass the heat stability test
described below.
5/9.10 The oil used as plasticiser shall be a mineral oil with colour and viscosity as
defined in paragraph 7a (ii) of B.S. 3262 (Part I), i.e. at least as pale as grade 4
on the P.R.S. Shellac and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 degree
C viscosity. In addition, when heated for 16 hours at 150 degrees C it shall not
darken excessively.
5/5
5/9.11 The softening point of the binder shall be used only as a guide to quality control,
and the behaviour of the thermoplastic shall be judged from the performance
tests described below.
5/9.12 The viscosity of the melted binder at the spraying temperature must be such as
to produce a thermoplastic mix of the required spraying properties.
5/9.13 The composition of the laid material as found on analysis shall comply with the
requirements of Table 1 of B.S. 3262 (Part I), reproduced below:-
A : Proportion of Constituents
Percent by Weight
Constituent -------------------------------------
Minimum Maximum
Binder 18 22
Aggregate, pigment and

extender and ballotini 78 82
B: Grading of Combined Aggregate Pigment and

Extender
Percentage by Weight Passing

Constituent ---------------------------------------------------
Minimum Maximum
No. 20 100 --
No.30 75 95
No.52 35 65
No.200 25 35
5/9.14 The temperature limits imposed by B.S. 3262 (Part I) for materials based on resin
shall not apply. Temperatures up to 220 degree C may be used; at these
temperatures the material shall not discolour in the time required for its use.
5/9.15 Containers shall be made of a material which does not contaminate the contents
and will protect the contents from contamination.
5/9.16 The capacity of each container shall be not less than 25 Kg or more than 100 Kg.
5/9.17 Each container shall be clearly marked with the manufacturer's name, batch
number and date of manufacture.
5/10 APPLICATION OF THERMOPLASTIC
5/10.1 Application shall be by mobile sprayer, either hand propelled or self-propelled.
5/10.2 The road surface shall be dry, and free of loose, detritus, mud, or other
extraneous matter. Where old paint or thermoplastic material are present, the
manufacturer shall be consulted as to whether or not the surface is suitable.
5/6
5/10.3 A tack coat should not be necessary when the thermoplastic is applied to
carriageways. Where it is considered necessary to use a tack coat, this shall be
rubberised type recommended by the manufacturers of the thermoplastic
material.
5/10.4 In addition to the ballotini included in the mix, an additional quantity of glass
beads shall be sprayed on to the hot thermoplastic line at the time of application.
The rate of application shall be at the rate of about 0.5 Kg/m2.
5/10.5 The thermoplastic material shall be applied in intermittent or continuous lines of

thickness 1.2 mm +/- 0.3 mm. For special lettering, arrows or symbols the
material shall be applied by hand methods. The finished lines shall be free from
raggedness at all edges and be true in place with the road surface. The upper
surface shall be level uniform and free from streaks, blisters, lumps and other
defects.
5/10.6 Application of thermoplastic material to new pavement construction should be

preceded by wire brushing to remove bitumen rich surface mortar. Sufficient
compatible mineral oil plasticisers should be incorporated in the thermoplastic
material to reduce levels of early shrinkage in the material and subsequent
cracking of the asphaltic pavement structure.
5/11 PERFORMANCE REQUIREMENTS AND TESTING
5/11.1 The thermoplastic material shall meet the performance requirements of the
following table.
THERMOPLASTIC MATERIAL
Property Minimum
Maximum
Density Mg/Cu.m. 2.0 (approx) -

Open Flashpoint C 230 -
Softening Point (ring and
ball ASTM D36) C 95 -
Luminance Factor
White 70 -
Yellow 50 -
White Remelting 65 -
Yellow Remelting 45 -
Flow Resistance after 48 hours
at 40 degrees Centigrade - 25
Abrasive wear, 9/100 revs - 0.3
Skid Resistance 45 -
5/11.2 Testing of thermoplastic material shall be as described below. All specimens shall
be prepared by carefully heating a representative sample to a temperature of
5/7
(softening point +50° C), stirring thoroughly to avoid segregation and used
without delay.
5/11.3 Luminance: The material shall be cast on to a suitable flat, glossy surface
coated with a colourless release agent to give a slab 100 mm square by 3 mm
thick. The luminance of the cast face, with reference to that of a block of
magnesium oxide (luminance factor 100) shall be measured with the sample
illuminated by a tungsten light source at an angle of 45 deg. viewed at right
angles by a selenium barrier layer photo-electric cell.
5/11.4 Flow Resistance: The material shall be cast into a conical mould having an
apex angle of 60 deg. and a vertical height of 100 mm. After cooling and setting
for 24 hours the cone shall be removed from the mould, placed on a flat level
surface and maintained at a temperature of 23 deg. C +/- 2 deg.C for 48 hours.
5/11.5 Impact Resistance: A 3 mm thick coating of material shall be screeded on to a

Monel alloy panel 1.25 mm thick, previously coated with rubberised bitumen
emulsion. The impact instrument, a 4.7 Kg weight, shall be dropped vertically
through 250 mm on to the surface of the panel, striking the surface with a
hemispherical indenter of radius 6mm. The panel shall be retained by a metal
block drilled to allow the indenter to strike the panel, with the depth of indentation
limited to 2 mm. Five panels shall be tested and no fracture shall result from
impact. A crack not longer than 2 mm will be accepted provided there is a
smooth indentation in the material.
5/11.6 Abrasion Resistance: A 3mm thick coating of material shall be screeded on to a

Monel alloy panel and subject to wet (water lubricated) abrasion at 23° C on a
Taber Model 503 standard abrasion tester using H-22 Calibrade wheels, refaced
between tests. The loss in weight after two successive tests of 100 revolutions
shall be recorded and the average taken as the abrasive wear.
5/11.7 Skid Resistance. A 100 mm wide line of material 1.5mm thick shall be screeded
on to a flat, level base for a minimum length of 800 mm. After cooling to ambient
temperature the skid resistance shall be measured using the TRRL Portable
Tester as described in Road Note 27. Measurements shall be made on different
parts of the specimen, corrected for temperature effects, and the average
recorded.
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS
5/12.1 The Contractor shall control the traffic in such a manner as to protect the freshly
marked surface from damage. The traffic control shall be so arranged as to give
minimum interference to the travelling public. Signs, barricades, flagmen and
control devices shall be supplied by the Contractor and a system of spaced
warning flags or blocks shall be used to protect the fresh marking until it has
dried as required. Any lines, stripes or markings which become blurred or
smeared by the traffic shall be corrected by the Contractor at his own expense.
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..)
5/13.1 Road marking paint shall be by an approved manufacturer. It shall be suitable for
applying by brush or mechanical means to cement concrete or bituminous
pavement to give a chemically stable film of uniform thickness and shall be either
chlorinated rubber, one pack epoxy or alkyd based.
5/13.2 White paint shall contain not less than 6% by mass of titanium dioxide as a
pigment, conforming to type A (anatase) or type R (rutile) specified in BS 1851.
5/8
5/13.3 Yellow paint shall be standard colour BS 381C No.355, except where an
alternative shade has been specified in the Contract, and contain not less than
6% by mass of a suitable yellow pigment.
5/13.4 The paint shall be supplied fresh and ready for use in sealed containers and
stored in accordance with the manufacturer's instructions. The paint shall be
applied without the use of thinners or other additives.
5/13.5 Paint shall be applied at a covering rate recommended by the manufacturer and
5/13.6 Where markings are to be reflectorised with ballotini it shall be sprayed uniformly
on to the wet paint film at the rate of 400 - 500 g/sq.m. Ballotini shall comply with
the requirements of BS 3262 Clause 15.
5/13.7 Road marking materials shall only be applied to surfaces which are clean and
dry. Markings shall be free from raggedness at their edges and shall be uniform
and free from streaks. Carriageway lane and edge lines shall be laid by approved
mechanical means to a regular alignment.
5/14 ROAD SIGNS, DESCRIPTION
5/14.1 This work shall consist of furnishing and installing road signs and posts
assemblies as shown on the drawings and in accordance with the Specifications
or as directed by the Engineer. All sign faces and lettering shall be in accordance
with the Employer's sign standards as shown on the drawings or as directed by
the Engineer.
5/14.2 Permanent traffic signs shall be reflectorised or non-reflectorised illuminated and

shall, in respect of quality, comply with the requirements of (i) BS 873 (ii) the
Traffic Sign Regulations and General Directions and the Traffic Sign Manual,
published by HMSO U.K. (iii)RTA/ Dubai Municipality Information Signs Manual
and Current Technical Circulars.
5/14.3 All foundations, framing and fixings for Information Sign shall be suitable for local
conditions. The design calculations shall be submitted to the Engineer for
approval. The design wind speed shall be taken as 120 Km/hour with gusts up to
160 Km/hr.
5/14.4 Within 3 weeks of acceptance of the manufacturer's tender the Contractor shall
submit for approval working drawings for signs posts and base plates.
Fabrication shall not be commenced until approval has been given. The
Contractor shall submit samples of the proposed materials for approval on
request by the Engineer prior to delivery to site, at his own cost.
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS
GENERAL
5/15.1 Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC -
1/2H, NS3-3/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11
swg) or from extruded aluminium plank sections to BS 1476, HE 9-WP, HE 9-P
or HE 30-WP or extruded aluminium allow plank sections to BS 1474, HE 9 TE
and HE 30 TF. However, information signs shall be constructed in extruded
aluminium planks, which will either be self-locking or rear fixing, and the
aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent
International Standard.
5/9
5/15.2 All sign plates shall have clean, smooth edges cut to the required shape of the
sign, and shall be etched and degreased to the sign sheeting manufacturer's
specifications before application of the sheeting.
5/15.3 Sign shall be covered with "Engineering Grade" reflective sheeting 3M or

equivalent or they shall be covered over the whole front face with "High Intensity"
reflective sheeting as detailed on the drawings. The sheeting of the specified
colours must have the manufacturer's guarantee for a period of not less than 5
years for "Engineering Grade" and 7 years for "High Intensity". The rear faces
shall be non-reflective grey and should give a similar lifespan to the sign face.
5/15.4 The reflective sheeting shall be fixed to the sign plate either with a heat activated
adhesive using vacuum applicator or with a pressure sensitive adhesive using a
pressure roller in accordance with the sheeting manufacturer's instructions.
5/15.5 Sign faces shall be formed from a single piece of reflective sheeting, but if for
any reason the sign face must be fabricated from more than one piece of
material all joints in the material shall be over lapped by not less than 6 mm and
where sheeting is applied to extruded sections it shall extend over the top and
bottom edges of the sections by not less than 3mm. No butt joints shall be
permitted and in horizontal joints the overlap shall be from the top.
The sheeting, after application to the sign base, will not come off at the edges
nor shall it peel off or warp. The surface shall be smooth, flat and free from any
bubbles, pimples, edge chipping or edge shattering. It shall be washable and
weatherproof.
5/15.6 The corners of all direction signs shall be rounded to a radius of 75 mm.
STIFFENING AND FRAMING
5/15.7 All stiffening and framing shall be of hot dipped galvanised steel of equivalent
strength (section modulus) to that of mild steel tabulated in Chapter 13 of the
Dubai Municipality Traffic Sign Manual.
5/15.8 Signs constructed of aluminium sheet shall, when recommended by the Traffic
Sign Manual, be framed on all edges using hot dipped galvanised steel angle or
angle-channel of equivalent section to that detailed in Chapter 13 of the Traffic
Signs Manual.
5/15.9 Stiffening to signs constructed of aluminium sheet, having dimensions less than
those given in Chapter 13, paragraph 52 of the Traffic Sign Manual but with an
area exceeding 0.10 sq.m. shall be confined to horizontal lengths at the top and
bottom edges of the sign plate.
5/15.10 Signs constructed from extruded aluminium plank sections are to present the
same flanged appearance on all edges of the sign by fitting an aluminium end
capping to the exposed ends of the plank section on both sides of the sign.
5/15.11 Where the specified sign width requires the use of more than one length of plank
section, support beams shall be provided and positioned as approved by the
Engineer.
5/15.12 For plank type signs supported on two posts the plank rails and support beams
shall be manufactured from one length of extruded aluminium section. One tie
bar shall be fitted between the bottom two plank rails (or the plank rail and
support beam) at the centre of the span between the mounting posts.
5/10
5/15.13 Where plank type signs are supported on more than two posts, and the specified
sign width is wider than the plank rail and support beams, the plank rail and
support beam may comprise two or three lengths provided butt joints occur at an
inner post. One tie bar shall be fitted between the bottom plank rail and support
beam at the centre of the span between the mounting posts.
5/15.14 All stiffening and framing shall be continuous.
5/15.15 All rivets or other devices fixing sign plates to their framework shall be of non-
staining steel or other materials approved by the Engineer and shall have a
sufficient cross sectional area to prevent failure from thermal stresses or wind-
pressure or such other stresses as may be specified. All rivet and bolt holes shall
be edge-sealed with clear lacquer after the application of the plastics sheeting.
Rivets shall be spaced at not more than 150 mm apart, around the outside edge
of the sign plate and on cross braces the spacing shall be not more than 300
mm.
5/15.16 Any rivet brought through the sign face shall be coloured to match the sign face.
Any rivet or other device fixing sign plates to their frame work shall have a
protective washer of nylon or other approved insulating material inserted where
they would be in contact.
5/15.17 All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates
to support posts shall be manufactured from stainless steel. For plank type signs
brackets and clips shall be extruded aluminium alloy section.
5/15.18 Saddles shall be aluminium alloy or other material approved by the Engineer and
shall be provided with a nylon strip or other approved insulating material.
5/15.19 Details about the mounting and the footing of the different type of signs are
shown on the drawings. Mild steel posts shall be treated with one of the following
treatments as approved by the Engineer.
1. Shot blasted, one coat primer (min. thickness 50 microns), one coat
micaceous iron oxide (min. thickness 50 microns), one coat undercoat, and
one coat finish of alkyd based oil paint (min. total thickness of both coats
100 microns).
2. Shot blasted, rustproof with hot wire zinc spray and under coat and finish coat
as (1).
3. Shot blasted, hot wire zinc spray rust proofing and wet applied PVC spray
giving a minimum plastic coating of 0.125 mm. The finish colour should be
grey.
For both (1) and (2) the finish coat should be black and white hoops as directed
by the Engineer.
All bolts and other fittings should be non-ferrous or hot dipped galvanised.
Connecting surfaces of different metals should be separated by neoprene
washers.
FINISH
5/15.20 There shall be full adhesion of all sheeting material including letters, symbols and
borders and there shall be no air bubbles, creases or other blemishes.
5/15.21 All panels, cut-out letters, numbers, borders, symbols and background on
reflective sheeting shall be carefully matched for colour at the time of sign
5/11
fabrication to provide uniform appearance both by day and night. The sheeting
manufacturer's recommendations on colour matching methods shall be observed.
Non uniform shading or undesirable contrast between reflective sheeting on any
one sign will not be accepted.
5/15.22 The edges of all applied sheeting materials including edges of all plates which
make up a sign, letters, symbols and borders shall be sealed as specified by the
manufacturer.
5/15.23 Where required by the sheeting manufacturer the face of the sign plate shall
have a coat of clear lacquer of a type specified by him.
5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS
5/16.1 All sign faces shall be of the type, colour and size shown on the drawings or as
specified by the Engineer. Sign lettering shall comply to RTA/ Dubai Municipality
Traffic Signs Manual requirements.
5/16.2 The Contractor shall submit to the Engineer and Traffic Police Department
Engineering Section for approval three (3) copies of his working drawings for all
sign faces both in Arabic and English. Size and style of lettering shall be as
shown on the drawings or as otherwise approved by the Engineer.
5/16.3 No order shall be placed without written agreement of the Engineer and the
concerned authorities.
5/16.4 The approximate position and mounting height of each sign is indicated on the
drawings, the exact sign position and mounting height shall be determined on site
and marked on the ground by pegs or painted marks. The exact position shall be
agreed by the Engineer and approved by the concerned authorities.
5/16.5 Post length shown in the drawings are approximate only. When progress of the
work is at the appropriate stage the Engineer will authorise the location of each
sign, with the station and off-set distance from the edge of the pavement. The
Contractor shall be responsible for determination of the exact post lengths to
provide the vertical clearance shown on the drawings. Field cutting of posts shall
be performed by sawing. Welded posts will not be permitted.
5/16.6 All excavations shall be approved by the Engineer before the sign is erected and
prior to the backfill with sand or concrete as shown or directed by the Engineer.
The sides of excavation shall be vertical and any additional excavations carried
out beyond that specified, for the particular post and sign being erected, shall be
filled at the Contractor's own expense with Class 25/20 concrete or granular
material as directed by the Engineer.
5/16.7 Where the sign has an area in excess of 10 sq.m. or the posts have a diameter
in excess of 110 mm, each foundation, above the foundation screed, shall be
poured with concrete up to the finished foundation level shown on the drawings.
5/16.8 All posts shall be erected vertically and where two or more posts are provided for
any sign the faces of these posts shall be lined up and their deflection angle
checked for compliance with sub-section 5/16.12) of this Clause, before
concreting in.
5/16.9 For a period of 14 days after concreting in position, all posts shall be suitably
braced to prevent movement. Sign faces should not be fixed to posts until after
the bracing has been removed and the Engineer has inspected and approved the
posts stability and foundations.
5/12
5/16.10 All posts shall be of the type specified on the drawings and shall be protected
against corrosion by painting in accordance with sub-section 5/35.
5/16.11 Signs delivered for use in the project shall be in new and unused condition,
except where otherwise specified; and shall be stored off ground and under
cover in a manner approved by the Engineer. Any sign damaged, discoloured or
defaced during transportation, storage or erection shall be rejected.
5/16.12 Unless otherwise shown on the drawings all signs shall be erected so that the
edge and face of the sign are truly vertical and the face is at an angle of ninety
five (95) degrees to the centreline; that is, facing slightly away from the centreline
of the lane which the sign serves. Where lanes divide or are on sharp curves, the
Contractor shall orient sign faces as indicated on the drawings or by the Engineer
so that they will be most effective both day and night and such to avoid reflection
and glare. All sign supports shall be plumbed vertical.
5/16.13 The distance between the lower edge of the signs and the road surface shall be
in accordance with the drawings.
5/16.14 Signs shall be fastened to sign supports in accordance with the requirements of
the drawings, specifications and the recommendations of the sign manufacturer
to the satisfaction of the Engineer.
5/16.15 COVERING OF SIGNS
The Contractor shall at his own expense, immediately after erection and approval
by the Engineer cover the sign in order to prevent misleading information being
displayed. The covering shall be close weave hessian securely fixed over the
face of the sign using a lacing of nylon cord so as not to damage the sign. The
Contractor shall maintain such coverings in good order until receipt of the
Engineer's instruction for their removal.
5/16.16 CLEANING OF SIGNS
Signs shall be thoroughly cleaned immediately prior to being handed over. The
cleaning shall be carried out in the manner described in the Traffic Sign Manual,
Chapter 12 (3). The type of detergent used shall be approved by the Engineer.
5/16.17 IDENTIFICATION OF SIGNS, POSTS AND ALL FITTINGS
The reference number of the sign shall be indicated by self adhesive numbers on
the reverse side of the sign in the bottom left hand corner and in a consistent and
readily visible position on all posts and fittings. The manufacturer's name or trade
mark will not be permitted on the face of the sign. The manufacturer's name or
trade mark together with the date of manufacture shall be permanently affixed on
the back of the sign, provided approval to the size and colour of the mark has
been obtained from the Engineer.
5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR
5/17.1 All road signs shall be guaranteed by the Contractor against any defect in
material and workmanship for the period stipulated in Clause 5/15.3 from the
date of completion of the works under the contract. If any defect should arise due
to poor material or workmanship it shall be rectified by the Contractor at his own
expense.
5/13
5/17.2 If such defect is rectified by other than the Contractor in accordance with the
Employer's instruction, the expense of rectification shall be deducted from any
monies due to the Contractor.
5/18 PAVEMENT REPAIRS
5/18.1 This work shall consist of the various types of repairs to existing pavement
described herein, necessary to correct structural failures, grade elevations, and
deterioration and/or to prepare the existing pavement surface prior to placing
bituminous pavement overlays. The Engineer on site shall investigate and find
out causes of failure and he shall instruct the Contractor on the type of repair.
The Contractor shall provide assistance in such investigation as instructed by the
Engineer.
5/18.2 The materials required for the various pavement repair items shall be as specified
and shall be in accordance with the requirements of Section 3 of these
Specifications.
5/18.3 The Contractor shall be responsible for the supply of all the equipment and
labour necessary to perform the work described for the various types of
pavement repair items in accordance with these Specifications and as directed
by the Engineer.
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS
REPAIR OF POTHOLES (ISOLATED HOLES IN THE PAVEMENT OF LESS

THAN ONE SQUARE METRE)
5/19.1 The Contractor shall cut the failed pavement back to solid material with
pneumatic asphalt cutting tools. Make the cut square or rectangular with faces
straight and vertical. One pair of faces shall be at right angles to the direction of
traffic.
5.19.2 Remove the cut pavement and loose unsuitable material from the hole and cart
away and dispose at a location designated by the Engineer.
5/19.3 If soil is removed, fill the excavation with granular road-base material which has
been premixed to optimum moisture content. Place the material in 150 mm layers
and compact each layer to 98% of the maximum dry density as determined
according to BS 1377 Part 9 Method 2.1/2.2 with mechanical compactors. The
same treatment is to be applied on subsoil before filling the excavation with
granular roadbase material.
5/19.4 Wire broom clean the cut edges of the pavement and paint with tack coat.
5.19.5 Prime the compacted soil or the upper surface of the roadbase layer with a light
coating of prime coat as directed by the Engineer.
5/19.6 Fill the hole with Bituminous Base Course and/or Wearing Course as appropriate
and compact in lifts not exceeding 5 cm to the same level as the adjacent
surface. Vibratory compactors shall be used to compact the hot-mix bituminous
layer.
5/19.7 Check levels of the patch with a straight edge and make corrections as directed
by the Engineer.
5/14
REPAIR TO FAILED PAVEMENT
5/19.8 The Contractor shall cut the failed pavement to solid material with pneumatic
asphalt cutting tools. Make the cut square or rectangular with faces straight and
vertical. One pair of faces shall be at right angles to the direction of traffic.
Vertical faces may be stepped where instructed by the Engineer.
5/19.9 Remove the cut pavement and excavate the underlying soil to a depth of not less
than 300 mm. The Engineer may, when deemed necessary order substantially
greater depths of excavation payable as common excavation. Cart away and
dispose all cut pavement and excavated soil at a location designated by the
Engineer.
5/19.10 Thoroughly compact the subsoil with mechanical compactors to 98% of Modified
Proctor Density in accordance with the standard test methods given in Section 2
of the Specification.
5/19.11 Fill the excavation to the bottom of the pavement with granular roadbase material
which has been premixed to the optimum moisture content. Place the materials in
150 mm layers and and compact each layer to 98% Modified Proctor Density with
mechanical compactors in accordance with the standard test methods given in
Section 2 of the Specification.
5/19.12 Wire broom clean the edges of the pavement and paint with tack coat.
5/19.13 Lightly prime the compacted road base layer with prime coat as directed by the
Engineer.
5/19.14 Place and compact wearing course or base course as applicable in the
excavation in 50 mm layers to the same level as the adjacent surface. The lower
layer shall be compacted with a vibratory compactor and the top layer shall be
compacted with a steel wheel roller by first compacting the hot-mix bituminous
layer 150 mm from the two traffic edges and then by rolling in the direction of
traffic. The drive wheel of the roller shall be in a forward position. Use of asphalt
pavement finisher will depend on the size of the area being patched.
5/19.15 Check levels of the repair with a straight edge and make corrections as required.
REPAIR OF DEPRESSED PAVEMENT
In case where the pavement has depressed but the asphalt has not fractured and
the pavement appears stable, the Contractor shall:
5/19.16 Cold plane and remove the upper 5 cm of the pavement starting just back from
the depression. Cart away and dispose of the removed pavement at a location
designated by the Engineer.
5/19.17 Wire broom clean the surface and lightly tack the surface and the edges with
tack coat (do not exceed 0.23 litres per square metre of tack coat).
5/19.18 Fill the cut with bituminous base course or wearing course as applicable and
compact with a steel wheeled roller by first compacting the hot asphaltic concrete
150 mm from the two traffic edges and then by rolling in the direction of traffic.
The drive wheel of the roller shall be in the forward position.
5/15
5/19.19 Check the level of the repair with a straight edge and make corrections as
required.
5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS
5/20.1 The Contractor shall barricade the immediate work site to protect workmen and
motorists without closing the entire carriageway width to traffic. A single lane
should be closed for such operations.
5/20.2 Cut and remove sufficient asphalt pavement, if any, and concrete from the
manhole to permit removal of the cover and frame without damaging the
reinforcing steel, cart away and dispose of the rubble at a site designated by the
Engineer. Raising or lowering of manhole cover will be executed as per details
shown on the drawings or as otherwise specified.
5/20.3 Before starting any adjustment activity the Contractor shall obtain approval from
the concerned Authority to which the manhole belongs.
5/20.4 The Contractor shall submit to the Engineer for approval shop drawings for each
manhole affected by the work showing existing and new levels and a statement
of the methodology that will be followed.
5/20.5 Payment will be made upon receipt by the Engineer of a certificate issued by the
concerned Authority stating their approval of the works.
5/21 METAL BEAM GUARD RAIL SAFETY FENCING
5/21.1 Safety fencing shall comprise untensioned corrugated rails, channel-section,

posts, blocking-out pieces, nuts, bolts and washers for fixings, and end
anchorages.
5/21.2 Steelwork shall be mild steel Grade 43A to BS 4360, and shall be hot-dip
galvanised after fabricating in accordance with BS 729 to the thickness shown on
the Drawings.
5/21.3 Fencing shall be erected to the dimensions and tolerances shown on the
drawings to produce a flowing alignment. The Contractor shall adjust the
elevation of any rail as required.
5/21.4 The rail section shall be such that when freely supported over a 3 m clear span,
with the road face uppermost, and centrally loaded with a point load of 1000 Kg,
the deflection measured at the centre of the span shall not exceed 40 mm.
5/21.5 Adjacent rails shall be connected by bolted lap of joints made in the relevant
direction to prevent vehicles striking rail ends.
5/21.6 Guardrail posts may be driven into the ground as detailed on the drawings
provided that:-
i. The accuracy of placing will permit the rail mounting to be erected to

present a flowing alignment.
ii. A representative sampling of driven posts selected by the Engineer shall

satisfactorily withstand a test load of 10 KN applied horizontally at the level
of the centre of the rail with a deflection at that level not exceeding 200
mm. Where the previous cannot be met all posts shall be set into Class
25/20 concrete or as detailed on the drawings.
5/16
iii. Driven posts shall have a protective coating of bituminous paint over the
length which is to penetrate the ground. The bituminous paint shall be of
high quality with excellent adhesion properties. A sample of the paint
together with the manufacturers specifications shall be submitted to the
Engineer for approval prior to use.
5/21.7 The ends of safety fences shall terminate with a mitred end rail and anchorage
flared away from the line of fence.
5/21.8 Site drilling or cutting of beams and posts shall not be permitted without approval.
Flame cutting shall not be permitted.
5/21.9 Minor surface damage to steel components shall be repaired by cleaning with a
wire brush to remove all corrosion products, the application of two coats of rust
inhibiting paint, and two coats of approved cold galvanising paint or similar over
the damaged area.
5/21.10 The horizontal alignment of fences shall not depart from the road alignment by
more than 30 mm overall, and the relative deviation shall not be more than 10mm
in any two successive rail lengths.
5/21.11 The height of the uppermost edge of the rail shall not depart from the dimensions
shown on the drawing by more than 30 mm, nor shall the relative deviation from
this line be more than 5 mm in any two successive rail lengths.
5/22 HEAVY DUTY CAT'S EYES (REFLECTIVE STUDS)
5/22.1 Reflective Road Makers shall be to "Prismo II" or "Alico" type or similar approved.
They shall be capable of withstanding the climatic conditions of Dubai and be
maintenance free. A performance guarantee of five years is required.
BODY AND DIMENSIONS
5/22.2 The Road stud shall measure 125 mm x 125 mm x required height when seated
on the road surface.
5/22.3 Exact size of the road stud shall be indicated on the drawings.
5/22.4 The shaft shall be "Anti-Twist/Hot-Tite" x 76 mm long.
5/22.5 The slope of the reflecting face shall be 20 degrees.
5/22.6 The body shall be smooth, pressure moulded aluminium alloy, complying with
British Standard 1490.
5/22.7 In addition to the above, the studs shall bear the following manufacturing
specifications or shall be approved equal.
5/22.8 The enveloping profile of the head of road studs shall be smooth and the studs
shall not present any sharp edges to traffic.
5/22.9 The body of the stud shall be constructed in one integral part.
5/22.10 The anchorage part of the stud shall consist of a circumferential ribbed shank
with parallel flats, the flats on the alternate ribs being at 90 degrees to each other
to prevent rotation of the stud when located in the road surface.
5/17
5/22.11 The studs shall be constructed in aluminium alloy to BS 1490 LM6-M to provide a
robust and durable location for the lenses. The alloy shall have the following
characteristics:-
5/18
----------------------------------------------------
COMPOSITION MINIMUM (%) MAXIMUM (%)
---------------------------------------------------
Copper - 0.1
Magnesium - 0.1
Silicon - 13.0
Iron - 0.6
Magnesium - 0.5
Nickel - 0.1
Zinc - 0.1
Lead - 0.1
Tin - 0.1
Titanium - 0.05
Aluminium - Remainder
REFLECTORS
5/22.12 The reflectors shall be rectangular in shape and shall contain reflective elements
in 2 rows. The rectangular reflective unit shall be firmly located into a recess
within the body of the stud such that the reflective face is established at the
correct orientation. A sample of the proposed reflective studs shall be submitted
for the Engineer's approval.
5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS
DEFINITIONS
5/23.1 Entrance angle shall mean the angle in the horizontal plane between the
direction of incident light and the normal to the leading edge of the stud.
5/23.2 Observation angle shall mean the angle at the reflector between observer's line
of sight and the direction of the light incident on the reflector.
5/23.3 Specific intensity (S.I) shall mean candle-power of the returned light at the
chosen observation and entrance angles for each foot candle of illumination at
the reflector on a plan perpendicular to the incident light.
OPTICAL PERFORMANCE
5/23.4 The specific intensity of each crystal reflecting surface shall not be less than the
following:-
OBSERVATION ANGLE (DEGREES) 0.3 0.5 1.02.0
ENTRANCE ANGLE (DEGREE) 5 10 10 15
SPECIFIC INTENSITY 160 100 27 3
SPECIFIC INTENSITY 120 72 20 2
5/23.5 For yellow reflectors the specific intensity shall be 50% of the value for crystal.
5/19
5/24 REFLECTIVE STUDS MINIMUM MECHANICAL AND PHYSICAL PROPERTIES
5/24.1 MECHANICAL PROPERTIES
0.2 Proof Stress Test N/sq.mm. 120
Tensile Strength N/sq.mm. 280
Elongation mm 2-5
5/24.2 PHYSICAL PROPERTIES
Specific Gravity 2.65
Method of Casting INJECTION
Corrosion Rating EXCELLENT
Brinell Hardness Number 55-60
5/24.3 COLORIMETRY
Requirements: The colour limits of the reflector(s) when illuminated by CIE

standard illumination A, with an entrance angle V = 0 degrees, H = 5 degrees L
or R, and an observation angle of 0.3 degrees shall comply with the requirements
given below.
5/24.4 WHITE (UNCOLOURED) REFLECTORS
White (uncoloured) reflectors shall not produce a selective reflection; that is to

say, the trichromatic co-ordinates Z and Y of the standard illuminant A used to
illuminate the reflector shall undergo a change of more than 0.01 after reflection
by the reflector.
5/24.5 RED REFLECTORS
Red reflectors shall have chromaticity co-ordinates which lie within the area
formed by the straight lines defined by the following pairs of points, 1 and 2, 2
and 3, the spectrum locus, and the line joint the ends of the spectrum locus:
----------------------------------------------------
CO-ORDINATE POINT 1 POINT 2 POINT 3
----------------------------------------------------
X 0.665 0.657 0.730

Y 0.335 0.335 0.262
5/24.6 AMBER REFLECTORS
Amber reflector shall have chromaticity co-ordinates which lie within the area
formed by the straight lines defined by the following pairs of points, 1 and 2, 2
and 3, 3 and 4, and the spectrum locus:-
5/20
---------------------------------------------------
CO-ORDINATE POINT 1 POINT 2 POINT 3 POINT 4
---------------------------------------------------
X 0.330 0.228 0.302 0.302
Y 0.385 0.351 0.693 0.692
5/24.7 TESTS
Compliance with the colorimetric requirements shall normally be verified by

means of a visual comparison test. If any doubt remains after this test,
compliance shall be verified by the determination of the trichromatic co-ordinates
as defined in the proceedings of the 1951 meeting of the International
Commission (CIE).
5/25 REFLECTIVITY
5/25.1 The reflectivity of the stud when new shall exceed minimum standard as laid
down in BS 873 and meet typical values as shown below:-
White reflectors tested to BS 873.
ORIENTATION CIL VALUE (MOD/1X)

TYPICAL
- Observation angle 2 degree

Entrance Angle 15 degree
L and 15 degree R. 5-7.5
- Observation Angle 1 degree

L & 10 degree R. 26.5-30

TYPICAL
- Observation angle 0.5 degree

L and 10 degree R. 59-93
- Observation Angle 0.3 degree

L & 5 degree R. 100-190
AMBER REFLECTORS TESTED TO B.S. 873

TYPICAL


5/21
L & 10 degree R. 10-20


L & 5 degree R. 30-90
RED REFLECTORS TESTED TO B.S. 873

TYPICAL

L and 15 degree R. 1.5-2.0

L & 10 degree R. 4.5-7


L & 5 degree R. 16-35
5/25.2 A sample of the road stud shall be submitted by the Contractor and relevant
technical information, catalogues supplied by the manufacturers shall accompany
the sample.
5/26 INSTALLATION OF REFLECTIVE STUDS
5/26.1 Reflective studs shall be installed and anchored to the pavement as follows:-
5/26.2 Drill a hole into the asphalt pavement to the dimensions recommended by the
manufacturer or 35 mm x 80 mm or 55 mm x 80 mm. Ensure, that the hole is free
of dust and also the pavement surface within a radius of 200 mm of the hole is
free from debris and dust.
5/26.3 Fill the hole to overflow with two parts epoxy adhesive.
5/26.4 Immediately after pouring the grout, the road stud shall be inserted into the hole
and the reflective face aligned to the oncoming traffic. The road stud shall be
firmly embedded into the ground, ensuring a good bed of Grouting compound
under the road stud and solid fixing. Protect the installed marker until the epoxy
adhesive has completely set.
5/26.5 Clean off any surplus Grouting and protect the road stud from traffic for
approximately sixty minutes.
5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION
5/22
5/27.1 This work shall consist of the placement of stone pitching on mortar bedding on
slopes at the locations shown on the plans, or as ordered by the Engineer, in
accordance with these Specifications and in conformity with the lines, grades,
thickness and typical cross-section shown on the plans or established by the
Engineer.
5/28 MATERIALS FOR STONE PITCHING
5/28.1 Stone for pitching shall be hard, sound, durable, stones as approved by the
Engineer. Samples of the stone to be used shall be submitted to and approved
by the Engineer before any stone is placed.
5/28.2 Tests for specific gravity and absorption, shall be determined in accordance with
AASHTO T 85. The minimum apparent specific gravity shall be two and five-
tenths (2.5) and the maximum absorption shall be three (3) percent. The stone
shall not have an abrasion loss greater than forty five (45) percent when
subjected to five hundred (500) revolutions in a Los Angeles Abrasion Machine in
accordance with AASHTO T 96.
5/28.3 The size and shape of the stones shall be such to allow for proper placement.
The widths of the stone shall not be less than one and one-half (1-1/2) times their
respective thickness and lengths of not less than two (2) times their respective
widths. The minimum width shall be 100 mm.
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING
5/29.1 The bed upon which the stones are to be placed shall be excavated to the
required grades and lines as shown on the plans or as directed and approved by
the Engineer. A footing trench shall be excavated along the toe of the slope as
shown on the plans or as directed by the Engineer. All footings trenches and
excavations shall be approved by the Engineer prior to placement of stones or
concrete. Subgrade or base should be firm and well compacted as approved by
the Engineer. Stones shall be placed on a mortar bed as detailed on the
Drawings.
5/29.2 Stones shall be arranged in such a way that the largest stones are at the bottom
of the slope. The surfaces of the stone shall be cleaned of adhering dirt and clay
and shall be moistened immediately prior to grouting.
5/29.3 The space between stones of stone pitching shall be filled with grout consisting of
one (1) part Portland cement and three (3) parts of fine aggregate, and one-fifth
(1/5) part of hydrated lime with sufficient water to produce a plastic mix as
approved by the Engineer. Immediately after pouring, the grout shall be spaded
and rodded into place with suitable spades, trowels or other approved method,
and broomed into the spaces until the voids are completely filled. The exposed
surface of the rocks shall project not less than 40 mm and not more than 80 mm
above the grout surface. The grouted stone pitching shall be cured by an
approved method for a minimum period of four (4) days. Immediately after the
expiration of the curing period, the exposed surfaces shall be cleared of all
curing mediums.
5/29.4 Joints as detailed on the drawings will be provided at a maximum interval of 12

meters.
5/30 GABIONS
DESCRIPTION
5/23
5/30.1 Gabions shall consist of furnishing and placing wire mesh boxes rectangular in
shape filled with clean and uniform rocks larger than the mesh openings in
accordance with the drawings, and these Specifications.
Gabions shall be of approved quality.
MATERIALS
5/30.2 Wire mesh shall consist of galvanised steel fabricated in double twist woven
hexagonal shape with the following requirements:-
WIRE DIAMETER MESH SIZE
Boxes 2.7 mm 8 cm x 10 cm
Mattresses 2.2 mm 6 cm x 8 cm
5/30.3 The rocks shall consist of clean solid rock non- friable and resistant to weathering
and frost action meeting the following requirements:-
Bulk Specific Gravity (ASTM C128/C127) Min. 2.6

Absorption (ASTM C128/C127) Max. 2%
Soundness by Magnesium Sulphate Max. 12%
(ASTM C88)
5/30.4 The rock shall be greater than 150 mm in size.
5/30.5 Excavation required for the placement of gabions shall be made in accordance
with the dimensions as shown on drawings or as directed. Gabions shall be
constructed in units to the dimensions indicated on the drawings.
5/30.6 The sides, ends, and diaphragms of the gabions shall be lifted into a vertical
position, and located together with binding wire to form the base.
5/30.7 The binding shall be carried out in a continuous lacing operation, the wire being
passed through each mesh and around both selvedges which must be tied
together with two round of turns after every second mesh.
5/30.8 Assembled gabions may be placed in position for filling singly, or wired together
in groups suitable for man-handling. The baskets shall be securely wired together
at all corners and edges in the same manner as described above. Where there
are more than one course of gabions, the one in the upper course must be laced
to those below. Gabions shall be slightly over-filled to allow for subsequent
settlement.
5/31 CHAIN LINK FENCING
5/31.1 The chain link fencing shall be PVC coated and erected according to the lines
shown on the drawings or as otherwise directed by the Engineer. The fencing
components shall have a five year corrosion warranty from the manufacturer.
5/31.2 The Contractor shall supply shop drawings showing all fixing and erection details,
for approval prior to erection.
5/31.3 Steel posts, mesh, braces and struts shall conform to the requirements of BS
1722 Part 1 and they shall be hot-dipped galvanished in accordance with BS 729
and then polyester coated to a minimum thickness of 60 microns.
5/24
5/31.4 Polyester coating shall conform to the requirements of BS 6496 and BS 6497.
MECHANICAL TESTS
Flexibility (Conical Mandrel) Pass 3 mm
Adhesion (2 mm Crosshatch) BS 3900-E6 Pass GTO
Erichsen Cupping BS 3900-E4 Pass > 7 mm
Hardness (400 gms) BS 3900-E2 Pass - No

Penetration
to substrate
Impact Resistance BS 6496 Clause 16 Pass 2.3J

direct and
reverse
CHEMICAL AND DURABILITY TESTS
Salt spray ASTM B117 @ 35 deg.C) Pass at 1000 hrs

Acetic Acid/Salt spray BS6496 ) no corrosion area
Clause 15 ) more than 2 mm from
scribe
Cyclic Humidity BS 3900-F2 Pass at 1000 hrs

no blistering or
loss of gloss
Distilled Water Immersion Pass - no blistering

BS 3900-G5 or loss of glass
after 24 hours.
Sulphur Dioxide BS 3900-F8 Pass - no blistering

loss of gloss, or
discolouration after
240 hours.
Exterior Durability BS 6496 Excellent performance.

Clause 4.10 Slight even loss of
12 months Florida 40 deg. South gloss, no checking,
cracking or flaking.
- Chalking None in excess of

minimum in ASTM
D659:1980.
5/32 STEEL AND METAL WORK
5/32.1 Steel for the fabrication of bridge parapets and sign gantries shall comply with
the requirements of BS 4, Part 1, BS 5400, BS 4360 and BS 4848 as
appropriate.
5/32.2 Fixing bolts and accessories complying with BS 5400, BS 4190 and BS 4320
as appropriate.
5/25
5/33 ALUMINIUM FOR PARAPETS
5/33.1 Extruded sections shall conform to the following requirements:-
Posts Alloy 6082 TE to BS 1474
Other Locations Alloy 6082 TF to BS 1474
5/33.2 Casting shall be in alloy LM6M to BS 1490.
5/34 FASTENINGS FOR ALUMINIUM PARAPETS
5/34.1 Holding down bolts shall be of stainless steel A4-80 to BS 6105.
5/34.2 Aluminium parapets in contact with concrete shall have bearing pads of
rubber/fabric, new and unvulcanised.
5/34.3 All other fastening shall be of stainless steel 315S16 quality to BS 970 Part 4.
5/35 PAINT AND OTHER PROTECTIVE COATINGS
5/35.1 All paints forming any one painting system shall be obtained from one
manufacturer and, unless otherwise agreed by the Engineer, the source of
supply shall not be changed after the Engineer's approval has been given. Paint
shall be supplied in sealed containers of not more than 5 litres capacity and
these shall be used in strict order of delivery.
5/35.2 The Contractor shall obtain from the paint manufacturer paint ready for the use
specified under the contract. The paints shall be adequate in all respects for the
purpose intended.
5/35.3 The system of protection for all non-galvanised steel work shall be as follows:-
- Prime Coat : Inter zinc QHA 027/028 (or equivalent) minimum dry film
thickness 65 microns.
- Second Coat : Intergard EBA 070/EBA 100 JB (or equivalent) natural

M.I.O. minimum dry filter thickness 100 microns.
- Third Coat : Intergard EBA 070/EBA 100 JB (or equivalent) silver grey
M.I.O. minimum dry film thickness 100 microns.
- Fourth Coat : Intergard EFK 724 (or equivalent) epoxy finish grey
minimum dry film thickness 50 microns.
Total dry film thickness - 315 microns (minimum).
The coating shall have a minimum adherence to the steel work of 2.5 MPa when
tested with an adhesive tester.
5/35.4 Prior to painting the steel work shall be grit blasted to SA 2-1/2 Swedish Standard
055900 or by other approved method to equivalent standard. Before the steel
surface shows signs of flash rusting the first coat of zinc primer shall be applied.
If the steel does flash rust then the cleaning process is to be repeated.
5/26
5/35.5 Steel work specified as galvanised shall be hot- dipped galvanised to the
standard required by BS 729.
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES
WATERPROOFING BRIDGE DECK SLAB - TYPE 1
GENERAL
TYPE 1
5/36.1 Deck waterproofing shall be composed of a proprietary membrane of a polyester

reinforced, SBS (Styrene-Butadiene Styrene) polymer modified bitumen sheet
sprayed or torched applied to primed concrete deck as detailed on the drawings.
MATERIALS
5/36.2 Membranes shall comply with the requirements of Technical Memorandum BE 27

(Bridges) Waterproofing and Surfacing of Bridge Decks and the system shall be
certified by the British Board of Agreement. Materials shall have the following
physical properties.
- Minimum thickness 1.5 mm
- Flexibility Over 20 mm dia Mandrel - 20 deg.C
- Longitudinal Elongation at Constant

temperature (20 deg.C, 100 mm/min) 54%
- Longitudinal Elongation with Thermal

shock (20 deg. C., 100mm/min) 57%
(-10 deg.C., 10 mm/min) 42%
- Longitudinal Tear Resistance at

Constant Temperature (20 deg.C.,
100 mm/min) 180 N/mm
- Adhesion to Concrete at 20 deg.C > .40 MPa
- Puncture Resistance at 20 deg.C.,

500 mm/min. > 800 N
PREPARATION OF SURFACE
5/36.3 All concrete surfaces to be waterproofed shall be smooth and free from
projections or holes which might cause puncture of the membrane. The surface
shall be dry and immediately before the application of primer or membrane, the
surface shall be thoroughly cleaned of dust and loose materials.
5/36.4 Immediately after cleaning and drying of surface, priming should be applied in
strict compliance with manufacturer's instructions. Primer coat shall be allowed to
cure completely before membrane application. Membrane shall be laid parallel to
traffic direction and tangent to the bridge curve in such a manner that overlaps
are never less than the specified width. In all cases, waterproofing shall begin at
the low point of the surface to be waterproofed. End laps should be staggered
one metre so that at no point are there more than three thicknesses of
5/27
membrane. It shall be installed with 100 mm side laps and 150 mm staggered
endlaps.
APPLICATION DETAILS
5/36.5 At the edges of the membrane and at any point where it is punctured by
appurtenances such as drains or pipes, suitable provision shall be made to
prevent water from getting between the waterproofing and the waterproofed
surface, as recommended by the manufacturer.
5/36.6 Precautions must be taken to prevent injury to the finished membrane by any
cause.
5/36.7 The bituminous wearing course should be laid as soon as possible after a
minimum period of four hours has elapsed from completion of the membrane.
WATERPROOFING BRIDGE DECK SLAB - TYPE 2
GENERAL
5/36.8 Type 2 deck waterproofing membrane shall consist of a two part rapid curing
liquid applied system based on methacrylate resins. The complete system shall
comprise of a primer to ensure good adhesion to the substrate; the membrane
and a tack coat to ensure good adhesion to the bituminous road surfacing. The
system must be suitable for use in Dubai. The temperature of the bituminous
surfacing at the time of laying onto the waterproofing membrane must be
according to Clause 3/33.
CERTIFICATION
5/36.9 The Type 2 waterproofing membrane system must hold a British Board of
Agreement Certificate.
APPLICATION
5/36.10 Application shall be strictly in accordance with the manufacturer's instructions.
WATERPROOFING OTHER SURFACES
5/36.11 Waterproofing membranes for structures other than top of bridge deck slab, shall
consist of an impervious laminate comprising a 0.3 mm PVC sheet and 1.5 mm of
flexible self adhesive rubber/bitumen compound. The laminate shall withstand
cracking of the substrate up to a crack width of 0.6 mm and shall have a tear
resistance (ASTM D1004) of 340 N/mm longitudinally and 310 N/mm
transversely, an elongation film (ASTM D638) of 210% longitudinally and 160%
transversely and a backing sheet tensile strength (ASTM D638) of 4.2 N/mm2
longitudinally and 4.8 N/mm2 transversely. Rubberised mastic and primer for use
with waterproofing membranes shall be special compounds provided by the
manufacturer of the membrane and formulated for its intended use.
5/36.12 Vertical and horizontal faces shall be made smooth, dry and free from nails or
concrete projections. It shall immediately be primed and allowed to completely
dry before installation of membrane. Installation procedures shall be strictly in
accordance with manufacturer's instructions.
5/28
5/36.13 Joints between sheets shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. If the work must be left partially complete temporarily,
the exposed edges of outside strips of the membrane shall be finished with a
trowelled bead of mastic.
5/36.14 Waterproofed surfaces to be backfilled or otherwise exposed to possible damage

by plant or other construction operations shall be protected by proprietary
protection boards specifically designed for this purpose and installed strictly in
accordance with the manufacturer recommendations. As an alternative to the
waterproof membrane plus protection boards a composite membrane consisting
of a rubberised bitumen compound and integral geotextile layer (min. 400g/sq.m)
shall be permitted. The protection boards shall be a minimum of 6 mm thick.
5/37 RUBBERISED BITUMEN EMULSION
5/37.1 Rubberised bitumen for application to buried concrete surface as detailed on the
drawings shall comply with D.M. 500 and consist of a water bound emulsion
containing not less than 65% of bitumen with fine particles of rubber dispensed in
the bitumen, the consistency being such that it can be applied to the surface by
brush at normal air temperature. The rubber content of the dried film shall not be
less than 10%.
5/37.2 The Contractor shall submit to the Engineer for approval three samples in one
litre containers of the rubber bitumen emulsion. The Contractor shall also submit
to the Engineer certificates that the material complies with the requirements of
the Specification, and is suitable for the intended purpose.
5/38 WATERSTOPS
5/38.1 Alternatives from those indicated on the drawings will be accepted only if the
Engineer is satisfied that their material and their performance are not inferior. The
waterstop, used must be installed strictly in accordance with the manufacturer
instructions.
5/38.2 Waterstops shall be manufactured either from rubber or from polyvinyl-chloride

(PVC), at the discretion of the Contractor subject to the approval of the Engineer.
PVC waterstops when tested in accordance with BS 2571, the PVC compound
shall exhibit the following properties:-
- Tensile Strength 13.78 N/sq.mm
- Elongation at Break 300%
- BS Softness 45
- Specific Gravity 1.3
For rubber waterstops the rubber compound shall comply with U.S. Fed. Spec.
22R-601 a except ASTM D 395-52 for compression and ASTM D2240-75 for
hardness.
5/38.3 No splices will be permitted in straight strips. Strips and special connection pieces
shall be well cured in a manner such that cross section shall be dense,
homogeneous and free from all porosity. All junctions in the special connection
pieces shall be full moulded. During welding or vulcanising periods the joints shall
be securely held by suitable clamps. The materials at the splices shall be dense
and homogeneous throughout the cross section.
5/29
5/38.4 If, after placing concrete, waterstops are materially out of position or shape or if
voids are found, the surrounding concrete shall be removed, the waterstop reset,
and the concrete replaced, all at the Contractor's expense.
5/39 PREFORMED JOINT FILLERS
5/39.1 Joint fillers in expansion joints for structures shall consist of a compressive non-
extruding board manufactured from bitumen impregnated fibres.
5/39.2 The physical properties of the materials shall conform to the requirement of
ASTM D-1751.
5/40 COLD APPLIED JOINT SEALANT
5/40.1 Cold applied joint sealant shall be a mullti- component, gun applied material of a
grade suitable for the hot climate with a service temperature of up to 70 degrees
centigrade and high resistance to ultra-violet exposure.
5/40.2 The compound shall comply with U.S.Federal Specification TTS-00227 E.
5/40.3 The sealant must be suitable for the particular application whether the joint to be
sealed is horizontal or vertical and with the ability to accommodate any
movement at the joint without rupturing or losing adhesion.
5/40.4 The hardness of the joint sealant shall be no less than 20 on the "Shore A" scale.
5/40.5 The Contractor shall supply samples together with the manufacturers literature
relevant to any sealant for any application for the Engineer's approval prior to
use. Only high quality products with demonstrable resilience to the local climate
conditions shall be approved. If a polysulphide based sealant is proposed for
locations exposed to biological attack or wet conditions then it should have a
minimum 40% polymer content. All polysulphide based sealant must utilise a
manganese dioxide curing system.
5/40.6 The mixing, application and curing of the approved sealant shall be strictly in
accordance with the manufacturers recommendations.
5/40.7 The approved sealants shall be delivered to site in sealed containers showing
date of manufacture, batch number and shelf life.
5/41 BRIDGE DECK EXPANSION JOINT
5/41.1 GENERAL
Expansion joint assembly shall be as shown on the drawing.
Full details of the proposed suppliers with their technical specifications,

maintenance manual, design calculations, covering materials, dimensions and
sizes shall be submitted to the Engineer for approval before the Contractor
places an order.
All expansion joints shall be guaranteed by the manufacturer against any defect
in material and workmanship for a period of ten years.
The Contractor shall submit the detailed shop drawings and obtain the Engineer's
approval before manufacture is commenced.
5/30
During placing and hardening of concrete or mortar under the expansion joint
components, relative movement between them and the supports to which they
are fixed shall be prevented.
Thorma-Joints shall comprise Thorma-Joint with BJ 200 binder as manufactured

by Prismo Ltd., of Crawley, West Sussex, United Kingdom, or equal approved.
Elastomeric expansion joints shall be waboflex SR Type as manufactured by

Servicised Ltd., or equal and approved.
Installation details shall be as shown on the drawings and as otherwise

recommended by the manufacturer and approved by the Engineer.
5/41.2 All anchoring steel plates, bolts and sockets shall be protected against corrosion.
5/41.3 Joint installation shall be carried out strictly in accordance with manufacturer's
recommendations and in the presence of the manufacturers representatives.
5/42 LOCKABLE MEDIAN BOLLARD
5/42.1 Lockable median bollards shall be as shown on the drawings.
5/42.2 Movable bollard and locking mechanism shall be galvanised steel to BS 729
standard and treated with anti-corrosion paint.
5/42.3 Post sleeve shall be 4 mm thick PVC pipe.
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED

CONCRETE SURFACES
GENERAL
5/43.1 The coating system shall be an elastomeric system of single component

products, a weather resistant top coat used in conjunction with a penetrating
primer. The coating shall have the ability to provide in-depth protection for
reinforced concrete structures against corrosion associated with the ingress of
chloride and sulphate ions, carbon dioxide and other air-borne acid gases, and
shall have the ability to allow water vapour to escape from the structure.
PRIMER
5/43.2 The primer shall be a low viscosity reactive silane- siloxane/acrylic blend
dissolved in a penetrating organic carrier. The primer shall have the capability to
penetrate and produce a chemically bound Hydrophobic barrier to prevent the
passage of chloride and sulphate ions. The primer should also be film forming to
condition and stabilise the substrate prior to the application of the topcoat. The
primer should be applied in full accordance with the manufacturers instructions.
TOPCOAT
5/43.3 The top coat shall be a pure aliphatic acrylic resin, decorative, high performance
water based, pigmented coating. It shall have resistance to water, carbon dioxide
and other air-borne acids and have the ability to allow the passage of water
vapour from within the structure.
5/43.4 The top coat shall have elastomeric and flexural capabilities and should be
applied in strict accordance with the manufacturer's instructions.
5/31
5/43.5 The system will, during trials, display the following properties when applied in
accordance with the manufacturer's specification to samples obtained from
concrete made without additives.
Reduction in Water Absorption 82% minimum at 28

(measured against a control days
concrete sample in accordance
with ASTM C 642)
Reduction in Chloride Ion 90% minimum at 28

Penetration days.
Water Vapour Transmission > 13g/m2/day
Carbon Dioxide Diffusion Equivalent to 500mm

Resistance of 30 N/mm2 concrete
TRIAL PANELS
5/43.6 Prior to applying the system in the works, trial applications shall be carried out on
trial panels made by the Contractor under Clause 4/33. The trials will
demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating. Representatives of the
coating manufacturers shall be present at the trials and the surface preparation
and application of the coating shall be carried out under their direction. The
Contractor shall at his own expense surface coat as many panels as required by
the Engineer until a trial panel has been accepted by the Engineer as
satisfactory. The coated panel, when accepted will form the standard against
which the corresponding coating in the works will be judged. No application of the
coating in the works shall be undertaken until trials have been completed to the
Engineer's satisfaction.
INSPECTION OF CONCRETE
5/43.7 The Contractor shall not proceed with the surface finish or making good of
concrete surfaces until he has received the Engineer's Representative's
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck until
the concrete has been inspected and approved by the Engineer's
Representative.
FAULTY CONCRETE WORK
5/43.8 The Contractor shall on the written instruction of the Engineer remove and
reconstruct any such portion of the work which in the opinion of the Engineer is
unsatisfactory as regards quality of concrete, incorrect dimension of the cast
portion, badly placed or insufficient reinforcement, honeycombing or other such
cause as shall render the construction not up to the standard required and which
in the opinion of the Engineer may prejudicially affect the strength or durability of
the construction.
APPROVAL PRIOR TO COATING APPLICATION IN THE WORKS
5/43.9 The Engineer's approval must be obtained prior to applying the coating system in
the works. Before approval is given the Engineer will need to be satisfied as to
the following:-
5/32
a. All construction work in the immediate vicinity of the structure to be coated
has been completed.
b. The surface preparation of the structure has been completed.
c. The whole of the structure can be coated in a continuous operation.
d. Adequate measures have been taken to protect the property of third

parties, including vehicles, from coating splatters.
e. The weather conditions accord with the coating manufacturer's directions

for coating application.
5/33
APPENDIX 5
LABORATORY TESTING
APPENDIX 5
LABORATORY TESTING
Testing of all materials and completed work shall be carried out in accordance with
DM Administrative Decision No. (160) for 2000 by:
1) Dubai Municipality – Dubai Central Laboratory (DCL) in accordance with

Appendix “5-1”.
2) Independent Laboratory in accordance with Appendix “5-2”.
1
APPENDIX 5-1
(1) TESTING AT DUBAI MUNICIPALITY –

CENTRAL LABORATORY DEPARTMENT (DUBAI DCLD)
1.1 All transportation of personnel and material on site and to/from the DCL shall
be borne by the Contractor. Suitable approved transport with driver shall be
maintained for this specific use by the Contractor.
1.2 The Contractor shall pay for all the tests carried out by the DCL.
1.3 Any testing which is required under the contract which cannot be carried out
by DCL shall be carried out at Contractor’s expense at an Independent
Laboratory in accordance with Appendix “A2”. Copy of such sampling and
testing reports shall be forwarded to the DCL and to the RTA/DM
Departments concerned for information not later than a week from the date of
the issuance of the reports.
1.4 The testing of the works by the DCL shall in no way absolves the Contractor
from his responsibilities to carry out his own job control testing of the quality
of his work and the materials used.
1.5 Representatives of the Consultant and the Contractor shall be permitted to

witness the testing carried out by DCL.
1.6 DCL will not be held liable for interpreting test data, since this will be the
responsibility of the Consultant.
1.7 All sampling for such tests shall be carried out by the Consultant’s
Representative and labeled as per relevant standard sampling requirements
and submitted by the Consultant to DCL.
1.8 The Contractor shall submit to DCL Monthly Laboratory Testing Programmes.
The programme shall details the specific test requirement for the coming
month which includes the type, number and approximate date that testing will
be required.
1.9 Minimum twenty four (24) hours notice shall be given to DCL before any test
are scheduled to be carried out.
1.10 The Consultant shall inform DCL and RTA/ DM Departments concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.
2
APPENDIX 5-2
(2) TESTING AT AN INDEPENDENT LABORATORY
2.1 Any testing which is required under the contract and as detailed in DM
Administrative Decision No. (160) for year 2000 may be carried out at the
Contractor’s expense at an approved Independent Laboratory, provided this
laboratory meets the following requirements:
2.1.1 Independent laboratories that operate in Dubai Emirate shall meet all the
requirements of RTA/DM rules and regulations including DCL accreditation
requirements.
2.1.2 Independent laboratories that operate outside Dubai Emirate shall be

accredited to one of the National Accreditation Systems for laboratories such
as NAMAS, NATA, etc. The Contractor shall forward a copy of the
accreditation certificate to DCL for approval prior to approaching such
laboratories for testing services.
2.2 All sampling for such tests shall be carried our by the Consultant’s
Representative and labeled as per relevant standard sampling requirements
and submitted by the Consultant to the independent laboratory along with
sampling reports.
2.3 Representatives of the Consultant and the Contractor shall be permitted to

witness the testing carried our by the independent laboratory.
2.4 The testing of the works by the independent laboratory shall in no way
absolves the Contractor from his responsibilities to carry out his won job
control testing of the quality of his work and the materials used according to
the contract specifications.
2.5 The Consultant shall inform DCL and RTA/DM Departments concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.
2.6 The independent laboratory shall give original copies of the sampling and
testing reports to the Consultant copies to:
2.6.1 DM Department concerned
2.6.2 DCL
2.6.3 Contractor
2.7 The independent laboratory shall divide non – destructive samples into four
representative sub-samples:
Part “A” : to be tested by the independent laboratory;

Part “B”.: for RTA/DM Department concerned/Consultant Recheck;
Part “C” : for independent laboratory internal quality control;
Part “D”: for DCL Cross – Check.
3
2.8 The Contractor shall enter into an agreement with an independent laboratory.
This agreement shall include all conditions as detailed in Appendix “A2”.
2.9 Any material requiring certification as per RTA/DM regulations shall not be
used unless certified by DCL.
LABORATORY TESTS WHICH MAY BE CARRIED OUT BY INDEPENDENT

LABORATORIES ACCREDITED IN ACCORDANCE WITH DCL ACCREDITATION
REQUIREMENTS AND DM ADMINISTRATIVE DECISION NO.(160) FOR YEAR
2000.
Sr. NAME OF TEST TEST METHOD

(1)* Determination of insitu Density Test by Sand BS 1377 : 1990
Replacement Method Suitable for Fine and Medium Part 9 Clause 2.1
Grained Soils.
(Small Pouring Cylinder Method).
(2)* Determination of insitu Density Test by Sand BS 1377 : 1990
Replacement Method Suitable for Fine, Medium and Part 9 Clause 2.2
Coarse Grained Soils.
(Large Pouring Cylinder Method)
(3)* Determination of Dry Density – Moisture content BS 1377 : 1990
Relationship Using 4.5 kg. Rammer for Soils with Part 4 Test 3.5
Particles up to Medium – Gravel Size.
(4)* Determination of Dry Density – Moisture Content BS 1377 : 1990
Relationship Using 4.5 kg. Rammer for Soils with some Part 4 Test 3.6
Coarse Gravel – Size Particles.
(5)* Method for Determination of Compressive Strength of BS 1881 : 1983
Concrete Cubes. Part 116
(6) Determination of the Compressive Strength of Pre-Cast BS 6073 : 1981
Concrete Masonry Units. Part 1 & 2
*For road works, the above tests (1), (2), (3) and (4) may be carried out at an
independent accredited laboratory only for earthworks and filling outside the road
corridor.

Volume 2 - Part 1 - Standard Specifications

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Project: DS 208/1

‫ربط مشاريع المطورين العاجلة على نظام الصرف الصحي التابع‬

INTERCONNECTING URGENT DEVELOPMENTS TO DM SEWERAGE SYSTEM

BUR DUBAI AREA

VOLUME 1 : TENDER AND CONTRACT CONDITIONS

VOLUME 2 : PROJECT SPECIFICATIONS

PART 1: STANDARD SPECIFICATIONS

PART 2: PARTICULAR SPECIFICATION

VOLUME 3 : BILL OF QUANTITIES

PART 2: PROJECT DRAWINGS

VOLUME 5: INFORMATION TO TENDERER

December 2022 Page 1 of 1

DRAINAGE AND IRRIGATION DEPARTMENT

Section 2 Site Clearance and Earthworks

Section 4 Pipe, Pipework, Manholes and Chambers

Section 5 Brickwork and Blockwork

Section 6 Inspection and Testing of Pipelines and Structures

Section 7 Corrosion protection and Surface Coatings

Section 8 Buildings Specifications

Section 9 Metals and Plastic Materials

Section 10 Safety Procedures

Section 11 Pipeline Renovation , Replacement and Abandonment

Section 12 Manhole Renovation and Abandonment and Pumping

Section 13 Piles and Piling

Section 14 Microtunnelling and Pipejacking

Section 15 Geotechnical Instrumentation and Monitoring

Section 16 Protection of Existing Structures and Services

OPEN DATA / ‫ﺑﻳﺎﻧﺎﺕ ﻣﻔﺗﻭﺣﺔ‬

DM/SRPD Section 1 General Rev 00 June

OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/SRPD Section 1 General Rev 00 June Page i of iii

OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

1.1.1 Preamble .............................................................................................................. 1

1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE ................................................... 10

1.2.1 General ............................................................................................................... 10

1.3 GENERAL REQUIREMENTS .......................................................................................... 18

1.3.1 Materials and Manufactured Items ..................................................................... 18

OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

1.3.16 Sign Boards ........................................................................................................ 42

1.4 TOPOGRAPHICAL SURVEY........................................................................................... 57

1.4.1 GENERAL REQUIREMENTS ............................................................................. 57

1.5 SPECIFIC OBLIGATIONS ............................................................................................... 59

1.5.1 Sequence of Construction .................................................................................. 59

1.6 VENDOR LIST FOR CIVIL ITEMS.................................................................................... 67

DM/SRPD Section 1 General Rev 00 June Page iii of iii

OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

1.1.2 Abbreviations and Standards

The following abbreviations are used in the Specifications:

DM/SRPD Section 1 General Rev 00 June Page 1 of 74

OPEN DATA / ‫ﺑ ﺎﻧﺎت ﻣﻔﺘﻮﺣﺔ‬

m², sq m Square Metre

AABC Associated Air Balance Council

AAN American Association of Nurserymen

AAMA Architectural Aluminium Manufacturers Association

AASHTO American Association of State Highway and Transportation Officials

ACI American Concrete Institute

ADC Air Diffuser Council